JBC VPI SYSTEM I, II, III, IV SNAPON LOW DIGITAL BFH 1000 / 800 /800b /800c
EEWB504A, EEWB503A, EEWB502A, EEWB516A, EEWB304A, EEWB519A, EEWB526A, EEWB526B, EEWB526C
Service Manual
VPI System II VPI System III
VPI System IV
Snapon Low Digital VPI System I December, 2007 All information contained or disclosed in this document is considered confidential and proprietary by Snap-on Equipment Company. All manufacturing, use, repro- duction, and sales rights are reserved by Snap-on Tools Company and the information contained herein shall not be used in whole or in part without the express written consent of Snap-on Tools Equipment.
SNAP-on® is a registered trademark of Snap-on Incorporated. TABLE OF CONTENTS Table of Contents
INTRODUCTION GENERAL...... I FUNCTIONAL DESCRIPTION ...... I BASIC BALANCER OPERATION ...... I WEIGHT APPLICATION ...... I ALLOY MODES...... I ALU-S MODE ...... I DISPLAY / CONTROL PANEL ...... I GENERAL SPECIFICATIONS AND MACHINE FEATURES ...... II MAJOR FEATURES ...... II SPECIFICATIONS ...... II IMPORTANT SAFETY INSTRUCTIONS ...... III LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE ...... IV ELECTRICAL SAFETY PRECAUTIONS ...... IV SERVICE GUIDELINES / HANDLING STATIC SENSITIVE PCB’S ...... V
CHAPTER 1 AC/DC POWER DISTRIBUTION LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE ...... 1-1 ELECTRICAL REQUIREMENTS ...... 1-1 AC THEORY OF OPERATION ...... 1-2 AC DISTRIBUTION ...... 1-2 DRIVE MOTOR ...... 1-2 DC THEORY OF OPERATION ...... 1-2 PROCESSOR BOARD ...... 1-2 ENCODER BOARD ...... 1-2 DISTANCE POTENTIOMETER (SYSTEM I,II,III,IV SOT LOW DIGITAL) ...... 1-2 DIAMETER POTENTIOMETER (SYSTEM II,III,IV SOT LOW DIGITAL) ...... 1-2 WIDTH POTENTIOMETER (SYSTEM III,IV) ...... 1-3 TRANSDUCERS ...... 1-3 DISPLAY BOARD ...... 1-3 KEYPAD...... 1-3 AUTO STOP LOCK SWITCH (VPI III, IV) ...... 1-3 ELECTROMAGNETIC BRAKE ...... 1-3 EMBEDDED PCB (SYSTEM IV, BFH) ...... 1-3 TROUBLESHOOTING ...... 1-4 PROCESSOR PCB ...... 1-7 KEYPAD SCHEMATIC (VPI SYSTEM III) ...... 1-7 KEYPAD SCHEMATIC (VPI SYSTEM I, II) ...... 1-8 KEYPAD SCHEMATIC (SNAPON LOW DIGITAL) ...... 1-8 EMBEDDED PC (JBC SYSTEM IV) ...... 1-10
CHAPTER 2 THEORY OF OPERATION FUNCTIONAL DESCRIPTION ...... 2-1 TERMINOLOGY JBC SYSTEM IV ...... 2-2 TERMINOLOGY JBC SYSTEM III ...... 2-3 TERMINOLOGY JBC SYSTEM I, II ...... 2-4 TERMINOLOGY SNAPON LOW DIGITAL ...... 2-5 BALANCER COMPONENTS ...... 2-6 MAIN PROCESSOR PCB...... 2-6 POWER SUPPLY PCB ...... 2-6 KEYPAD...... 2-6
Effective 05/2007 TABLE OF CONTENTS DISPLAY PCB ...... 2-6 TEMPERATURE SENSOR ...... 2-6 DRIVE MOTOR ...... 2-6 TRANSDUCERS ...... 2-6 SAPE (SEMI-AUTOMATIC-PARAMETER-ENTRY) ...... 2-7 ENCODER ...... 2-7 VIBRATORY SYSTEM ...... 2-8 ELECTROMAGNETIC BRAKE ...... 2-8 AUTO STOP LOCK SWITCH (JBC SYSTEM III, IV) ...... 2-8
CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE GENERAL...... 3-1 SHAFT IMBALANCE, WHEEL ADAPTER TO SHAFT REMOUNT TEST ...... 3-1 BALANCER DIAGNOSTICS (TROUBLESHOOTING) ...... 3-1 TROUBLESHOOT USING CORRECT DIAGNOSTICS PROCEDURES ...... 3-2 TOOLS REQUIRED WHEN SERVICING THE Y2K BALANCERS ...... 3-2 FUNCTIONS OF SNAPON / JBC VPI BALANCERS ...... 3-3 SERVICE CODES ...... 3-3 F/P CODE DESCRIPTIONS OF THE BALANCER...... 3-4 F/P 1 TOGGLE FINE WEIGHT MODE ...... 3-4 F/P 2 RIM WIDTH INCH / MILLIMETER ...... 3-4 F/P 3 GRAM / OUNCE ...... 3-4 F/P 4 CALIBRATION WITH ADAPTER OR DISABLE ADAPTER COMPENSATION ...... 3-4 F/P 7 TOGGLE MILLIMETER AND INCH FOR DIAMETER ...... 3-4 F/P 12 READ COUNTERS ...... 3-4 F/P 14 USER CALIBRATION PROCEDURE ...... 3-5 F/P 18 ALU-S MODE ...... 3-6 F/P 19 ALU-S ONE PLANE BALANCING MODE ...... 3-6 F/P 21 KERNEL SOFTWARE ...... 3-6 F/P 28 KERNEL ERROR MESSAGES ...... 3-6 F/P 36 TOGGLE ANGLES OF LEFT AND RIGHT WEIGHTS...... 3-6 F/P 43 RESETTING THE COUNTERS ...... 3-6 F/P 44 READ OR RESET PRODUCTIVITY OF USER ...... 3-6 F/P 50 READ OUTPUT VOLTAGE OF THE DISTANCE POTENTIOMETER OF SAPE ...... 3-7 F/P 51 READ OUTPUT VOLTAGE OF THE DIAMETER POTENTIOMETER OF SAPE ...... 3-7 F 52 READ OUTPUT VOLTAGE OF THE WIDTH POTENTIOMETER ...... 3-7 F/P 53 DISPLAY TEST ...... 3-7 F/P 55 CHECK AC AND DC VOLTAGES ...... 3-7 F/P 59 DISPLAYS THE UNBALANCE OF THE BARE SHAFT ...... 3-7 F/P 60 READ SHAFT RPM ...... 3-7 F/P 63 CONTINUOUS BALANCING ...... 3-7 F/P 64 DISPLAYS THE TRANSDUCER OUTPUT ...... 3-7 F79 CALIBRATION OF WIDTH SAPE ...... 3-8 F/P 80 SAPE GAUGE CALIBRATION...... 3-9 F/P 83 FACTORY CALIBRATION PROCEDURE ...... 3-11 F/P 84 EMPTY SHAFT CALIBRATION PROCEDURE ...... 3-13 F/P 85 COPY CONTENTS OF MAIN PCB TO ENCODER ...... 3-13 F/P 86 COPY CONTENTS OF ENCODER TO MAIN PCB - BK 1.21 ...... 3-13 F/P 90 MATCH BALANCE ...... 3-13 F/P 91 OPTIMIZATION ...... 3-13 F/P 92 SPLIT WEIGHT ...... 3-13 F/P 93 CHANGE MODEL SETTING...... 3-13 F/P 94 SPOKE MODE ...... 3-14 F/P 95 CLEAN & RESET EEPROM 1 & 2 ...... 3-14 F/P 97 STICKY AT TOP STOP AT TOP ...... 3-14 F99 SAPE-2 ACCURACY TEST ...... 3-15
Effective 05/2007 TABLE OF CONTENTS SERVICING THE BALANCER ...... 3-16 CONTROL PANEL REMOVAL & REPLACEMENT...... 3-16 MAIN PROCESSOR REPLACEMENT ...... 3-17 TO ACCESS THE INSIDE OF THE MACHINE ...... 3-18 POWER SUPPLY BOX...... 3-18 TRANSDUCER REMOVAL ...... 3-19 INSTALLATION OF TRANSDUCER ...... 3-19 ENCODER REMOVAL ...... 3-20 VIBRATORY MEMBER REMOVAL...... 3-20 VIBRATORY INSTALLATION ...... 3-20 DIAMETER SAPE / POTENTIOMETER VPI II, III, IV & SOT LD ...... 3-21 DIAMETER SAPE / POTENTIOMETER ADJUSTMENT ...... 3-21 SAPE GAUGE ...... 3-21 DISTANCE SAPE / POTENTIOMETER VPI III, IV ...... 3-22 DISTANCE SAPE / POTENTIOMETER INSTALLATION VPI III, IV ...... 3-22 WIDTH SAPE / POTENTIOMETER INSTALLATION ...... 3-23 ELECTRIC BRAKE PEDAL ADJUSTMENT ...... 3-23 ELECTROMAGNETIC MOTOR BRAKE ADJUSTMENT ...... 3-23 MOTOR REMOVAL ...... 3-24 HOOD SWITCH / CAM / SPRING ...... 3-25
CHAPTER 4 JBC SYSTEM IV GENERAL...... 4-1 SELF TEST DURING START UP ...... 4-1 DISPLAY DESCRIPTION ...... 4-4 BALANCER SETUP ...... 4-4 FUNCTION SCREEN ...... 4-5 FUNCTION DESCRIPTION ...... 4-5 CUSTOMER CALIBRATION ...... 4-7 ENTERING SERVICE MODE ...... 4-9 C CODES ...... 4-10 C28 DISPLAY AND CLEAR ERROR CODES ...... 4-10 C43 RESET COUNTERS ...... 4-11 C47 SELECT MACHINE MODEL ...... 4-11 C55 INCOMING LINE VOLTAGE ...... 4-11 C56 CIRCUIT STATE OF THE WHEEL GUARD ...... 4-11 C57 VIBRATORY TEMPERATURE SENSOR ...... 4-11 C60 MOTOR RPM ...... 4-11 C74 POSITION COUNTER AND BASIC INCREMENTAL ENCODER TEST ...... 4-11 C75 DISPLAY VALUES OF A/D CONVERTER ...... 4-12 C80 CALIBRATION OF DISTANCE, DIAMETER AND AUTO STOP SYSTEM ...... 4-12 C81 MEASURING ADAPTOR FLANGE AND ZERO PLANE ...... 4-17 C82 WIDTH GAUGE ARM ADJUSTMENT / CALIBRATION ...... 4-17 C83 CALIBRATION OF UNBALANCE MEASUREMENT ...... 4-19 C84 EMPTY SHAFT COMPENSATION ...... 4-21 C88 ANGULAR UNBALANCE POSITION ...... 4-22 C90 SAVING ADJUSTMENT DATA ...... 4-23 FIELD PROGRAMMING THE BALANCER ...... 4-24
CHAPTER 5 BFH SERIES INTRODUCTION ...... 5-1 THEORY OF OPERATION ...... 5-1 BFH/OPTIMA SERIES MAJOR COMPONENTS ...... 5-4 CAMERA PROCESSOR BOARD ...... 5-4 ELECTRONIC BOX ...... 5-5 SCANNER / LASER / CCD ...... 5-6
Effective 07/2006 TABLE OF CONTENTS POWER SUPPLY PCB ...... 5-6 POWER CLAMP ASSEMBLY ...... 5-7 SELF TEST DURING START UP ...... 5-8 DISPLAY DESCRIPTION ...... 5-11 BALANCER SETUP ...... 5-11 FUNCTION SCREEN ...... 5-12 FUNCTION DESCRIPTION ...... 5-12 CUSTOMER CALIBRATION ...... 5-14 ENTERING SERVICE MODE ...... 5-16 C CODES ...... 5-17 C28 DISPLAY AND CLEAR ERROR CODES ...... 5-17 C43 RESET COUNTERS ...... 5-18 C47 SELECT MACHINE MODEL ...... 5-18 C55 INCOMING LINE VOLTAGE ...... 5-18 C56 CIRCUIT STATE OF THE WHEEL GUARD ...... 5-18 C57 VIBRATORY TEMPERATURE SENSOR ...... 5-18 C60 MOTOR RPM ...... 5-18 C74 POSITION COUNTER AND BASIC INCREMENTAL SHAFT ENCODER TEST ...... 5-18 C75 DISPLAY VALUES OF A/D CONVERTER ...... 5-19 C83 CALIBRATION OF UNBALANCE MEASUREMENT ...... 5-23 C84 EMPTY SHAFT COMPENSATION ...... 5-26 C88 WHEEL WEIGHT POSITIONING ...... 5-27 C90 SAVING CALIBRATION DATA ...... 5-28 C98 POWER CLAMP ENCODER ...... 5-28 C110 VCC VOLTAGE ...... 5-29 C120 ENABLE / DISABLE LASER POINTER ...... 5-29 C122 SCANNER / LASER / CCD CALIBRATION ...... 5-30 C123 DIAGNOSTIC FUNCTIONS ...... 5-32 ACCESSING THE DIAGNOSTIC FEATURES ...... 5-32 DIAGNOSITC BITS (SHOWN IN BLACK) ...... 5-35 STATUS FLAGS (SHOWN IN BLUE) ...... 5-36 ANALOG INPUTS: (SHOWN IN GREEN) ...... 5-36 C123 MECHANICAL SCANNER / LASER / CCD ADJUSTMENT ...... 5-37 CCD / LASER / SCANNER INSTALLATION ...... 5-39 INNER SCANNER INSTALLATION ...... 5-39 OUTER SCANNER INSTALLATION ...... 5-40 HOOD ADJUSTMET ...... 5-40 OUTER SCANNER INSTALLATION CONTINUED ...... 5-41 REAR SCANNER INSTALLATION ...... 5-42 REAR SCANNER DRIVE BELT ...... 5-43 FIELD PROGRAMMING THE CAMERA PROCESSOR PCB ...... 5-44 REMOVING THE BELL HOUSING ...... 5-45 IMPORTANT BALANCER INFORMATION ...... 5-46 QUALIFYING THE BALANCER ...... 5-46
CHAPTER 6 BFH800B6 INTRODUCTION ...... 6-1 SETUP AND CALIBRATION ...... 6-1 CALIBRATION OF WHEEL GUARD POTENTIOMETER ...... 6-2 C122 CAMERA AND SONAR CALIBRATION ...... 6-4 BFH800B SPECIFIC COMPONENTS ...... 6-6
APPENDIX A CODES KERNEL CODES ...... A-1 H CODES SYSTEM IV...... A-7 E CODES SYSTEM IV...... A-7
Effective 05/2007 INTRODUCTION
GENERAL
The BFH, VPI SYSTEM & SOT Low Digital balancers are designed to compute static and dynamic imbalance of car, light truck, motorcycle and truck wheels. The VPI SYSTEM & SOT Low Digital have a delay of ap- proximately 8 to 10 seconds during power up. During the delay, the processor electronics are checking the status of all electronics. These components include the Encoder board, the transducers, the thermocouple, the power interface board, the display board, and the membrane switch. After the status check is complete (approximately 8-10 seconds) the units beeps, the displays all light up, and then the unit goes to the idle state and displays dashes on the 7 segment LED’s. The unit is now ready for parameter inputs and can take measurements.
