Balancing Tips: In-house and On-site

EASA Convention 2011

Colorado Convention Center
Denver, CO
June 25, 2011

Presented by

Gene Vogel
Pump & Vibration Specialist
Electrical Apparatus Service Association
St. Louis, MO
 BALANCING TIPS: IN-HOUSE AND ON-SITE
By Gene Vogel
Pump & Vibration Specialist
Electrical Apparatus Service Association, Inc.
St. Louis, MO
BALANCING AND VECTORS
Any balancing technician (and most supervisors
and managers) knows how to do a simple single-plane
balancing vector solution. Using amplitude (usually in
displacement) and phase, the original unbalance vector
is drawn. A weight is added to the rotor and the resulting
amplitude and phase vector is drawn (Figure1).
FIGURE 1: EXAMPLE OF A VECTOR PICTURE
‘T’
Correction
‘O+T’ Angle
‘O’
The vector from the Original to the Original+Trial is the
effect of the trial weight (the T vector). By comparing the
O and T vectors, the correction amount and location can
be calculated.
Automatic balancing instruments and calculators
complete this process in nanoseconds. But even when
you have digital corrections calculated to three decimal
places, it’s important to keep the image of those vectors
in your head as you work through balancing a rotor. It
is especially important to be constantly aware of the O
vector. Below are a few tips that show why the vector
picture is important.
Correction vs. trim weights
Every weight that is added to the rotor can be used as
a trial weight. Compare the results to the prior condition
and there is single plane vector picture. A correction
weight is a weight that is added to the original unbalance
condition. A trim weight is a weight added in addition to
1
a correction weight. However, a trim weight is also a trial
weight to the corrected weight condition. So there are
several opportunities for single plane vector pictures.
Do the results agree? If not, the chances of a success-
ful balance solution are not very good.
Often after several balance corrections, the decision
is made to start over with a new trial weight to the exist-
ing rotor condition. Rather than just guess at a new trial
weight location and amount, use the last two runs as an
O and O+T vector and calculate the best trial weight. It
may save you a run.
Vector sums of correction weights
When several correction and trim weights have been
added and there is the need for further reduction, the
weights can be added together as weight vectors to
produce a single trial weight. The calculated correction
weight from that composite trial weight will be more ac-
curate than for any of the individual weights.
The “moving” O vector
Successive attempts to trim balance may seem to
produce diminishing returns. There are many potential
causes for poor trim balancing results. It is often a good
practice to remove any weights that have been added
and recheck if the original vector has moved. If the O
vector has moved from its original amount and location,
the only solution that will work is luck. It will be necessary
to find what caused the change in the O vector.
The 120° rule and “flash angle”
Suppose a correction weight has been added to the
rotor and a trim weight has been calculated. If the trim
weight is to be located at 120° from the correction weight,
then the correction weight is about the right amount,
but needs to be shifted slightly toward the trial weight
location. (A little practice sketch of vectors at 120° will
confirm this.)
So, if the trial weight location is less than 120° from
the correction weight, the correction weight is a little light
and needs to be shifted slightly toward the trial weight.
And, of course, more than 120° means it’s too heavy
and needs to shift in the same direction. (See Figure 2.)
Obviously, a trim weight location of 0° or 180° means
the correction weight is in the correct location, but too
light or too heavy. That leads to the conclusion that the
“flash angle” is the relationship between the O vector

FIGURE 2: 120° RULE
2.2 gm
A little more weight
2.2 gm
120° = compare closely, but a couple are way off, those weights
2.2 gm
A little less weight
and the light spot. The term “flash angle” relates to the
strobe light method of measuring phase. Digital instru-
ments may refer to this as the “high spot”.
Once the flash angle or high spot has been located,
further balancing will be easier. A similar analysis works
for the amount of weight.
Zero location
It is important to reference the direction or rotation
when referring to any angle, either direction of rotation
(DR) or counter direction of rotation (CDR). Avoid clock-
wise (CW) and counter-clockwise (CCW) since these are
always relative to the end from which the rotor is viewed.
An occasional point of confusion with digital instru-
ments is how to determine the zero location on the rotor.
There are many methods that work and consistency is
most important. One particular method does have some
advantages. Let’s call it the V method. To locate the zero
location, turn the rotor DR to the trigger position on the
tach pickup. Zero is the location in line with the vibration
transducer. Using this method will allow the setup to be
repeated with accurate phase angle reference, even if
the tach or reference mark are moved. (Note: There can
be no movement of the tach or reference mark between
the original and trial runs.)
Suppose that after a trim run, the reference tape or the
tach comes off and it isn’t clear where it had originally
been. Using the V method, the tape or tach can be at
any angular location and the subsequent trim runs will
be accurate.
If the setup data is saved and recalled for a future
re-balancing, the V method will insure the phase data
is correct, without regard to the reference mark or tach
locations.
Calculating “coherence”
From the previous discussion, it should be known that
for every weight added to the rotor, there is a single-plane
vector picture with a T vector. There should be a constant
relationship between each weight and its T vector. This
relationship is know as the “influence coefficient”.
If accurate data has been kept, a little trigonometry will
2
allow that relationship to be calculated for each weight
added. Theoretically, that relationship is constant. Devia-
tion indicates a problem.
When a balance job goes awry and you have one that
“can’t be balanced,” a post analysis of the data may
show why. For instance, if several influence coefficients
may have been added in the wrong location (CW instead
of CCW?).
BALANCING TOLERANCES
Vibration vs. unbalance
Vibration may be measured in displacement:
• mils
• micrometers
• mm
Unbalance is measured in weight (mass) at radius:
• oz-in
• g-in
• g-mm
There is no universal relationship between vibration
and unbalance; each rotor in each installation must be
evaluated to determine the vibration/unbalance relation-
ship. The technique is simple and goes directly to the
single-plane vector solution. The T vector is the vibration
effect of the trial weight (That’s the vibration-to-weight
relationship). A weight has to be added to the rotor to
determine the relationship.
ISO 1940/1 is a standard that assigns a Balance
Quality Grade number (the G number) to the amount
of residual unbalance per unit of rotor weight per rpm.
Put simply, a heavier rotor will tolerate more residual
unbalance than a lighter rotor and a higher speed rotor
will tolerate less residual unbalance than a slower one.
The standard also lists types of rotor with recommend-
ed grade numbers. Standard electric motors are listed
at G6.3, however, most service centers balance rotors
to at least a G2.5. This is an easily attainable balance
quality and provides a motor that should be able to meet
the NEMA standards for motor vibration. Keep in mind
that the grade number takes rotor weight and operating
speed into account. So it is not acceptable to balance
lower-speed motors to a higher grade number; the rotor
speed is already accounted for in the grade number.
The standard provides a cross reference chart between
rotor operating speed and a value labeled Eper (the E
reflects the relationship to the eccentricity of the center
of gravity of the rotor due to unbalance). The Eper value
is multiplied by the rotor weight to get the Uper (allow-
able residual unbalance for the rotor). Thus, both speed
and rotor weight are accounted for. The standard also
provides a convenient formula to determine Uper directly:
 FIGURE 3: TWO-PLANE VECTOR

‘T’
‘O+T’

‘O’
‘O2+T1’

‘T1’
‘O2’

First correction plane Second correction plane

(Note: Most service centers round 6.05 off to simple 6.)
This formula can also be converted to provide the
grade number for a given residual unbalance on a rotor:
primary side. Use an extra run if necessary.
• Use the single-plane results from the first side to
calculate the trial weigh for the second side.
• After you have a pair of correction weights calculated,
apply them in two runs as new trial weights to get a
new two-plane correction.