FUNCTIONAL DESCRIPTION
BASIC BALANCER OPERATION Once the balancer reaches balancing speed (>200 RPM System III, IV, BFH >90 RPM System I, II, SOT Low Digital) the balancer display will show “Spn”, calculation is done at this time. Once the weight imbalance and location is known the balancer will reverse polarity sending 230VAC via a relay on the Power Supply Board to the motor bringing the shaft to a stop. Imbalance amounts and corrective weight locations will be shown on the display.
WEIGHT APPLICATION Rotate the wheel until the center green LED in the right hand row of LEDs illuminates. Apply the corrective weight at top dead center (12 o'clock position) on the right side of the wheel. Repeat this process for the left side of the wheel.
ALLOY MODES In addition to the standard Dynamic and Static modes there are 5 Alloy modes, each of which are illustrated by LEDs on the balancer touch panel when activated. Alloy modes 1 through 5 are accessed by first toggling the MODE key until the balancing mode desired is displayed. See the Operator's Manual for an explanation of Alloy Mode balancing. The last used mode will again be used even when power is cycled.
ALU-S MODE ALU-S mode balancing allows the operator to balance custom wheels in a true dynamic mode using con- cealed weights while maintaining specified weight separation. See the Operator's Manual for an explanation of ALU-S mode balancing.
DISPLAY / CONTROL PANEL The display of the VPI SYSTEM & SOT Low Digital balancer shows weight amount and position for counter- balancing, plus acts as a message center for the operator of the machine or for the technician who is repairing the machine.
Everytime the machine powers on, the software automatically performs a system check. The Main Processor performs a SAPE error check. If the SAPE is good the machine enters idle state as normal. If one of them fails, for example, the distance gauge fails, machine displays “DIS” “SAP” “FAL” (System III) when the machine is powered on. If diameter gauge fails, it displays “DIA” “SAP” “FAL” (System III). If both of them fail, machine displays “2-D” “SAP” “FAL” (System III). The operator must press the “STOP” button to exit the display and enter idle state. The machine masks the function of the failed part after SAPE check. For example, if the diameter gauge fails, the machine disables the measurement of diameter and measures the distance only. Or if the distance gauge fails the machine disables the measurement of the distance gauge and measures the diameter only. The BFH performs the same kind of checks on each scanner. The BFH requires that the inner and outer scanner be present and working before proper operation. Should any scanner assem- bly fail on boot up the balancer will display an “E code”.
Effective 10/2007 Page i INTRODUCTION GENERAL SPECIFICATIONS AND MACHINE FEATURES
MAJOR FEATURES 3D (SAPE) System III, 2D (SAPE) System II SOT Low Digital, 1D (SAPE) System I Large cabinet (System III) - Small cabinet (System I, II, SOT Low Digital) Large weight tray with weight pockets, cone storage (System III), 1 miscellaneous pocket, a can storage pocket, and weight pliers storage. 4 storage pegs (Side of unit) Speed nut with pressure cup and pressure ring (System II, III SOT LD) - Standard nut (System I) Automatic wheel stop at top dead center and motor to TDC for second plane weight placement Sticky at top Fine and coarse weight readings ALUS mode with automatic distance gage lock and tape weight applicator Spoke mode 5 ALU modes and static balance Split weight Mode 3 Window display (System III, SOT LD) - 2 Window display (System I, II) 200 RPM rotational speed (System III) - 90 RPM rotational speed (System I, II, SOT LD) 6 second cycle time with P225/55 R16 Tire and Wheel mounted Full size wheel guard and frame 230 volt 50/60 Hz power requirements (System III) - 115 volt 60 Hz (System I, II, SOT LD) Upgradeable software Multiple users Spin count: total # of all spins since manufacture, # of spins since last calibration, # of spins in service mode, # of spins in user mode Optimization and Matchmount Ounce and gram display toggle Millimeter / inch display toggle Emergency stop: When unit is spinning, if any button is pressed the shaft will stop rotating. Balancer Optimized AC induction motor with belt drive Shaft lock
SPECIFICATIONS Shaft size: VPI 40mm (1.57”) - Snapon Low Digital 28mm (1.10”) Balance (shaft) speed: 200 RPM (System III) 90 RPM (System I, II, SOT LD) Cycle time: 7 seconds with an average 14" tire & wheel combination Balance Types: Five 2-plane alloy modes, plus static, dynamic and Match Balance modes. Accuracy: 0.1 oz. (2.8g) Weight Positioning resolution: ± 0.7 degrees Rim Width capacity: 3"-20" / 76 mm - 508 mm Rim Diameter capacity: 8"-26" / 203 mm-660 mm Maximum Tire Diameter: 44" (1118 mm) Maximum wheel weight: 120 lbs/54Kg (System I), 133lbs/60 Kg (System II, SOT LD), 154lbs/69Kg (System III)
Effective Page ii 10/2007 INTRODUCTION IMPORTANT SAFETY INSTRUCTIONS
When using this equipment, basic safety precautions should always be followed, including the following:
1. Read all instructions.
2. Do not operate equipment with a damaged power cord or if the equipment has been damaged until it has been examined by a qualified authorized service tech- nician.
3. If an extension cord is used, a cord with a current rating equal to or more than that of the machine should be used. Cords rated for less current than the equip- ment may overheat. Care should be taken to arrange the cord so that it will not be tripped over or pulled.
4. Always unplug equipment from electrical outlet when not in use. Never use the cord to pull the plug from the outlet. Grasp plug and pull to disconnect.
5. To reduce the risk of fire, do not operate equipment in the vicinity of open containers of flammable liquids (gasoline).
6. Keep hair, loose fitting clothing, fingers and all parts of the body away from moving parts.
7. Adequate ventilation should be provided when working on operating internal combustion engines.
8. To reduce the risk of electric shock, do not use on wet surfaces or expose to rain.
9. Do not hammer on or hit any part of the control panel with weight pliers.
10. Do not allow unauthorized personnel to operate the equipment.
11. Use only as described in this manual. Use only manufacturer’s recommended attachments.
12. Always securely tighten the wing nut before spinning the shaft.
13. ALWAYS WEAR SAFETY GLASSES. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses.
14. Balancer is for indoor use only.
15. This equipment uses class II lasers. Do not look into or allow by standers to look into the laser source.
Effective 10/2007 Page iii INTRODUCTION LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE
1. Notify all affected employees that a lockout or tagout system is going to be utilized and the reason thereof. The authorized employee shall know the type and magnitude of energy that the machine or equipment utilized and shall understand the hazards thereof.
2. If the machine or equipment is operating, shut it down by the normal stopping procedure (depress the stop button, open toggle switch, etc.)
3. Operate the switch, valve, or other energy isolating device(s) so that the equipment is isolated from its energy source(s). Stored energy (such as that in springs, elevated machine members, rotating fly- wheels, hydraulic systems, and air gas, steam or water pressure, etc.) must be dissipated or restrained by methods such as repositioning, blocking, bleeding down, etc.
4. Lockout and/or tagout the energy isolating devices with individual lock(s) or tag(s).
5. After ensuring that no personnel are exposed, and as a check on having disconnected the energy sources, operate the push button or other normal operating controls to make certain the equipment will not operate. CAUTION: RETURN OPERATING CONTROL(S) TO “NEUTRAL” OR “OFF” POSITION AFTER THE TEST [DE-ENERGIZED STATE].
6. The equipment is now locked out or tagged out.
ELECTRICAL SAFETY PRECAUTIONS
Make sure the balancer is unplugged before disconnecting any wires in preparation for replacing any boards, cables or other items within the unit. Use the “Lockout and/or Tagout” procedure.
Effective Page iv 10/2007 INTRODUCTION SERVICE GUIDELINES / HANDLING STATIC SENSITIVE PCB’S
Electrostatic discharge can destroy high impedance ICs if uncontrolled. Use the following techniques to avoid damaging ICs:
- Leave new circuit boards in their antistatic bags until ready for use. - When replacing boards, proms, etc. be sure to turn off power to the machine first. - Use an anti-static wrist strap. Connect it to chassis ground on the equipment or to an available raw ground. - Touch the chassis of the equipment to put yourself at the same static potential as the equipment. - Grasp the PCB from opposite sides using your fingertips. Do not grasp the components on the board.
! USE STANDARD ANT-STATIC PROCEDURES WHILE PERFORMING THESE INSTRUCTIONS
When inserting PCB’s: - Place boards on a grounded static mat after removal. - Remove the new PCB from the original package onto a grounded static mat. Save packaging to use when returning defective boards. - Remove power from the machine (unplug from wall) before installing the PCB. - Avoid handling components needlessly. - Do not set PCBs on insulating surfaces such as paper, glass, rubber, or plastic. - Static is generated by friction. The following actions promote static generation: - Wearing silk or nylon clothing. - Walking on carpets. - Walking with rubber soled shoes.
Static generation is increased when certain environmental conditions exist. Conditions of low humidity combined with wearing silks or nylons, walking on carpets, or walking with rubber soled shoes may create large electrostatic charges on your person, capable of blowing a hole in the substrate of an IC.
Effective 10/2007 Page v INTRODUCTION CAUTION! This product uses LASER RA- DIATION for measurements. DO NOT STARE INTO BEAM.
Refer to these laser safety statements whenever this sign is displayed.
Peak power 1.0 mW. Pulse duration 5 m sec. Emitted wavelength 650nm.
Class II laser product. Caution - the use of optical instruments with this product will increase risk of eye hazard.
WARNING!!! DO NOT STARE INTO LA- WARNING!!! IN THE EVENT OF MA- SER BEAM! EYE INJURY MAY OCCUR CHINE MALFUNCTION, DO NOT LOOK WITH PROLONGED EYE CONTACT INTO THE LASER AREA. PROLONGED WITH LASER. AVOID EYE CONTACT EXPOSURE TO THE LASER MAY WITH THE LASER SCANNERS CAUSE EYE INJURY.
PERFORM REGULAR CLEANING OF THE LASER SCANNER GLASS TO ENSURE OPTIMUM OPERATION.
ALWAYS OPERATE THE WHEEL BAL- ANCER WITHIN THE RANGES STATED IN THE LABEL SHOWN BELOW. DO NOT KNOCK OR TAMPER WITH THE LASER SCANNERS
Effective Page vi 10/2007 CHAPTER 1 AC/DC POWER DISTRIBUTION
LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE
1. Notify all affected employees that a lockout or tagout system is going to be utilized and why. The autho- rized employee should know the electrical power the machine uses and it’s hazards.
2. If the machine or equipment is running, shut it down by the normal stopping procedure (depress the stop button, open toggle switch, etc.)
3. Use appropriate devices to isolate the equipment from the power source(s). Stored energy (such as that in springs, elevated machine members, rotating flywheels, hydraulic systems, and air gas, steam or water pressure, etc.) must be dissipated or restrained by methods such as repositioning, blocking, bleeding down, etc.
4. Lockout and/or tagout the energy isolating devices with individual lock(s) or tag(s).
5. After ensuring that no personnel are exposed, and as a check on having disconnected the energy sources, operate the push button or other normal operating controls to make certain the equipment will not operate. CAUTION: RETURN OPERATING CONTROL(S) TO “NEUTRAL” OR “OFF” POSITION AFTER THE TEST [DE-ENERGIZED STATE].
6. The equipment is now locked out or tagged out.
ELECTRICAL REQUIREMENTS
NOTE: ANY ELECTRICAL WIRING MUST BE PERFORMED BY LICENSED PERSONNEL. ALL SERVICE MUST BE PERFORMED BY AN AUTHORIZED SERVICE TECHNICIAN.
Check on the plate of the machine that the electrical specifications of the power source are the same as that of the machine.
NOTE: THE Y2k BALANCERS PERFORM A SELF-TEST ROUTINE ON START-UP. THERE IS A DELAY OF SEVERAL SECONDS BEFORE THE DISPLAY IS ACTIVATED.
NOTE: ANY ELECTRICAL OUTLET INSTALLATION MUST BE VERIFIED BY A LICENSED ELECTRI- CIAN BEFORE CONNECTING THE BALANCER.