Static couple technique

Very narrow rotors, overhung rotors and non-sym-
SINGLE- & TWO-PLANE TECHNIQUES metrical rotors often are easier to balance using the
Every balance job has a first weight, so there is always
an opportunity to get a single-plane vector picture. If it
is a two-plane balance situation, there will be a primary
affect and a cross affect to that weight—that’s two single- FIGURE 4: STATIC COUPLE METHOD
plane pictures (Figure 3). If both pictures tell the same
story, you’re in luck! If they say to two different things,
you’re in for long project.
If the primary and cross affects agree, the best ap-
proach is to complete the single-plane correction.
Chances are both ends of the rotor will be improved. Now
you have another pair of single-plane pictures—the O
vectors and the new trial run with the correction weight.
(Remember, every time you add a correction weight, it’s
another trial run.) As long as both ends improve, keep
going. When the primary and secondary results begin
to disagree, it’s time to consider a two-plane approach. Couple correction plane (R)
Couple correction plane (L)
“Educate” your two-plane balance procedure Static correction plane
• Use trial weights that improve the balance on the

3
static-couple method (Figure 4). There are many tutori-
als available on static-couple balancing. Here are just a
few key points.
• Keep the “static” correction plane as close to the c/g
plane as possible. When a static weight is added in a
plane away from the c/g plane, a couple is created.
• Place the “couple” correction planes as far apart as
possible. It doesn’t matter where along the rotor they
are located; only the distance between them has an
affect.
• Calculate the static and couple vectors and use
each of them in a single-plane vector picture just as
if they were ordinary affect vectors (because they
are ordinary affect vectors).
• If you notice that the static correction has an adverse
affect on the couple vector (or vice versa), use the static
and couple vectors as inputs to the two-plane solution.
The results from the two-plane solution are static and
couple corrections, not two-plane corrections. For
convenience, only enter one of the two couple weights
as the trial weight. The other couple weight is simply
the same amount 180° away. This is especially helpful
with extreme overhung configurations.
FIELD SERVICE GOTCHA’S
Watch out for that “moving” O vector
Balancing will be frustrating or impossible if the original
vector data is not stable. Below are a few conditions that
lead to an unstable original vector.
Operational changes
If the temperature, speed, load or flow through a ma-
chine change due to operational changes, the actual or
apparent unbalance may change. For field balancing, it
is important to keep track of any operational changes.
If a rotor operates at an elevated temperature, and
original data is taken before it reaches that temperature,
the balancing results will be poor. Likewise, if the rotor
operates at varying speed, balance data should only be
taken at the same speed as the original data.
There are numerous other operating conditions that
can affect both the 1x rpm forces and the actual rotor
unbalance. Any such forces must be controlled to have
good balancing results.
Rotor heating or cooling
The need for stable temperature is mentioned above.
However, temperature during balancing may change
apart from normal operation. Rotors of electric motors
which are started repeatedly during balancing may be
hotter than during normal operation. Fans and pumps
may be operated for balancing in by-pass mode or with
dampers closed which affects temperature. Such abnor-
mal temperature (hot or cold), can affect the success of
the balancing operation.
4
“Dirty” rotor
When a rotor has accumulated a coating of dirt or
contamination, the cycle of starts during balancing may
cause some of that material to fall or flake off, thus chang-
ing the rotor unbalance. When the rotor unbalance has
changed, the O vector has changed, and further balanc-
ing will be unsuccessful. It is always recommended to
have a rotor thoroughly cleaned prior to beginning the
balancing process.
Base looseness
A loose base allows the stiffness of the base to change
from one balance run to another. The change in stiffness
will cause a change in the amplitude and/or phase of the
vibration, effectively changing the O vector.
Since the changes resulting from the loose base can-
not be separated from the change resulting from trial
and correction weights, the balance calculations will be
inaccurate. The vibration characteristics of looseness will
likely be present in the vibration signature.
Problem is not unbalance (not 1x rpm)
Problems such as pulley eccentricity and electric motor
rotor eccentricity generate vibration at exactly 1x rpm. To
some extent, a balance weight in the correct amount and
location may counteract these forces, but only partially.
With pulley eccentricity, the force is only in the direc-
tion of belt tension and the force of the balance weight
is purely radial. Vibration will shift 90°, as from horizontal
to vertical.
In the case of electric motor rotor eccentricity, the motor
may run smoother with power on, but will vibrate more
when power is disconnected; or vibration may vary with
load. In both cases, the O vector is not constant and
balancing will be frustrated.
Non-linear response
The vectors that all balancing solutions rely on are lin-
ear vectors; that is, changes in amplitude and phase are
directly proportional to changes in the unbalance amount
and location. Conditions such as resonance or a loose
base introduce restraining forces which are not linear.
A first balancing attempt may be somewhat success-
ful, but further attempts to trim balance will fail, since
at lower vibration levels the influence coefficient will be
different. Non-linear response can be recognized when
successive trim weights seem to “chase” each other;
continually moving around the rotor or switching from “a
little more” to “a little less” weight.
Horizontal vs. vertical results
In some instances, balancing in one the horizontal
plane increases vibration in the vertical plane, or vice ver-
sa. Directional forces such as pulley or gear eccentricity,
certain resonant conditions and coupling misalignment