NOTE: ENSURE THAT THE OUTLET HAS AN AUTOMATIC GROUND FAULT CIRCUIT BREAKER WITH A DIFFERENTIAL CIRCUIT SET AT 30 MA.
Effective 08/2007 Page 1-1 CHAPTER 1 AC/DC POWER DISTRIBUTION AC THEORY OF OPERATION
! DANGEROUS HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENT
Always use the “One Hand Rule” when working with AC voltages by keeping one hand in your pocket or behind your back. Before removing wires from the Balancer, always verify that the unit is “OFF”. Turn off the Main Power Switch on the back and unplug the AC power cord from the AC outlet.
AC DISTRIBUTION The balancer requires 230VAC (System II, III, IV) 115 VAC (System I, SOT Low Digital) for proper operation. The AC voltage comes in through a switch and immediately is sent to the Power Supply PCB via X41 pin 1. The drive motor is the only component that requires the 230VAC ± 10%. The primary voltage applies 230V, 60Hz AC to the BALANCER via the hot side (Black Wire) of the AC power cable. The Main Power routes to one side of the “ON/OFF” Rear Panel Power Switch. The hot wire continues to one side of the Line Filter. The neutral side routes to the other side of the Line Filter. The earth ground directly connects to the BALANCER chassis, and the Line Filter. It is critical to have the proper input voltage in order for the balancer to operate correctly.
DRIVE MOTOR The drive motor for the unit receives AC power VIA two relays mounted directly to the Power Supply Board. To keep arcing at the relays to a minimum the relays are switched in synchronism. The switching times of the relays are determined individually and taken into consideration for optimum pull-in times. The motor also utilizes a capacitor to generate a sufficient amount of torque during acceleration and braking.
DC THEORY OF OPERATION
PROCESSOR BOARD The operating voltage for the Main Processor is 5VDC. It receives this power from the Power Supply Board at X1 pins 32 and 34. This 5 volts also passes through the Processor Board and supplies the Encoder PCB and both the Distance and Diameter SAPE.
ENCODER BOARD The encoder receives 5VDC from the Processor Board. This voltage can be measured at the Processor Board at X3 pin 6. The encoder is built so that there are no adjustments. The encoder disk is built onto the shaft and cannot be replaced without replacing the vibratory member. The encoder is fitted in the vibratory tube and consists of a reflective slotted sleeve which is mounted on the main shaft and the optoelectronic unit.
DISTANCE POTENTIOMETER (SYSTEM I,II,III,IV SOT LOW DIGITAL) The distance potentiometer is a 5K pot. It is supplied 5VDC from the main processor. This input voltage can be measured at the Processor Board X6 pin 3. The output voltage is dependent upon the deflection of the guage from the home position.
DIAMETER POTENTIOMETER (SYSTEM II,III,IV SOT LOW DIGITAL) The diameter potentiometer is a 5K pot. It is supplied 5VDC from the main processor. This input voltage can be measured at the Processor Board X7 pin 3. The output voltage is dependent upon the rotation of the guage from the home position.
Effective Page 1-2 08/2007 CHAPTER 1 AC/DC POWER DISTRIBUTION WIDTH POTENTIOMETER (SYSTEM III,IV) The width potentiometer is a 5K pot. It is supplied 5VDC from the main processor. This input voltage can be measured at the Processor Board X8 pin 3. The output voltage is dependent upon the rotation of the guage from the home position.
TRANSDUCERS The transducers are installed in a manner that it forms a virtual transducer on each end of the shaft. This configuration gives the balancer greater accuracy along with minimal amount of erroneous readings. Both measuring transducers are arranged in one plane. The tranducers produce a DC output. The DC voltage that is generated is sent back to the processor.
DISPLAY BOARD The Display Board receives 5VDC from the Power Supply Board. This 5 volts can be checked at the harness of the display board X2 pin 6 or at the Power Supply Board X2 pin 6.
KEYPAD The keypad allows operator input to the Main Processor Board. The output signal passes through the Power Supply Board directly to the Main Processor.
AUTO STOP LOCK SWITCH (VPI III, IV) The auto lock switch receives 5VDC from the Power Supply Board when the balancer is in the ALU-S mode. The voltage can be measures at the Power Supply Board at X13 pin 1&2 .
ELECTROMAGNETIC BRAKE Early Model VPI System III only The Power Supply board sends 150VDC to the Electromagnetic brake on the motor stopping the tire and wheel assembly at TDC for the outside weight location. The voltage can be measured at X13 pins 7&8 on the Power Supply Board.
EMBEDDED PCB (SYSTEM IV, BFH) The System IV balancer has a processor pcb that controls the system BIOS for COM1 and the CRT. The PCB has a 32mb CompactFlash card that stores all screen shots for the balancer the processor interfaces with the Main balancer processor inside the EBox via COM1. The board is powered by 5VDC via cable from the Power PCB inside the Ebox.
Effective 08/2007 Page 1-3 CHAPTER 1 AC/DC POWER DISTRIBUTION TROUBLESHOOTING
COMPLAINT CORRECTIVE ACTION
I. Machine will not power up. Is the machine plugged in at the wall? NO-> Plug machine in.
Is the balancer plugged in at the back? NO-> Plug machine in.
Are the fuse(s) inside the switch good? NO-> Replace the fuse(s)
Is 230VAC present at X41 pin 1? NO-> Checking wiring.
Is 5 VDC LED lit up on Processor Board? NO-> Replace Processor Board.
Is 5 VDC present at pins 3 and 6 at X2? NO-> Replace Power Board.
Are LED lit up on Display Board? NO-> Reload Software Replace Display Board.
II. Machine will not brake. Is 230 VAC present at X43 pins 2 during brake cycle? NO-> Replace Power Board. (Retest) Replace Processor Board. (Retest) Replace the encoder. (Retest) Replace the Motor. (Retest)
III. Keypad will not function. Use keypad schematic jumper pins of non working function.
NO-> Replace keypad. (Retest) Replace Display Board. (Retest) Replace Main Processor. (Retest)
IV. Distance gauge does not work. Is the distance arm in the HOME position during power up? NO-> Place it in the home position and retest.
Check pins 1 and 3 at connector X6 on the Processor Board. Is the voltage reading 5 VDC +/- 1 volt? NO-> Replace Processor Board and retest.
Press F/P 50 and pull the distance gauge out, does the voltage reading on the display change? NO-> Check to make sure string is attached to dis- tance gauge. Replace potentiometer.
Effective Page 1-4 08/2007 CHAPTER 1 AC/DC POWER DISTRIBUTION Check F/P 50 with the SAPE in the home position, is the voltage reading correct? NO-> Readjust voltage reading to desired setting.
V. Diameter gauge does not work. Is the diameter arm in the HOME position during power up? NO-> Place it in the home position and retest.
Check pins 1 and 3 at connector X7 on the Processor Board. Is the voltage reading 5 VDC +/- 1 volt? NO-> Replace Processor Board and retest.
Press F/P 51 and move the SAPE gauge up, does the voltage reading on the display change? NO-> Check to make sure the cog wheels are meshed. Replace potentiometer.
Check F 51 with the SAPE in the home position, is the voltage reading correct? NO-> Readjust voltage reading to desired setting.
VI. Width gauge does not work. Is the width arm in the HOME position during power up? NO-> Place it in the home position and retest.
Check pins 1 and 3 at connector X8 on the Processor Board. VPI System III, IV Is the voltage reading 5 VDC +/- 1 volt? NO-> Replace Processor Board and retest.
Press F 52 and move the SAPE to the flange, does the voltage reading on the display change? NO-> Check to make sure the cog wheels are meshed. Replace potentiometer.
Check F 52 with the SAPE in the home position, is the voltage reading correct? NO-> Readjust voltage reading to desired setting.
VII. Auto Lock does not work. Check pins 1 and 2 at connector X13 on the Power Board. VPI System III Is the voltage reading 5 VDC +/- 1 volt? NO-> Replace Power Board and retest.
Check connections at Auto Lock switch is the voltage reading 5 VDC ± 1 volt? NO-> Replace Auto Lock switch.
Effective 08/2007 Page 1-5 CHAPTER 1 AC/DC POWER DISTRIBUTION VIII. Machine chases weights. Are the mounting accessories in good condition? NO-> Clean backing plate and all accessories. Replace if necessary.
Mount a Pruefrotor and manually enter parameters. Attach the 100 gram weight on the inside of the Pruefrotor and spin. Does the balancer display 100 gr (3.5 oz) on the inside? YES-> Move the weight to the outside plane and spin, does the outside plane display 100 grams? YES-> Return the balancer to service. NOTES: THERE IS NO NEED TO PERFORM ANY OTHER TEST THE BALANCER IS WORKING. TRAIN OPERATOR ON TROUBLESHOOTING CHASING WEIGHTS. NO-> Perform F/P 80,83,84 and retest (Pruefrotor required).
Check vibratory system mounting bolts, are they tight? NO-> Tighten to specification and recalibrate and retest.
Check F/P 64 does the left display change and then stabilize when the shaft is hit? NO-> Replace the rear transducer and recalibrate
Check F/P 64 does the right display change and then stabilize when the shaft is hit? NO-> Replace the front transducer and recalibrate & retest.
Are both the Front and Rear transducers tight? NO-> Adjust to specification, recalibrate and retest.
Check F/P 36, does the left display change from 0 to 511 and the right display change from 0.00 to 359?
NO-> Replace the Encoder Board. (Retest) Replace the Vibratory System. (Retest) Replace the Main Processor. (Retest)
Does the shaft spin smoothly and freely? NO-> Replace vibratory system. (Retest)
IX. Electro Brake does not work. Check pins 7 and 8 at connector X13 on the Power Board. VPI System III Is the voltage reading 150 VDC when foot pedal is pressed? NO-> Replace Power Board and retest.
Check for 0.2 gap between electro switch and plate assem bly. Is the gap correct? NO-> Adjust gap and retest.
Check voltage at Electro Magnetic switch is 150VDC present when brake pedal is pressed? NO-> Replace Electro Magnetic switch.
Effective Page 1-6 08/2007 CHAPTER 1 AC/DC POWER DISTRIBUTION PROCESSOR PCB
X1 - From Power Supply Board. X3 - Encoder, Tranducers & Temp Sensor. • Pin 6=5 VDC X6 - Distance SAPE • Pin 1=Gnd • Pin 2=Output • Pin 3=5 VDC X7 - Diameter SAPE • Pin 1=Gnd • Pin 2=Output • Pin 3=5 VDC X8 - Width SAPE • Pin 1=Gnd • Pin 2=Output • Pin 3=5 VDC X9 - Serial Connection. To COM1 on Embedded PCB (Sys IV, BFH)
KEYPAD SCHEMATIC (VPI SYSTEM III)
Effective 08/2007 Page 1-7 CHAPTER 1 AC/DC POWER DISTRIBUTION KEYPAD SCHEMATIC (VPI SYSTEM I, II)
KEYPAD SCHEMATIC (SNAPON LOW DIGITAL)
Effective Page 1-8 08/2007 CHAPTER 1 AC/DC POWER DISTRIBUTION Power Supply Box
Effective 08/2007 Page 1-9 CHAPTER 1 AC/DC POWER DISTRIBUTION EMBEDDED PC (JBC SYSTEM IV)
To Processor To CRT
To Power PCB
Effective Page 1-10 08/2007 Snap-on Diagnostic 355 Exchange Ave Conway, AR 72032 U.S.A.
VPI - I,II,III,IV Snapon Low Digital 02/2003 REV B. Rod Harrison Fred Rogers Rod Harrison Fred Rogers AC / DC POWER DISTRIBUTION 1-1 1-11/12 Page left blank intentionally CHAPTER 2 THEORY OF OPERATION
FUNCTIONAL DESCRIPTION
The JBC VPI & SOT Wheel balancers are designed to compute static and dynamic imbalance of car, light truck, motorcycle and truck wheels.
Wheels are attached to the shaft using precision centering adapters and retainers. The shaft rotates on precision bearings on the shaft support. The rotating shaft is perfectly balanced. The wheels attached normally represent an imbalance, which creates centrifugal force and a dynamic momentum as it is spun on the balancer shaft. The wheel is spun by means of a low RPM motor.
The centrifugal forces created by any imbalance are detected by the two transducers located between the shaft support and the machine frame. These transducers contain small discs of special quartz which generate millivolts of electric current when compressed. The current created is linearly proportional to the compression force.
Centrifugal force vectors are generated by imbalances in the rotating wheel. This causes a signal to be generated by the transducers (which pick up only the vertical component of the constrained forces) in the form of a periodic sine wave.
The signal is not perfectly sinusoidal, due to noises from in the suspension system, which add to the signal generated by the imbalance of the wheel. To determine acutal imbalance the signal must be filtered.
To compute correct imbalance values, the parameters (diameter, width, and offset) of the wheel to be bal- anced must be entered. Enter wheel parameters using the Distance Entry Arm. Slide the gauge to touch the rim and hold. The distance to the rim and the wheel diameter are entered automatically by means of two mounted potentiometers. The rim width can be done automatically by simply pulling the width arm and touching the outside of the rim (System III,IV only). The rim width may also be done manually by using the supplied rim width calipers and entering the measured value. This is done by pressing and releasing the rim width button and toggling the UP/DOWN arrow keys on the display panel or by rotating the tire and wheel assembly until the desired number is shown.
To find wheel imbalance, the transducers signal magnitude and encoder timing are both required. A series of timing marks on the shaft that interrupt light transmitted between two optocouplers generate a DC Square wave each time a mark moves past an optocoupler. One additional mark offset from the encoders’ metallic strip, interrupts a third optocoupler on the board, creating a zero-signal reset or home position. The encoder detects 512 angular positions during each turn of the shaft, plus the home or reset position. The frequency of the DC square wave generated by the encoder allows the balancer to compute shaft speed, wheel accelera- tion and weight location. The encoder and transducer signals are multiplexed by the CPU to give weight amount and location readings.
The CPU board gathers the information generated from the encoder and transducer via a ribbon cable. This board is powered with 5 VDC received from the Power Supply Board.
Calculated imbalance values are then shown on the LED display panel after a spin cycle.
Effective 02/2003 Page 2-1 CHAPTER 2 THEORY OF OPERATION TERMINOLOGY JBC SYSTEM IV Before using the wheel balancer it is suggested that you become familiar with the terminology and features of the machine’s components. Refer to Figures 2-1 and 2-2 for identification and location
1. Main Screen: Main information screen for the user interface. 2. Function Key area: Six function keys F1 to F6, the functionality of the keys can Status change in every screen. Represents the Main function of the keys on the keyboard. Area Screen 3. Status Area: Status information from top to bottom, balancer model and software revision, date and time, screen name, balancer status (i.e. adapter com- pensation active, loaded user), error mes- Function sages. Key 4. Start - Start Spin Cycle Area Stop - Stop the Main Shaft Escape - Moves back one page Help - Go to Help Screen
6. Foot Operated Shaft Lock - A foot oper- ated shaft lock is used to stabilize the shaft during the weight placement process. 7. Shaft Adapter - A common 40 mm size shaft is used. The easily removable shaft can be replaced for service or during use of certain wheel adapters. 8. Wheel Guard - The standard wheel guard is a safety feature for prevention of opera- tor injury in the event of loose weights, de- bris or wheel mounting failure. The bal- ancer is programed to spin upon guard clo- sure as well as brake when the guard is raised. 9. Semi-Automatic Parameter Arm - Rim dis- tance is automatically input with the SAPE. The SAPE is also used in several proce- dures for determining accurate rim profiles. 10. 3DP SAPE - Rim width is automatically input with the SAPE by touching the out- side of the wheel where the weight will be located. 11. Display - Easy to read, user friendly dis- play featuring large LEDs and one button functions. 12. Accessory Storage - Four sturdy side mounted pegs are supplied for storage. 13. Weight Storage Tray - Generous storage for a variety of weight profiles and sizes as well as built in storage pockets for the stan- dard centering cones
Effective Page 2-2 02/2003 CHAPTER 2 THEORY OF OPERATION 14. Enter - This key activates whatever selection has TERMINOLOGY JBC SYSTEM III been requested, it also spins the wheel if guard Before using the wheel balancer it is suggested that frame is down. you become familiar with the terminology and features 15. Mode Selection - A series of placement locations of the machine’s components. Refer to Figures 2-1 for custom weight location. Useful for the wide va- and 2-2 for identification and location. riety of custom wheels on today's market. Figure 2-1 16. Up and Down Value - Buttons are used to raise or lower displayed values for parameter entry or func- tion code activation. 17. Spoke Mode Indicator - When lit indicates the balancer is in the “Spoke Mode”.
1. Inside Weight Amount and Function Display Window - Shows inside or left weight amount and various operation messages. 2. Position Indicator LEDs - Displays the location for wheel weight placement. 3. Middle Display - Used to display wheel param- eters or messages. Figure 2-2 4. Outside Weight Amount and Function Display Window Shows outside or right weight amount and various operation messages. 5. Fine Mode Indicator - When lit indicates the bal- 18. Foot Operated Shaft Lock - A foot operated shaft ancer is in the “Fine Mode”. lock is used to stabilize the shaft during the weight 6. Weight Mode and Placement Display - Displays placement process. a pictorial reference of the chosen balance mode. 19. Shaft Adapter - A common 40 mm size shaft is 7. Multi-Operator Selection - This key toggles be- used. The easily removable shaft can be replaced tween four operators designated as A, B, C, and D. for service or during use of certain wheel adapters. Wheel parameters are recalled upon command. 20. Wheel Guard - The standard wheel guard is a NOTE: ROTATING THE SHAFT IN EITHER DIREC- safety feature for prevention of operator injury in TION WILL ALSO VARY DISPLAYED VALUES. the event of loose weights, debris or wheel mount- 8. ALU-S Activates the ALU-S mode. ing failure. The balancer is programed to spin upon 9. Function Button - Used to activate the various guard closure as well as brake when the guard is functions. Press this button followed by pressing raised. the up or down arrow buttons until the desired num- 21. Semi-Automatic Parameter Arm - Rim distance ber is displayed. Press the “Enter” button to active is automatically input with the SAPE. The SAPE is the function. also used in several procedures for determining 10. Spoke Mode - Activates the Spoke Mode. accurate rim profiles. 11. Rim Offset - Key is used to enter the rim offset 22. 3DP SAPE - Rim width is automatically input with position using numbers from the distance gauge. the SAPE by touching the outside of the wheel Rim Diameter - Enter the rim diameter. Read the where the weight will be located. size stated on the tire sidewall. 23. Display - Easy to read, user friendly display fea- Rim Width - Press this key to enter the rim width. turing large LEDs and one button functions. Use the rim width calipers for measurement 24. Accessory Storage - Four sturdy side mounted 12. Fine Weight Toggle - In normal mode “FIN OFF” pegs are supplied for storage. round off is 0.25 oz or 5 gram, fine mode “FIN 25. Weight Storage Tray - Generous storage for a va- ON” round off is 0.05 oz. or 1 gram. riety of weight profiles and sizes as well as built in 13. Cancel - Pressing this key interrupts any process. storage pockets for the standard centering cones. Effective 02/2003 Page 2-3 CHAPTER 2 THEORY OF OPERATION TERMINOLOGY JBC SYSTEM I, II
Figure 2-3 Display Layout
Before using the wheel balancer it is suggested that you become familiar with the terminology and fea- tures of the machine’s components. Refer to Figures Figure 2-4 2-3 and 2-4 for identification and location.
1. Inside Weight Amount and Function Display 12. ALU-S and Spoke Mode - Activates the ALU-S or Window - Shows inside or left weight amount and Spoke Mode. Each time this button is pressed pro- various operation messages. gramming toggles between the two. 2. Position Indicator LEDs - Displays the location 13. Rim Offset - This key is used to enter the rim off- for wheel weight placement. set position using the numbers from the distance 3. Outside Weight Amount and Function Display gauge. Window Shows outside or right weight amount and 14. Multi-Operator Selection - This key toggles be- various operation messages. tween four operators designated as A, B, C, and D. 4. Weight Mode and Placement Display - Displays Wheel parameters are recalled upon command. a pictorial reference of the chosen balance mode. 15. Display - Easy to read, user friendly display fea- 5. Function Button - Used to activate the various turing large LEDs and one button functions. functions. Press this button followed by pressing 16. Weight Storage Tray - Generous storage for a the up or down arrow buttons until the desired num- variety of weight profiles and sizes as well as built ber is displayed. Press the “Enter” button to active in storage pockets for the standard centering cones. the function. 17. Accessory Storage - Four sturdy side mounted 6. Enter - This key activates whatever selection has pegs are supplied for storage of additional acces- been requested, it also spins the wheel if guard sories. frame is down. 18. Foot Operated Shaft Lock - A foot operated shaft 7. Up and Down Value - Buttons are used to raise or lock is used to stabilize the shaft during the weight lower displayed values for parameter entry or func- placement process. tion code activation. 19. Shaft Adapter - A common 40 mm size shaft is NOTE: ROTATING THE SHAFT IN EITHER DI- used. The easily removable shaft can be replaced RECTION WILL ALSO VARY DISPLAYED VAL- for service or during use of certain wheel adapters. UES. 20. Wheel Guard - The standard wheel guard is a 8. Cancel - Pressing this key interrupts any process. safety feature for prevention of operator injury in 9. Mode Selection - A series of placement locations the event of loose weights, debris or wheel mount- for custom weight location. Useful for the wide va- ing failure. The balancer is programed to spin upon riety of custom wheels on today's market. guard closure as well as brake when the guard is 10. Rim Width - Press this key to enter the rim width. raised. Use the rim width calipers for measurement. 21. Semi-Automatic Parameter Arm - Rim distance 11. Rim Diameter - Enter the rim diameter after press- is automatically input with the SAPE. The SAPE is ing this key. Read the size stated on the tire also used in several procedures for determining sidewall. accurate rim profiles.
Effective Page 2-4 02/2003 CHAPTER 2 THEORY OF OPERATION TERMINOLOGY SNAPON LOW DIGITAL
2 3 4 1 5
6 17
7 16
8 15
9 14
10 11 12 13
Figure 2-5 Display Layout
23 Before using the wheel balancer it is suggested that you become familiar with the terminology of the machine’s components. Refer to Figures 2-5 and 2-6.
1. Display for inner plane imbalance 2. Inner plane imbalance position indicator 3. Operator / Rim width 18 4. Outer plane imbalance position indicator 5. Display for outer plane imbalance 6. Display all parameters button 7. Fine-Normal button 8. Operator A-B-C-D toggle 20 9. Function button - “P” codes 10. Mode select button 11. Balance mode indicator 12. Rim width knob & manual distance entry 13. Cancel/Stop button 14. Manual Rim diameter 19 21 15. Manaul Rim offset button 16. ALU-S button 17. Enter / Start button 18. Wheel weight tray 19. Accessories storage location 20. (SAPE) gauge 22 21. Arbor - shaft adapter 22. Foot operated shaft lock 23. Wheel Guard Figure 2-6
Effective 02/2003 Page 2-5 CHAPTER 2 THEORY OF OPERATION BALANCER COMPONENTS
MAIN PROCESSOR PCB The microcontroller normally takes its instructions from the FLASH memory. A 40-pin IC socket is used to transfer the program from an EPROM to FLASH memory. Unlike EPROMs, FLASH memories do not require windows for UV light in order to delete data - they can be cleared and programmed electronically. Unless otherwise stated in the program revisions, new program versions can be installed without the need for adjust- ment. The main processor receives its power from the power supply pcb and distributes the power to the encoder, transducers and SAPE potentiometers. Calibration factors are stored in this location along with the encoder PCB.
POWER SUPPLY PCB The Power Supply Board receives 230VAC from the power cable (System II,III). The Power Supply Board on a Systems I & SOT LD receives 230VAC via power step-up transformer. The main AC power is sent to an on- board power supply which directs this power to on-board relays. This power is switched on and off via instruc- tions from the Main Processor to spin or brake the motor. 5VDC voltage is used to power the Main Processor Board, Encoder PCB & both SAPE potentiometers.
KEYPAD The keypad is used to input data into the Display PCB. It connects directly to the display pcb via a ribbon cable.
NOTE: ALL BUTTONS FUNCTION AS AN EMERGENCY STOP BUTTON WHEN THE MOTOR IS SPINNING
DISPLAY PCB The Display PCB receives power directly from the power supply pcb. It passes 5VDC to power the tone generator and the LED display. It receives the information from the Main Processor Board via the power supply pcb. This information is passed back to the Main Processor routed through the Power Supply Board.
TEMPERATURE SENSOR The system has a new force guidance structure (patent pending). The forces at the measuring transducers have been reduced, thus achieving long-term stability and high measuring accuracy. Pre-tensioning of the transducers is achieved by two leaf springs. On the vibratory system the measuring transducers are very close together so that the difference in temperature has only a slight effect. The current vibratory sensor has a temperature sensor. The transducers can therefore be measured by one temperature sensor and taken into account in a fraction of a second. The temperature sensor is attached to the vibratory plate by means of a U- shaped spring. This temperature sensor effects the transducers and is set during calibration.
DRIVE MOTOR The drive unit is mounted directly to the vibratory system by means of (4) bolts. Three of the mounting holes are slotted, these are used for setting the tension on the drive belt. The drive belt is used to drive a large pulley which is mounted directly to the drive shaft of the vibratory system.
TRANSDUCERS The transducers are installed in a manner that they form a virtual transducer on each end of the shaft. This gives the balancer greater accuracy along with minimal amount of erroneous readings. Both measuring transducers are arranged in one plane. The rear transducer picks up the alternating forces of the left-hand virtual measuring plane and is supported on the machine housing. The front measuring transducer is clamped between the vibratory tube and vibratory plate and transforms the alternating forces of the right-hand virtual plane into electrical signals.
Effective Page 2-6 02/2003 CHAPTER 2 THEORY OF OPERATION
SAPE (SEMI-AUTOMATIC-PARAMETER-ENTRY)
Brand SAPE Display JBC System I 1D 2 Window JBC System II 2D 2 Window SOT LD 2D 3 Window JBC System III 2D 3 Window JBC System IV 2D CRT
3 Window Display Every time the machine powers on, the software automatically checks the SAPE system in its initialization procedure. The SAPE’s must be in the HOME position during start up. If the SAPE is good the machine enters idle state as normal. If for example, the distance gauge fails, the machine displays “DIS” “SAP” “FAL” when the machine is powered on. If the diameter gauge fails, it displays “DIA” “SAP” “FAL”. If both of them fail, the machine displays “2-D” “SAP” “FAL”. The operator needs to press the STOP button to exit the display and enter idle state. The machine masks the function of the failed part after SAPE check. For example, if the diameter gauge fails, the machine disables the measurement of diameter and measures the distance only. Or if the distance gauge fails the machine disables the measurement of the distance gauge and measures the diameter only.
2 Window Display If the distance gauge fails, the machine displays “DIS” “FAL” when the machine is powered on. If diameter gauge fails (VPI SYSTEM II), it displays “DIA” “FAL”. If both of them fail, machine displays “SAP” “FAL”. Checks should be made to make sure the SAPE’s are in their HOME position during start up. The operator needs to press the STOP button to exit the display and enter idle state. The machine masks the function of the failed part after SAPE check. For example, if the diameter gauge fails, the machine disables the measure- ment of diameter and measures the distance only. Or if the distance gauge fails the machine disables the measurement of the distance gauge and measures the diameter only.