FIGURE 5: BEAT FREQUENCIES AND
INTERFERENCE FROM OTHER MACHINES
Interference vector
Unbalance vector
can cause this occurrence. The best that balancing can
produce in these instances is a compromise balance
between the vertical and horizontal planes. Some bal-
ancing programs allow for two vibration inputs for each
correction plane (2 point single plane or 4 point 2 plane
balance setups). These programs find a best compromise
solution between the data points. However, it is always
best to identify and correct any non-unbalance sources
of vibration before attempting balancing.
Final correction weight at different radius than trial
weight
It is often the case that trial weights are placed at one
radius while permanent weights will be placed at a dif-
ferent radius. For instance, a clamp-on weight may be
placed over the outside edge of a blower wheel, while
permanent weights are welded further in, to the blower
shroud or vanes. The change in radius has an inverse
affect to the force developed by the weight. So more
weight is needed at smaller radii. The correct amount
can be easily calculated from the proportion of the two
radii. Failing to perform this calculation will result in poor
balancing results.
Beat frequencies and interference from other
machines
A beat frequency occurs when two radial forces occur
at slightly different frequencies. The forces can be rep-
resented as vectors which are moving in relationship to
each other. The vector sum of the two forces produces
a vibration amplitude and phase which oscillates in a
syncopated fashion. The oscillations occur over a regular
period of time, and thus have a frequency of their own
which is call the beat frequency. A common example is
multiple fans mounted on a common structure and op-
erating at nearly the same speed. This situation can be
5
found on industrial ovens with zone fans. The oscillations
in amplitude and phase frustrate the balancing process
if special data collection techniques are not employed.
The regular variations in amplitude and phase are
observable if the original balance data is tracked for an
extended period – at least several periods of the beat
frequency. Since the unbalance vector is constant for
the machine that is being balanced, and the interference
vector moves in relationship to the unbalance vector, the
unbalance vector is the average of the data over at least
one beat cycle.
Many digital balancing instruments have the option
to increase the number of averages, which will provide
much more accurate balancing data. Setting the aver-
ages to at least 50 (about a minute of data collection
time), is adequate for many beat frequency situations.
As many as 150 averages may be necessary in cases
where the beat frequency is very low (a very long period).
As balancing reduces the unbalance vector, the inter-
ference vector will become dominant and the phase angle
will appear to rotate continually. Further balancing at this
point will be unproductive, since the dominant vibration
is not longer from unbalance.
BALANCE MACHINE SETUPS
Using V-blocks
The roller work assemblies on most balancing machines
present challenges to the balancing process. The roller
may cause fretting to the journal which is unacceptable
for most bearing journals. If the rollers run on the shaft
adjacent to the bearing journals, any eccentricity of that
surface will directly reduce the balance quality. An alter-
nate to using roller work assemblies is to use V-blocks.
If the rotor to be balanced has rolling bearings, the
bearings can be installed on the shaft and set in the V-
blocks. Any bearing caps that mount behind the bearings
can usually be installed, then tied with twine to prevent
them from rotating with the shaft, with a small amount of
oil where they ride on the shaft. If the rotor has sleeve
bearings there are several options. Teflon sheets can
be placed in the V-blocks with a small quantity of oil for
lubrication. While this works well at low balancing speeds,
some Teflon will be infused into the steel of the bearing
journal and must be polished out before assembling the
machine. An alternate method is to mount the actual
sleeve bearings in the V-blocks and provide an oil drip
or circulation system for lubrication. This option has the
draw back of slightly reduced balance sensitivity due to
the internal clearance of the bearing.
IMPORTANT: On balancing machines with a single de-
gree of freedom, V-blocks should have a slight crown to
the surface that allows the mounted shaft to pivot slightly
(similar to a self-aligning bearing). Failure to provide for a
slight pivot will eliminate the balancing machine response
to couple unbalance.
Using bolted in pillow blocks for overhung
configuration
Some rotors, such as overhung fans, may use pillow
block bearings for their installed operating bearings.
These bearings can also be set directly onto the bal-
ancing machine mounting surface of some balancing
machines. In the overhung configuration, the outboard
bearing mount must accommodate an upward load.
Caution: Do not depend on belt tension to hold the rotor
in place. If the belt breaks or comes loose the spinning
part will come out of the machine.
Shielding aerodynamics
When the rotor being balanced includes fans or blades
that move a significant volume of air, irregular air flow may
produce large excursions of the supports in soft bearing
balancing machines. These large displacements can
swamp the balancing instrument electronic circuits and
produce erroneous data. Baffling off the fans will help
eliminate these large excursions. Any baffles should be
stationary, not attached to the fan. If baffles are attached
to the fan they become part of the balance of the rotor,
which will then change when the baffles are removed.
An alternate method is to mount dampers, such as small
industrial shock absorbers, to limit the motion of the
balancing machine mounts.
produce movie like images of machine vibration.
Summary
An understanding of basic vectors and balancing vector
pictures is essential for optimizing dynamic balancing in
the service center and in field balancing. For field balanc-
ing, it is important to evaluate the machine vibration to
be certain the problem is indeed unbalance. Many other
problems may cause vibration similar to unbalance, or
may frustrate the balancing process. Resonance is pres-
ent in all machines, and balancing procedures should
include basic tests for resonance.
Balance tolerances are in oz-in, gm-in or gm-mm;
vibration tolerance are in units of displacement, veloc-
ity or acceleration. An understanding of both vibration
tolerances and unbalance tolerance is important when
communicating with customers and technicians.
Balancing machines setups can often be adapted to
accommodate unusual rotor configurations, or to optimize
the balancing process.

Avoiding and dealing with resonance and base

problems
Rotors running near resonance have unstable am-
plitude and phase: Very small changes in speed cause
significant changes in amplitude and phase. Most digital
balancing instruments have Bode plot capability; the
setup is the same as for balancing. Just switch instrument
modes and get the Bode plot on coast down. Look for
the characteristic peak in amplitude and shift in phase.
Phase shifts 180 degrees through resonance, so a 90°
shift indicates the rotor is running right at resonance. Try
balancing at a different speed if that is possible. A rotor
balanced at one speed is balanced at any speed (up to
the first rotor critical speed).
In many cases, base looseness is the root of resonance
and other unsteady amplitude and phase readings. If the
base is a steel frame mounted on a concrete foundation,
wedges driven between the base and the foundation may
provide a temporary fix to allow the unit to be balanced.
When wedges driven under the machine cause the
vibration level to drop, it goes a long way to convincing
the customer the problem is the base, not the balancer.
Since the balance instrument setup provides amplitude
and phase, it is often easy to do a simple operating de-
flection shape (ODS) analysis. Lay out a simple sketch
of the machine, take amplitude and phase data at key
locations and plot the results. For more sophisticated,
animated ODS projects, software is available that will