The potentiometers plug into the main processor at connection X6 (Distance) and X7 (Diameter) and X8 (Width). The potentiometers are supplied with 5VDC from the Processor Board. As the SAPE is pulled out and up towards the wheel the voltage(s) change. The distance from the balancer to the wheel is generated from the voltage output and the diameter of the wheel is generated from the amount of voltage output when the arm is moved up. Adjustment are made using the F/P 50, F/P 51 and F 52 code, this procedure can be found later in this manual.
ENCODER The encoder disk is built onto the shaft. It cannot be adjusted and can only be replaced by replacing the vibratory member. The new incremental encoder is fitted in the vibratory tube and consists of a reflective slotted sleeve which is mounted on the main shaft and the optoelectronic unit. To prevent dirt and light entering, the opening in the vibratory tube must be sealed with black adhesive tape. A red visible LED and four light detectors are fitted in the encoder part of the optoelectronic unit behind the lenses. Part of the light is reflected back from the webs of the slotted sleeve to the encoder part and focussed by the lens, such that the web-slot pattern of the sleeve is mapped on the four light detectors. Two light detectors are connected to one amplifier in the encoder part. The difference in brightness between the detector pairs determines the instanta- neous output states of channels A and B. To exclude interference from extraneous signals and to guarantee reliability the two signals are amplified by an IC. One slot in the sleeve is wider than the other 255 slots. Therefore the absolute angular position of the main shaft can be determined at constant rotating speed. The surface of the slotted sleeve must be clean and shiny, the slots must have a dull black background. Should a dirt particle have settled on a web or in a slot, it can be lifted off of the slotted sleeve with self-adhesive tape by applying it onto a strip of strong paper so that half of the tape is on the paper and the other half overhang- ing. CAUTION! If the slotted sleeve is twisted relative to the main shaft when being cleaned, the step com- pensation of residual shaft unbalance must be performed with F/P 84. A defective slotted sleeve cannot be replaced in the field because the ball bearings of the main shaft are pressed in. The incremental encoder can be checked with test functions F/P 36. The calibration factors are stored in this location along with the Main PCB.
Effective 02/2003 Page 2-7 CHAPTER 2 THEORY OF OPERATION VIBRATORY SYSTEM The vibratory member is the foundation of the balancer. It houses the encoder and transducers along with a temperature sensor for the tranducers.
ELECTROMAGNETIC BRAKE The electromagnetic brake is used on earlier JBC System III balancers. Once the balancer reaches a low RPM the Main Processor looks for the outside weight position. Once this location is known the Processor sends a command to the Power Supply Board to turn on the Electromagnetic brake. The Power Supply board sends 150VDC to the Electromagnetic brake on the motor stopping the tire and wheel assembly at TDC for the outside weight location. Once the weight is applied the operator can then press the “F” button, this sends the command to the Main Processor which in turns sends a command to the Power Supply Board to rotate the motor. The Main Processor then sends a command to the Power Supply Board to engage the Electromag- netic brake. The Power Supply Board sends 150VDC stopping the tire and wheel assembly at TDC for the inside weight location.
AUTO STOP LOCK SWITCH (JBC SYSTEM III, IV) In the ALU-S mode the operator is required to apply stick on weights in exact location on the inside of the wheel. Through normal operation the balancer receives input from the SAPE arm. The balancer enters D1 (inside weight) and D2 (outside weight) by means of the operator pulling the SAPE arm to the locations of where the weight will be applied. Once these parameters are known after cycling the tire and wheel through it’s spin cycle the operator can then apply the correct amount of sticky weight to the weight applicator on the end of the SAPE arm and pull the SAPE arm towards the tire and wheel assembly. D1 and TDC determines when to auto lock the SAPE arm to apply the sticky weight. The Power Supply Board sends 5VDC to the auto lock switch engaging it to lock the SAPE arm. Once the weight is applied the outside sticky weight is applied to the weight applicator and the operator pulls the SAPE arm towards the tire and wheel assembly. D2 and TDC determines when to auto lock the SAPE arm and apply the sticky weight. The Power Supply Board sends 5VDC to the auto lock switch engaging it to lock the SAPE arm.
Effective Page 2-8 02/2003 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE
GENERAL This Chapter incorporates all motorized “Y2k” balancers manufactured in Conway Arkansas. The test codes for each digital display balancer are alike, and so are the results. This Chapter is written using the 3 window display results, if a two window display balancer is being serviced the display will be abbreviated from the 3 window display, keep this in mind on all results that show up in the display windows. The JBC balancer uses “F” to begin any service procedure, the Snapon balancer begins all service procedures with a “P” code. All “F/P” codes run parrallel. If a service routine is not available for any particular balancer the result will be displayed as “NOt USE”.
SHAFT IMBALANCE, WHEEL ADAPTER TO SHAFT REMOUNT TEST
This test proves the wheel balancer centering device is balanced, turns true and proves the centering device inside taper and balancer shaft outside taper (mating surfaces) are true.
1. Mount a medium size wheel assembly (14”), input the rim dimensions and balance the wheel assembly to 0.00 ounces imbalance in both planes. This must be fine balanced to exactly 0.05 in both planes.
2. Spin the balancer several times. Verify that no more than 0.05 oz. imbalance is displayed.
3. Loosen the Speed nut and rotate the tire and wheel assembly 180 degrees, making sure the cone does not rotate. NOTE: DO NOT REMOVE THE WHEEL ASSEMBLY.
4. Operate the balancer. The new imbalance displayed should not exceed 0.25 oz.
TEST PRODUCES READINGS OUT OF TOLERANCE:
5. Remove the tire and wheel assembly from the balancer.
6. Check the tapered surfaces of the basic centering device and balancer shaft. They should be clean and smooth. Clean and retest. Check all mounting accessories cones, wingnut etc. making sure each fit on the shaft snug, there should be no play between the shaft and mounting accessories.
7. If the test still produces unacceptable results use a dial indicator, measure runout of the balancer shaft tapered mounting surface. Acceptable tolerance is 0.0015" T.I.R. (Total Indicated Runout). If the surface measures out of tolerance, replace the vibratory system.
8. Perform a F/P80, F/P83 and a F/P84 and retest. These test can be found later in this Chapter. NOTE: A FINE BALANCED TIRE AND WHEEL ASSEMBLY ALONG WITH A 3.5 OUNCE WEIGHT CAN BE SUBSTITUTED.
BALANCER DIAGNOSTICS (TROUBLESHOOTING)
Many problems may be found by process of elimination. By determining the problem, then eliminating potential problem areas starting with the most-likely to fail items, solutions to problems may be rapidly found. The Y2k balancer is composed of subsystems, each requiring several inputs for proper function. With proper inputs the subsystem performs as expected and produces an output. Every piece of equipment, when operable, functions in a predetermined manner. Events have to take place in the proper sequence every time. A balancer must:
Effective 08/2004 Page 3-1 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE Be supplied with correct power and ground. Give a display output. Accept Keypad input. Process commands through the Computer. Receive and process encoder/transducer inputs. Brake Display proper weight amount and location.
The technician should watch a machine work and make performance assessments based on what is seen. If subsystem failure is suspected, use diagnostic tests to confirm the failure. Remember, every part requires input to produce the expected output. These outputs in turn become inputs for further use by the system.
TROUBLESHOOT USING CORRECT DIAGNOSTICS PROCEDURES
Balancers are relatively simple pieces of machinery. With proper diagnostic procedures, balancer problems should be quickly resolved. The Basics that the technician must never overlook are:
1. AC Power. The unit must be supplied with correct AC power. 2. Ground. These machines depend on proper Grounding for proper and safe function. Improper or poor ground will create problems that are quite difficult to diagnose, and may create a dangerous condition. Check, never assume ground is correct! 3. DC Power. The microprocessor will not run correctly (if at all) if it is not supplied with proper DC power and ground. Check DC power for ripple or drift ( may indicate faulty regulation or failing PCB's). Ensure there is enough power and a good ground. 4. Inputs. Check for proper Encoder and Transducer signals. 5. Output - Once all voltages and signal levels are present a proper output can be expected.
TOOLS REQUIRED WHEN SERVICING THE Y2K BALANCERS
Tools Metric Sockets (4mm Thru 15mm) Metric Wrenches (6mm Thru 15mm) Assorted Hex Wrenches metric / standard Inch Pound Torque Wrench Foot Pound Torque Wrench Mounting the Pruefrotor #2 Phillips Screwdriver #2 Flat Head Screwdriver Digital Volt-ohm Meter Small Screwdriver Hilti Rotor hammer drill (Installation Option) Pruefrotor (H6416946) or fine balanced tire/wheel assembly. 3.50 ounce (100gr) wheel weight Figure 3-1 Program EPROM Loctite #242 and #272 or #609 Silicone based grease - Used for transducer ball place- ment Putty for fine wheel balancing. 1, 2 and 3 ounce weights verified accurate (weigh on postal scales and trim to exact weight - paint and label)
A test tire and wheel balanced to within 0.10 oz. (2.8 gr.) on both inside and outside planes or 0.20 oz. statically (mode 7) is required during some troubleshooting procedures.
In the event of vibratory system replacement, the use of a certified Pruefrotor (Figure 3-1) will be required to confirm conformance to design specifications and certification requirements. Effective Page 3-2 08/2004 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE FUNCTIONS OF SNAPON / JBC VPI BALANCERS
All the service codes are entered using F/P codes. The procedure for activating an F/P code is described below.
1. Press and release the
SERVICE CODES The JBC balancer requires that the F button be pressed while the Snapon balancer uses the P button. 1 Toggle switch between fine and normal balancing mode. 2 Toggle switch between inch and millimeter display of width. 3 Toggle switch between gram and ounce display. 4 Calibration with adapter or disable adapter compensation. 7 Toggle switch of millimeter and inch for diameter measurement. 12 Read counters 14 Calibration by user 18 Enter ALU-S 2 plane mode (press the balancing mode key to exit back to the dynamic mode) 19 Enter ALU-S 1 plane mode (press the balancing mode key to exit back to the dynamic mode) 21 Check revision of balancing kernel software. 28 Check last 10 kernel error messages & Clean all recorded error codes. 36 Toggle reading the positions and angles of left and right weights. 43 Read or reset re-setable counter. 44 Read or reset productivity of user. Display counter number of default user only. 50 Read output voltage of potentiometer of distance measurement of SAPE. 51 Read output voltage of potentiometer of the diameter measurement of the SAPE. 52 Read output voltage of potentiometer of the width measurement of the SAPE. 53 Display test 55 Check AC and DC voltages 59 Read resident imbalances of shaft in fine mode. (The fine mode LED indicator is automatically turned on and off if the machine is in the regular accuracy mode). 60 Read shaft speed RPM. 63 Continuous spin. 64 Read outputs of transducers. 79 Calibration of the width SAPE. 80 Calibration of SAPE 83 Manufacture calibration (Pruefrotor required). 84 Empty Calibration of the bare shaft. 85 Copy contents of Processor to Encoder, only available in initialization. 86 Copy contents of Encoder to Processor, only available in initialization. 88 Top Dead Center calibration (TDC) 90 Enter match balancing mode. 91 Optimization balancing mode. 92 Split weight mode. 93 Change model settings 94 Spoke mode. 95 Clean and reset EEPROM 1 & 2. 97 Sticky at Top. 99 SAPE 2 Accuracy test.
Effective 08/2004 Page 3-3 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE F/P CODE DESCRIPTIONS OF THE BALANCER
F/P 1 TOGGLE FINE WEIGHT MODE When F/P 1 is activated, the machine displays “FIN” “ON” for one second (round off 0.05 oz or 1 gram). Toggle F/P 1 again changes back to the normal round off and display changes to “FIN” “OFF” for one second (round off 0.25 oz or 5 gram).
F/P 2 RIM WIDTH INCH / MILLIMETER Selecting F/P 2 toggles the balancer between inch and millimeters for rim width. Unit will display “DtH I NCH” for inches pressing F/P 2 again toggles to millimeters and the display changes to “DtH” for millime- ters.
F/P 3 GRAM / OUNCE Selecting F/P 3 toggles the balancer between Grams and Ounces. Unit will display “ “ “OU” “NCE” for ounce pressing F/P 3 again toggles to Grams and the display changes to “GR” “GR” “GR”.
F/P 4 CALIBRATION WITH ADAPTER OR DISABLE ADAPTER COMPENSATION Some special tires and those wheels whose center holes are not the primary reference but are lug-centric require an adapter. Lug-centric identifies that the tire and wheel assembly to be centered on it’s axis of rotation must be mounted using the lug pattern instead of the center hole of the wheel. In this case, the adapter may introduce an unbalance to the spin system. This means that this unbalance has to be compen- sated for after tire unbalance is measured. This F/P code is used to measure the unbalance of shaft and adapter together and saves it in memory and set an adapter compensation flag to tell the program to use adapter compensation after tire balance is done. F/P4 is a toggle, it is used to turn this flag off.
• After F/P4 is activated, machine displays “CAL ADP” for one second. And then it displays “SPN” “1”. Operator spins the shaft just like ordinary balancing. When the machine is taking data and calculation, it displays “CAL BAL” to tell the operator the machine is working on the balancing procedure. Once the calibration is done, machine displays “ADP” “FIN” to indicate the calibration is successful. Once the shaft stops, machine displays “---” “ ---” and exits the F/P4 automatically. The machine is now in an idle state. • When the machine is working under the application of an adapter, the balancing mode display is different than ordinary balancing. In ordinary balancing the machine displays “---” “2PL” while the machine is taking data. In balancing with an adapter, the machine displays “AdP” “2PL” as it takes data. This reminds the operator he is under adapter compensation mode. So if the operator does not use an adapter and the machine displays “AdP” in left the window, the operator should turn off the adapter compensation by toggling
F/P 7 TOGGLE MILLIMETER AND INCH FOR DIAMETER If a metric tire is to be balanced, the diameter can be changed to enter the tire parameters in millimeters instead of inches. The default is set to inches. Pressing
F/P 12 READ COUNTERS The balancer has 4 counters that keeps track of total number of cycles for a certain parameter. The bal- ancer will automatically cycle through the counters after
1. Display “Ctr” “ALL” for one second. Total number of spins. 2. Display “Ctr” “CAL” for one second. Total number of spins since last calibration. 3. Display “Ctr” “SrV” for one second. Total number of service spins. 4. Display “Ctr” “USR” for one second. Total number of user spins. 5. The display will cycle through continuously through each step until “STOP” is pressed.
Effective Page 3-4 08/2004 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE F/P 14 USER CALIBRATION PROCEDURE The JBC VPI and SOT balancers feature a user calibra- tion program which requires only a few minutes to complete. Perform this procedure when the balancer has been moved, disturbed, or whenever accuracy is questioned. Occasional field calibration will ensure years of reliable service.
1. Activate Calibration. Press and release the key while turning the Diameter/Function Knobuntil the display reads “F/P” “14” (Figure 3-2b). • Once F/P14 activates, the display will read Up / Down F Key “CAL” “GAN” for one second. Keys • The display will then read “SPN” “1”. Figure 3-2a P Key 2. Spin shaft. (Figure 3-3) • Lower the wheel guard and/or press the enter key. The shaft will spin. • Displays “CAL” “1” when the shaft reaches speed RPM’s. The machine is taking data and Figure 3-2b Diameter doing calculations. After taking data, shaft is Function automatically braked to a stopped. • Displays “SPN” “2” when shaft stops. 3. Spin shaft with calibration slug on the left side. Mount calibration slug (EAM0005D40A) to the shaft. (Figure 3-4). • Lower the wheel guard and/or press the enter key. The shaft will spin. • Displays “CAL” “2” when the shaft reaches speed RPM’s. At this moment the machine is taking data and doing calculation work. After taking data, shaft is automatically stopped. • Displays “CAL” “FIN” “ISH” when the second Figure 3-3 step of calibration is finished and machine says the calibration result is FINE. • Displays “---” “---” when shaft stops and machine is in the idle state. CALIBRATION COMPLETE NOTE: THE BALANCER WILL NOT FUNCTION UNTIL A VALID CALIBRATION HAS BEEN PERFORMED. ERROR MESSAGES WOULD BE DISPLAYED IN THE EVENT PROBLEMS OCCUR DURING THE CALI- BRATION PROCESS. Figure 3-4 Effective 08/2004 Page 3-5 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE F/P 18 ALU-S MODE Aluminum Static: See the operation manual for a detailed explanation. F/P 19 ALU-S ONE PLANE BALANCING MODE Aluminum Static: See the operation manual for a detailed explanation. F/P 21 KERNEL SOFTWARE When F/P21 is activated the machine display changes to “REV” “ISI” “ON” for 1 second. The display then changes to “Obj” “???” “???” for 3 seconds, this is the persistent object revision. The number means the release date of the object. For example, if the number is Obj 20 729, it indicates year of 2002, month of July and date of 29th. The display then changes to “B--” “???” “???” for 3 seconds, this is the balancing kernel revision Ex: “B” 1.21” (Balancing Kernel rev 1.21). The display then changes to “UI-” “???” “???” for 3 seconds, this is the user interface revision Ex: “UI-” “110” 802” it indicates Month (November) the day (08) and the year (2002). The unit will then go back into an idle state. F/P 28 KERNEL ERROR MESSAGES Enter F/P 28 the machine will display “CHC Err” for 2 seconds and then display “Err 0” for 1 second followed by the error code. Pressing the F/P 36 TOGGLE ANGLES OF LEFT AND RIGHT WEIGHTS. After F/P36 is activated, machine displays “POS” “ANG” first. Once the shaft moves, machine displays encoder position in integer form (from 0 to 511) in left window and angle in floating form (from 0.00 to 359) in right window. Meanwhile, machine lights on the position bars to indicate the left weight position. So working with number and position LEDs, it is very easy to find the left weight’s position value and angle value. Once user presses F/P 43 RESETTING THE COUNTERS The counter can be reset using this code: 1. Press and release the key while turning the Diameter/Function Knob keys until “F/P” “43” is displayed and press enter. 2. The balancer will display “Ctr” “rSt”. 3. The display shows the total number of spins since last reset. Press the STOP key while this number is displayed. 4. The total number of spins since the last reset has been reset to zero. 5. The display changes to “rE-” “Set” for one second. F/P 44 READ OR RESET PRODUCTIVITY OF USER This displays or resets the total number of spins for either operator A,B,C or D depending what is chosen on the main display. 1. Choose the operator that you would like to read or reset from the main PCB by pressing the operator mode key (A,B,C or D). 2. Press and release the key while turning the Diameter/Function Knob until “F/P” “44” is displayed and press Effective Page 3-6 08/2004 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE F/P 50 READ OUTPUT VOLTAGE OF THE DISTANCE POTENTIOMETER OF SAPE 1. Slide the SAPE in the home position. 2. Press and release the key while turning the Diameter/Function Knob until “F/P” “50” is displayed and press enter. 3. Displays “Ad9” “dIS” and then changes to “Ad9” “___” With the Distance guage in the home position the voltage in the right hand display on the VPI System II, III and SOT LD should read 4.30VDC ± 0.05. The voltage reading for the VPI System I is 4.00VDC ± 0.1. F/P 51 READ OUTPUT VOLTAGE OF THE DIAMETER POTENTIOMETER OF SAPE 1. Slide the SAPE in the home position. 2. Press and release the key while turning the Diameter/Function Knob until “F/P” “51” is displayed and press enter 3. Displays “A10” “dIA” and then changes to “A10” “___” The voltage should read 4.00VDC ± 0.10 when the SAPE is on the vibratory tube or 3.30VDC ± 0.10 in the home position. F 52 READ OUTPUT VOLTAGE OF THE WIDTH POTENTIOMETER This function is only available with the JBC VPI System III balancer. 1. Slide the SAPE in the home position. 2. Press and release the F/P 53 DISPLAY TEST Used to diagnose the display panel. Once activated the display will either scroll a message or all LED’s will light up. Pressing F/P 55 CHECK AC AND DC VOLTAGES Press and release the key while turning the Diameter/Function Knob until “F/P” “55” is displayed and press enter. Machine displays “POr VOL tSt” for one second, the display toggles between AC voltage and DC voltage. Example: “AC 230” and “dc 5.15”. Although some machines require only 120VAC the machine still displays AC 230 volts, the step up transformer generates 230VAC on these units. Press STOP button to exit this function. F/P 59 DISPLAYS THE UNBALANCE OF THE BARE SHAFT Press and release the key while turning the Diameter/Function until “F” “59” is displayed and press enter. Display should read 0.10 or less. Anything greater than .10 requires bare shaft calibration F84. Press F/P 60 READ SHAFT RPM This test displays the motor RPM, a reading of 190 RPM’s +/- 10 on a VPI III and SOT Low Digital or 90 RPM’s on a VPI I,II. A tire and wheel must be used to perform this test. Press “STOP” to exit this function. F/P 63 CONTINUOUS BALANCING Mount a tire and wheel assembly. Activating this code puts the balancer in a continuous spin cycle and updates the amount of imbalance every 5 seconds. Press F/P 64 DISPLAYS THE TRANSDUCER OUTPUT Transducer output should be steady. Any slight vibration of the unit should cause the readings to fluctuate. After activating F/P 64 the display will change to “ADE” “1-2” “___” for one second. By forcing the shaft rearward the read should display negative, forcing the shaft forward the reading should display a positive voltage. Press the F/P key to toggle to the front transducer (2). Effective 08/2004 Page 3-7 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE F79 CALIBRATION OF WIDTH SAPE NOTE: THIS PROCEDURE IS PART OF THE F80. 1. Press and release the 2. Pull the distance gauge to the outside flange of the backing collar, use the flat head of the calibration weight as an index (Figure 3-5a). After a short beep the machine displays “bAC” “H” “POS” and Figure 3-5a changes to “tO” “FLA” “NGE”. NOTE: THIS STEP HAS BEEN ADDED TO BK1.21 SOFTWARE. SKIP TO STEP 3 FOR EARLIER SOFTWARE. 3. Touch the tip of the width gauge to the face plate and hold it for one second or press the 4. Display will then change to “tO” “CAL” “SLG”. Screw the calibration weight onto the outside of the flange. Touch the tip of the width gauge to the tip of the calibration slug and hold it for one second or press the Effective Page 3-8 08/2004 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE F/P 80 SAPE GAUGE CALIBRATION To calibrate the SAPE gauge. 1. Make sure the SAPE arm is in the home position as shown in (Figure 3-7). NOTE: WEIGHT TRAY MUST BE INSTALLED 2. Activate the gauge calibration program. Press and release the key while turning the Diameter/ Figure 3-7 Function Knob until 80 is displayed on right display window and press enter. 3. The right display will read "CAL” “3-D” “SAP" for one second (Do not move the arm at this point) this means CALibration SAPE. Then it displays "SAP” “OUT” “FUL”. The SAPE calibration procedure is activated. 4. Gently pull the SAPE arm OUT until it is fully extended, (Figure 3-8) hold it steady for about 1 second, a tone will sound. 5. Display will read “bAC” “H” “POS” followed by a beep. Return the arm to the home position. NOTE: STEP 5 IS THE LAST STEP FOR A VPI Figure 3-8 SYSTEM I BALANCER. 6. Display changes to “dIA” “ -18” “POS”. 7. Gently pull the SAPE out and rest the arm of the SAPE gauge on the inner part of the bell housing as shown in (Figure 3-9). A tone will sound and the display will change to “bAC” “H” “POS”. 8. Return the arm to the home position. The display will change to “dIA” “42.1” “POS”. Figure 3-9 9. Locate the Calibration Weight. Place the calibration weight with the large end oriented on the bell collar. Extend the SAPE arm outward and rotate the extension to just touch the end of the calibration weight as shown in (Figure 3-10). A tone will sound and the display will change to “bAC” “H” “POS”. Return the SAPE arm to the home position. NOTE: THE REMAINING STEPS APPLY ONLY TO THE VPI SYSTEM III BALANCER. Figure 3-10 Effective 08/2004 Page 3-9 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE 10 The display will change to “SAP” “E-1” “FIN” for one second and the changes to “dis” “to” “FLA”. 11. Pull the distance gauge to the outside flange of the backing collar, use the flat head of the calibration weight as an index (Figure 3-11a). After a short beep the machine displays “bAC” “H” “POS” and changes to “tO” “FLA” “NGE”. NOTE: THIS STEP HAS BEEN ADDED TO BK1.21 SOFTWARE. SKIP TO STEP 11 FOR EARLIER Figure 3-11a SOFTWARE. 11. Touch the tip of the width gauge to the backing collar and hold it for one second or press the 12. Display will then change to “tO” “CAL” “SLG”. Screw the calibration weight onto the outside of the flange. Touch the tip of the width gauge to the tip of the calibration slug and hold it for one second or press the “F” button (Figure 3-12 ). The display will change to “SAP” “E-2” “FIN” for one second followed by a tone indicating a successful calibra- tion. Unit will then go into an idle state. Figure 3-12 CALIBRATION COMPLETE Effective Page 3-10 08/2004 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE F/P 83 FACTORY CALIBRATION PROCEDURE NOTE: THE F80 CALIBRATION MUST BE DONE BEFORE THIS OPERATION. A balanced tire and wheel assembly can be substituted if a Pruefrotor is not available. The calibration procedures are the same and can easily be performed. However custom parameters must be used for this procedure if using a balanced tire and wheel assembly Beginning with a balanced Tire and Wheel assembly • Mount the tire and wheel assembly on the shaft. For this example a 14” X 5.5” wheel will be used. • Enter the distance, diameter and width (user defined). • Press and release the key while turning the Diameter/Function Knob until “F/P” “83” is displayed and press • After entering the F/P83 function the balancer will automatically switch to default parameters (15” X 6.5”). • Press the NOTE: IF A TIRE AND WHEEL ASSEMBLY IS USED PROCEED TO STEP 6. Beginning with a Pruefrotor 1. Mount the Pruefrotor on the balancer shaft (Figure 3-13) 2. Pull the distance gauge arm out and touch the Pruefrotor (Figure 3-14). 3. Return the Distance Gauge to the home position. Figure 3-13 4. Press and release the key while turning the Diameter/Function Knob until “F/P 83” is displayed. The display changes to “CAL” “BAL” for one second. 5. The display then changes to “SPN” “1”. 6. Spin shaft with the Pruefrotor/Tire & Wheel by lowering the hood or pressing the enter key. The board displays the information in the following order. • Displays “CAL” “1” when the shaft reaches calibra- tion speed. The machine is taking data and doing calculations. After taking data, shaft is automatically braked to a stopped. • Displays “SPN” “2” when shaft stops. Figure 3-14 Effective 08/2004 Page 3-11 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE 7. Attach the 3.5 ounce weight (100 gr) on the inside of the Pruefrotor/Tire & Wheel. (Figure 3-15) • Spin the Pruefrotor/Tire & Wheel by lowering the hood or pressing the enter key. • Displays “CAL” ‘2” when the shaft reaches 90 RPM’s. The machine is taking data and doing calculations. After taking data, shaft is automatically braked to a stopped. • Displays “SPN” “3” when shaft stops. 8. Attach the 3.5 ounce weight (100 gr) on the outside of the Pruefrotor/Tire & Wheel. (Figure 3-16) Figure 3-15 NOTE: IF USING A TIRE AND WHEEL ASSEMBLY ATTACH THE 3.5 OZ WEIGHT ON THE OUTSIDE 180 DE- GREES OPPOSITE THE INSIDE WEIGHT LOCATION. • Spin the Pruefrotor/Tire & Wheel by lowering the hood or pressing the enter key. • Displays “CAL” ‘3” when the shaft reaches calibration speed. The machine is taking data and doing calculations. After taking data, shaft is automatically braked to a stopped. • Displays “CAL” “GOO” “d” when the third step of calibra- tion is finished and the calibration is successful or displays “CAL” “FAL” “L” if the calibration fails. • Display then changes to “F/P” “CNT” to prompt operator to press the 9. Press CALIBRATION COMPLETE Effective Page 3-12 08/2004 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE F/P 84 EMPTY SHAFT CALIBRATION PROCEDURE 1. Press and release the key while turning the Diameter/Function Knob until “F/P” “84” is displayed. The display changes to “CAL” “SHF” for one second. 2. Then it displays “SPN” “1“. 3. Spin the empty shaft by pressing the F/P 85 COPY CONTENTS OF MAIN PCB TO ENCODER When an Encoder PCB is replaced and on initial power up the unit will display “F/P 85”. The technician needs to simply press the F/P 86 COPY CONTENTS OF ENCODER TO MAIN PCB - BK 1.21 1. Change microprocesser board and download the new software. 2. Remove the software chip from the socket and return it to the carrying case. Senario 1 If the Balancing Kernel refered to as “BK” has not changed when a Main PCB is replaced and on initial power up the unit will display “F/P 86 S-b” meaning copy the (S)haft contents to the (b)oard. Simply press the F/P 90 MATCH BALANCE Matches the tire to the wheel. See operators manual for detailed information. F/P 91 OPTIMIZATION See operators manual for details. F/P 92 SPLIT WEIGHT See operators manual for details. F/P 93 CHANGE MODEL SETTING If the balancer is loaded with the incorrect software the technician can manually adjust the balancer for the Effective 08/2004 Page 3-13 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE correct operating system. Example: If a VPI System III is loaded with SOT Low Digital software. 1. Press and release the key while rotating the shaft until “F/P” “93” is displayed. Balancer will display “Cod” in the left hand display and “0” in the right hand display. 2. Press the NOTE: ALL FACTORY CALIBRATION PROCEDURES ARE REQUIRED. F/P 94 SPOKE MODE See operators manual for details. F/P 95 CLEAN & RESET EEPROM 1 & 2 Care should be taken before running this function. All information in the EEPROM will be lost including manufacture calibration which can not be reversed once performed. However this function can be very useful if data is corrupted on the EEPROM’s. Performing this function can be much quicker than re-flashing the software. 1. Press and release the key while turning the Diameter/Function Knob until “F/P” “95” is displayed. The machine displays “CLN EEP” immediately. The user can press the NOTE: ALL FACTORY CALIBRATION PROCEDURES ARE REQUIRED. F/P 97 STICKY AT TOP STOP AT TOP Used to turn “Sticky at Top” on or off. Press Effective Page 3-14 08/2004 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE F99 SAPE-2 ACCURACY TEST The balancer must have a width gauge for this procedure to work. 1. Place a flat edge (Calibration Slug) flat against the flange. (Figure 3-19) 2. Gently pull the distance arm and touch the back of the flat edge. (Figure 3-19) 3. Press and release the 4. Pull the 3-D-P SAPE arm and touch the face of the flange. (Figure 3-20) 5. View the value in the left display, the value should be 0 ± 2. Figure 3-20 6. Screw the caibration weight onto the outside of the flange. (Figure 3-21) 7. View the value in the left display, the value should be 116 ± 2 NOTE: IF THE READINGS DO NOT RETURN REQUIRED VALUES PERFORM AN F79 AND RETEST. Figure 3-21 Effective 08/2004 Page 3-15 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE SERVICING THE BALANCER ! DANGEROUS HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENT NOTE: BEFORE OPENING THE MACHINE FOR SERVICE, DISCONNECT ELECTRICAL SUPPLY LINE AND USE THE LOCKOUT / TAGOUT PROCEDURE. The balancer is supplied with 110/230 VAC . It is critical to have the proper input voltage in order for the balancer to operate correctly. The balancer performs a systems check on initial power up. If a problem is detected the balancer will emit random beeps. To check power cable: • Disconnect the power supply from the balancer. • Using a VOM, check for an output voltage at the end of the power plug 230VAC +/- 10%VAC VPI System III or 110VAC ± 10% VPI System I, II and SOT Low Digital. To check power to power supply box: • Remove the weight tray. • Using a VOM check for 230VAC at the power supply board, X41 pins 2&3 all balancers. CONTROL PANEL REMOVAL & REPLACEMENT The Digital Display Board is mounted directly to and behind the keypad on each balancer (Figure 3-22). • Using a 4mm Hex Key, remove to (4) screws holding the Display Panel to the upper Display on VPI and the SOT Low Digital is held in place with velcro. gently pry the display forward. • To remove the Display Board unplug the membrane panel and simply remove the (4) 8mm nuts holding it onto the backing plate. • Once the keypad is removed from the backing panel it cannot be reused. The keypad can be removed by gently peeling back at a corner. If a keypad is suspect for replacement, it is suggested testing a new keypad before replacement. Figure 3-22 Backing Display Membrane Effective Page 3-16 08/2004 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE MAIN PROCESSOR REPLACEMENT Before flashing the new Main PCB, check and adjust the SAPE potentiometers for the correct voltage settings (F/P 50, F/P51, F52) see chart below. If some part of a SAPE is broken and cannot be repaired immediately the technician can still down load the software, however some manual model settings will be required (See Senario 3). Checks should also be made on the part number of the processor mounted on the Processor PCB. Early balancers manufactured prior to December 2002 contained a part number on the processor of EAP0201D00A. This processor can be flashed with all releases of BK software up to 1.21. Balancers manufactured after November 2002 carries the part number EAP0201D00C. These processor will only accept BK 1.21 or greater software. SAPE voltage readings in the HOME position F50: Distance F51: Diameter F52: Width Model With Weight Tray No Weight Tray JBC System 1 3.9 – 4.1 JBC System 2 4.2 – 4.4 2.8 – 2.9 3.2 – 3.4 JBC System 3 4.2 – 4.4 2.8 – 2.9 3.2 – 3.4 4.3 – 4.4 Snapon Low Digital 4.2 – 4.4 2.8 – 2.9 3.2 – 3.4 Software Check Value < 3.6 fail < 2.5 fail < 4.0 fail 1. Disconnect the power from the unit. 2. Locate the Main Processor PCB, on the rear of the Display PCB for the Handspin or in the ! Power Supply Box on the motorized balancer. USE STANDARD ANT-STATIC PROCEDURES 3. Insert the program EEPROM in the socket on WHILE PERFORMING THESE INSTRUCTIONS the processor board. (Figure 3-23) NOTE: THE NOTCH ON THE END FACE OF THE EPROM MUST POINT TOWARDS THE NOTCH ON THE SOCKET OF THE PCB. 4. Plug the power cable into the balancer and switch the balancer to the on position. The balancer will emit three beeps. The upload will take approximately 45 seconds. After the completion of the upload the balancer will continuously emit beeps. CAUTION!: DO NOT REMOVE POWER FROM THE UNIT DURING THE UPLOAD PRO- Figure 3-23 CESS, PERMANENT DAMAGE TO THE MAIN PCB WILL OCCUR. 5. When the upload is complete remove power from the balancer. Remove the EPROM off of the socket using a screwdriver, and place it in packaging for transport. Reassemble the balancer and apply power. Senario 1 • If the version of balancing kernel has not changed, the balancer will automatically download the correct software. Senario 2 • If the version of balancing kernel has changed, the balancer will display the model automatically if the SAPE system is good and all potentiometers are set properly. • Press the “ENTER” key to set the model number. Effective 08/2004 Page 3-17 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE Senario 3 • If the version of balancing kernel has changed and some part of the SAPE is broken or the voltage is not set properly, the balancer may display a model that does not match the balancer. Example: If a JBC system 3 with a malfunction in the width SAPE, machine may display “SNP” “Ld” “__” instead of “JBC” “SYS” “3”, or it may display a SAPE failure message. • If the balancer displays the incorrect model or some SAPE failure message, the technician can use the “F” key to toggle the display to the correct balancer model. • Press the “ENTER” button to set the model of the balancer. • As a safety net the balancer may display “Sur” “E” (Sure) allowing the technician one last chance to change the model number before pressing the “ENTER” button. TO ACCESS THE INSIDE OF THE MACHINE 1. Remove the screws from the front and rear of the weight tray. (Figure 3-24) 2. Standing at the front of the machine, rotate the SAPE arm to it’s full most outward position. Lift and remove the weight tray. Avoid breaking or damaging wire harnesses. Harnesses may be held in place with various retainer clips. NOTE: WHEN INSTALLING THE WEIGHT TRAY, BE CAREFUL NOT TO CRUSH WIRES. Figure 3-24 POWER SUPPLY BOX All Balancers • Disconnect the power from the rear of the machine. • Remove the weight tray. • From the rear of the machine remove the two screws holding the Power Supply box. (Figure 3-25) • Gently pull the box out the back paying special attention to the wiring harness that are connected. • Un-plug each of the harnesses from the power supply box marking each harness to ensure correct installation. Figure 3-25 Effective Page 3-18 08/2004 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE TRANSDUCER REMOVAL • The transducers are held in place with setscrews and jam nuts. • Disconnect the power from the rear of the machine. • Remove the display panel. • Remove the weight tray. • Using a 2.5mm hex key remove the preload plate. (Figure 3-26) • Using a 13mm wrench loosen the jam nut. • Using a 5mm hex key, back the set screw off by turning counterclockwise. (Figure 3-27) Do not lose the ball bearings on each end of the tranducers. These allow the transducer to center easily on the vibratory member. • If the transducer is being replaced using a marker mark the front and rear transducer harnesses. Cut the two wires at the transducer. The positive lead of the harness is marked with a black band. (When using a harness and transducer assembly, this step is unnecessary.) INSTALLATION OF TRANSDUCER • The front and rear transducer must be installed Figure 3-26 correctly in order for the balancer to function cor- rectly. (Figure 3-27) The rear transducer uses the last 2 wires pins 15-16 in the harness. • Connect the positive and negative lead to the trans- ducer. The positive lead is marked with a black band. Set Screw • Insert the clip into the transducer firmly snapping it into place. Once the wire is installed it cannot be removed without destroying the transducer. Rear Transducer • Apply a small amount of grease to each end of the transducer. Place the ball bearings in place on the transducer. Place the transducer assembly in the vibratory system. • Finger tighten the set screw to position the trans- ducer. The wire connection should be on the bottom. Encoder A properly installed transducer will be able to rotate freely but must have no side to side motion. • Snug the jam nut that holds the setscrew. This nut should be tightened solidly, but need not be ex- tremely tight. Recheck the transducer to ensure that no lateral movement exists after tightening the jam nut. Adjust as necessary. • Hold the pre-load plate in position up to the jam nut Front Transducer and finger tighten the set screws to just hold the plate in place without movement. Tighten the Set Screw upper screw ½ turn, then tighten the lower screw one full turn, then tighten the upper screw an additional ½ turn. • Reassemble the complete balancer and perform a Figure 3-27 complete factory calibration to ensure proper opera- tion. NOTE: MOVING THE TRANSDUCER AFTER CALI- BRATION WILL CHANGE THE ACCURACY AND REQUIRE FACTORY CALIBRATION Effective 08/2004 Page 3-19 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE ENCODER REMOVAL All Balancers • Disconnect power. • Remove weight tray. • Disconnect the 10 Pin ribbon cable from the en- coder PCB. Screw • Remove the phillip screw holding the encoder PCB to the shaft tube. (Figure 3-28) NOTE: BE CAREFUL NOT TO LET FOREIGN DEBRIS FALL INSIDE THE TUBE. 10 Pin connector Figure 3-28 VIBRATORY MEMBER REMOVAL All Balancers • Disconnect the power from the rear of the machine. • Remove the weight tray. • Disconnect the mechanical brake at the vibratory system. • Disconnect the motor and encoder harness from the Power Supply box. • Remove the rear transducer. • Remove the access plugs from the front of the balancer. (Figure 3-29) • Using 1/4” drive 6mm hex head SOT part # TMAM6E remove the six (6mm) hex bolts to the vibratory. Pay special attention of spacer place- ment. (Figure 3-30) • Lift up on the vibratory member and remove. Figure 3-29 VIBRATORY INSTALLATION All Balancers • Lift and set vibratory member into the balancer housing. • Insert spacers. • Apply Loctite 242 to the hex bolts. • With the aid of a helper start the two lower hex bolts. • Install the 4 remaining hex bolts and tighten to 22ft. lbs. +/- 3 in. lbs. • Install the rear transducer and follow transducer installation. • Install mechanical brake and follow mechanical brake installation. Spacers • Install weight tray. • Connect power and follow all calibration procedures F/P/C 83, F/P/C 84 and test. NOTE: EARLY MODEL VPI III BALANCERS USED AN ELECTROMAGNETIC BRAKE. THE TECHNI- CIAN MAY HAVE TO REMOVE AND INSTALL THIS COMPONENT FROM THE OLD VIBRA- TORY SYSTEM TO THE NEW VIBRATORY. USE OF A PRUEFROTOR MUST BE USED TO Figure 3-30 MAINTAIN ISO 9000 STANDARDS. Effective Page 3-20 08/2004 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE Figure 3-31 DIAMETER SAPE / POTENTIOMETER VPI II, III, IV & SOT LD • Disconnect the power from the rear of the machine. • Remove the Display panel. • Remove the weight tray. • Disconnect the 2D SAPE harness from the Main Processor Board. • Remove the 10mm nut holding the SAPE wheel to the mounting bracket and slide the cog wheel off of the potetiometer shaft. (Figure 3-31) • Remove the 13mm nut holding the potentiometer to the frame. • Reverse procedure for installation. DIAMETER SAPE / POTENTIOMETER ADJUSTMENT • Install 5K potentiometer onto bracket and tighten 13mm nut. • Install cog wheel onto potentiometer shaft and hand tighten 10mm nut. (Figure 3-31) • Attach SAPE harness to Power Supply Board. • With the SAPE arm in the home position program SAPE GAUGE • To remove the index finger, remove the phillips screw from the backside of the gauge. • To remove the SAPE arm remove the phillips screw that attaches to the distance rod. • To remove the distance rod, disconnect the diameter string from the end of the rod. • Slide the distance rod completely out. Figure 3-32 • Reverse procedure for installation. Effective 08/2004 Page 3-21 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE DISTANCE SAPE / POTENTIOMETER VPI III, IV • Disconnect the power from the rear of the machine. • Remove the weight tray. Auto-Lock Mechanism • Disconnect the 1D SAPE belt from the distance rod. • Remove the 10mm nut holding the SAPE wheel to the frame. NOTE: DO NOT LET THE RETURN SPRING UN- COIL. • Remove the 13mm nut holding the potentiometer to the frame. (Figure 3-33) DISTANCE SAPE / POTENTIOMETER INSTALLATION VPI III, IV • Install 10K potentiometer onto bracket and tighten 13mm nut. Potentiometer Return Spring • Install SAPE Wheel onto potentiometer shaft and hand Figure 3-33 tighten 10mm nut. • Attach SAPE belt to the guide roller. • Route SAPE belt over guide roller. • Loop SAPE belt through the “auto lock” mechanism and attach the SAPE belt to the distance rod. • Test SAPE assembly by pulling on the SAPE arm to it’s full out position several times. Make sure their is no binding. • With the SAPE arm in the HOME position program DISTANCE SAPE / POTENTIOMETER VPI I, II & SOT LD • Disconnect the power from the rear of the machine. • Remove the weight tray. • Disconnect the 1D SAPE return spring from the lower base assembly. • Remove the 10mm nut holding the SAPE wheel to the frame. • Remove the 13mm nut holding the potentiometer to the frame (Figure 3-34) DISTANCE SAPE / STRING ROUTE INSTALLATION VPI I, II & SOT LD Figure 3-34 • Install 10K potentiometer onto bracket and tighten 13mm nut. • Install SAPE Wheel onto potentiometer shaft and hand tighten 10mm nut. • Attach SAPE thread to return spring. • Hook return sping to the lower base of the cabinet. • Route SAPE thread over guide roller. • Manually turn SAPE wheel counterclockwise and hold it into position. (Figure 3-35) • Loop SAPE thread around SAPE wheel and release the SAPE wheel. (Figure 3-35) • Test SAPE assembly by pulling on the SAPE arm to it’s full out position several times. Make sure their is no binding. • With the SAPE arm in the HOME position pro- gram Figure 3-35 Effective Page 3-22 08/2004 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE WIDTH SAPE / POTENTIOMETER INSTALLATION JBC VPI SYstem III, IV • Disconnect the power from the rear of the machine. • Remove the weight tray. • Disconnect the 3D SAPE wire from the Power Supply box and gently pull the wire through the hood tube. • Remove the three screws holding the top cover on the SAPE arm. Remove the three screws holding the bottom cover on the SAPE arm. • Remove the 10mm nut holding the gear to the potenti- ometer. (Figure 3-36) • Remove the 13mm nut holding the potentiometer. • Reverse procedure for installation. • The potentiometer comes equipped with a standoff, insert the standoff into the hole in the housing. • Reconnect all wiring. • With the Width SAPE arm in the home position program ELECTRIC BRAKE PEDAL ADJUSTMENT Early model JBC VPI System III balancers • Remove the two screws securing the brake pedal assembly. • Remove the weight tray. • Remove the cover from the electronic box. • Attach a VOM to each lead of the microswitch. • Rotate either the microswitch activator or the micro Activator switch on the brake pedal assembly until the circuit is Microswith open. (Figure 3-37) Figure 3-37 • Check to make sure that the circuit closes when the brake pedal is depressed. 0.2MM ELECTROMAGNETIC MOTOR BRAKE ADJUSTMENT • Remove power from the balancer. • Remove weight tray assembly. • Losen hex set screw from the motor pulley. • Adjust the distance between the magnetic brake and Electromagnetic clutch plate to 0.2mm by moving the motor pulley. Switch (Figure 3-38) • Apply power to the balancer and retest braking capabil- ity by pressing on the brake pedal. Cluctch Plate Figure 3-38 Effective 08/2004 Page 3-23 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE MECHANICAL BRAKE CABLE ADJUSTMENT • Mount a standard 15” tire and wheel assem- bly. • Using your foot apply pressure to the foot pedal assembly. Using a 13mm wrench hold the nut located at the top of the cable as indicated on. (Figure 3-39) • Using a flatblade screwdriver turn the cable counterclockwise to apply tension to the brake or clockwise to loosen the brake. • The cable is properly adjusted when the tire and wheel assembly has a little resistance. Figure 3-39 MECHANICAL BRAKE CABLE • Disconnect the power from the rear of the machine. • Remove the Display panel. • Remove the weight tray. • Disconnect the brake cable from the vibra- tory member. Make note of the location of the springs and washers. • Remove the two 5mm bolts holding the pedal to the frame. (Figure 3-40) • Separate the pedal from the pedal bracket. • Pull the cable through the protective flex Figure 3-40 tubing. • Reverse pocedures for installation. ! DANGEROUS HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENT MOTOR REMOVAL • Disconnect the power from the rear of the machine. • Remove the weight tray. • Disconnect the Motor wiring harness from the Power Supply box. • Remove the setscrew securing the motor pulley to the motor. • Remove the (4) bolts securing the motor from the vibratory system. (Figure 3-41) • Reverse procedure for installation. • Using a pry bar, pry against the motor spacers to tighten belt. Figure 3-41 Effective Page 3-24 08/2004 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE HOOD SWITCH / CAM / SPRING (VPI SYSTEM III, IV) • Disconnect the power from the rear of the machine. • Remove the weight tray. • Disconnect the Hood Switch from the Power Supply Board and remove the wiring from the connector. • Remove the two (2) screws holding the switch to the mounting bracket. (Figure 3-42) • Remove the set screw holding the cam to the hood shaft and slide the cam off of the shaft. NOTE: THE HOOD SPRING IS UNDER PRES- SURE. TO RELEASE PRESSURE RAISE THE HOOD TO THE OPEN POSITION. • Remove the screw from the shaft that at- taches the hood spring. Figure 3-42 • Reverse procedures for installation. HOOD SWITCH / CAM / SPRING (VPI SYSTEM II & SOT Low Digital) • Disconnect the power from the rear of the machine. • Remove the weight tray. • Disconnect the Hood Switch from the Power Supply Board and remove the wiring from the connector. • Remove the two (2) screws holding the switch to the mounting bracket. (Figure 3-43) • Remove the set screw holding the cam to the hood shaft and slide the cam off of the shaft. NOTE: THE HOOD SPRING IS UNDER PRES- SURE. TO RELEASE PRESSURE RAISE THE HOOD TO THE OPEN POSITION. Figure 3-43 • Remove the screw from the shaft that at- taches the hood spring. • Reverse pocedures for installation. HOOD SWITCH / CAM / SPRING (VPI SYSTEM I) • Disconnect the power from the rear of the machine. • Remove the weight tray. • Disconnect the Hood Switch from the Power Supply Board and remove the wiring from the connector. • Remove the cover plate from the wheel guard box. • Remove the two (2) screws holding the switch to the wheel guard box. (Figure 3-44) • Install the new switch and route the wiring harness through the access hole. • Install the wiring into the connector. • Reverse procedure for installation. Figure 3-44 Effective 08/2004 Page 3-25 CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE Blank Page Effective Page 3-26 08/2004 CHAPTER 4 JBC SYSTEM IV GENERAL The JBC System IV CRT balancer is manufactured under the Y2k balancer system. The balancer is similar to the JBC VPI System III. The cabinet and electronics used for the System IV balancer is identical to that of the VPI System III. Should any component on the System IV require replacement, the System III documen- tation outlines the necessary steps for these replacements. The System IV balancer incorporates a proces- sor used to drive the user interface software such as the screens used for display. This processor is pow- ered by a 5 VDC line coming from the main processor inside the electronic box inside the balancer. A serial connection between is used to carry information from the Main Processor in the electronic box to the proces- sor mounted in the upper display. This information is thus carried from the Display processor to the CRT. The System IV balancer uses diagnostic “C” codes. Many of these features are incorporated into the balancer software interface and do not require a “C” code to activate the feature. SELF TEST DURING START UP The VPI System IV performs a start-up routine when power is applied. A series of tests is accomplished after the machine has been turned on. If a test is not successful: a series of audible signals is given, or an error code is read out. A three-tone signal is given once, if the machine is operative. In case there is a functional error it must be acknowledged by pressing the STOP or ESC key and there is no three-tone signal. Listed below are the steps that the balancer performs along with possible “E Codes” “C Codes” or “H Codes that could occur. This is for information purposes. 1. Communication between microcontroller and embedded PC (Blue screen) Service Codes: No service code available Communication between micro-controller and embedded PC is not OK (check connecting cable). This can also indicate a bad connection to the keyboard. 2. Check content of permanent memories (E 145) Service Codes: C85, C86 to copy content of permanent memory Contents of both permanent memories are different, but both contain valid data. If the trouble signalled by the error code is not remedied (using service codes C85 or C86), the machine will remain in service code mode. 3. Check model information(E 900) Service Codes : C47 to set model The stored machine model is not known. If the trouble signalled by the error code is not remedied (using service codes C47), the machine will remain in service code mode. 4. Check keyboard (E 89) Service Codes : No service code available One of the keys F1 to F6, HELP, ESC, START supplies a key code. The machine will proceed with the next step only if the trouble is remedied. Effective 02/2003 Page 4-1 CHAPTER 4 SYSTEM IV 5. Hardware tests C1- --- - If an error occurs during the hardware test. The four hyphens replace the digits 0 to 9 and the letters A to F which all characterize an error/defect. Refer to all Error Codes in Appendix A The following test are performed: A. Power supply voltage (235V) B. 5V line C. Incremental encoder (Current of optoelectronic LED) D. Transducer signal available E. Auto Stop System (Voltage for relay) A. Hardware test - Power supply voltage C10800 C10801 C10804 Service Codes: C55 to check line voltage. If the line voltage is below or above a limit the error code is displayed. B. Hardware test - 5V line C10810 C10811 Service Codes: C110 to check 5V voltage. If the 5V voltage is below or above a limit the error code is displayed. C. Hardware test - Current of optoelectronic LED C10705 C10706 C10707 C10708 Service Codes: C75, AdC1 to check LED If the current / voltage is below or above a limit the error code is displayed. D. Hardware test - Transducer signals C10410 C10420 C10430 Service Codes: C103/C104 to check transimpedance and signal amplifiers and transducer values. If no signals from the transducers are detected the error code is displayed. E. Hardware test - Auto stop system C10380 C10381 C10382 C10383 Service Codes: C75, Adc21 to check voltage on capacitor of the auto stop system. If the voltage is below or above a limit or the recharging time is above a limit the error code is displayed. 6. Hardware test disturbed H 82 Service Codes : All codes available for the model A self test was disturbed (e.g. wheel was rotated during the transducer test) The code is read out for 3 seconds, then measurement is repeated (10 times maximum), or aborted using the STOP or ESC key. Effective Page 4-2 01/2005 CHAPTER 4 SYSTEM IV 7. Check home position of left SAPE E3 Service Codes : C80 (& C81) to calibrate SAPE C92 to check distance and diameter of actual calibration Inner SAPE gauge arm not in home position. Replace SAPE gauge arm in home position and press STOP or ESC key to continue. 8. Disable left SAPE E92 Service Codes : C80 (& C81) to calibrate SAPE C92 to check distance and diameter of actual calibration During the second attempt the inner SAPE gauge arm was again not replaced to home position. Inner and outer SAPE gauge arms are turned off. Wait for 5 seconds, or press STOP or ESC key to continue. 9. Check home position of right SAPE E4 Service Codes: C82 to calibrate SAPE Outer SAPE gauge arm not in home position. Replace SAPE gauge arm in home position and press STOP or ESC key to continue. 10. Disable right SAPE E93 Service Codes : C82 to calibrate SAPE During the second attempt the outer SAPE gauge arm was again not replaced to home position. Outer SAPE gauge arms are turned off. Wait for 5 seconds, or press STOP or ESC key to continue. 11. Check calibration E901 Service Codes : C80, C81, C82, C83, C84, C88, C90 Machine was not calibrated. For calibration the following calibration codes will have to be carried out in the sequence as given below: C80 – Calibration of inner SAPE gauge arm C81 – Measurement of flange to zero plane distance C82 – Calibration of outer gauge arm C83 – Basic calibration of vibratory system C84 – Measurement of residual main shaft unbalance C88 – Adjustment of 12 h position C90 – Saving calibration data After a successful boot up the following screen should appear. (Figure 4-1) Figure 4-1 Effective 01/2005 Page 4-3 CHAPTER 4 SYSTEM IV DISPLAY DESCRIPTION The Display of the VPI System IV balancer is divided into three parts. Each of these parts display different information throughout the use of the balancer. (Figure 4-2) • Main Screen: Main information screen for the user interface. • Function Key area: Six function keys F1 to F6, the functionality of the keys can change in every screen. Represents the function of the keys on the keyboard. • Status Area: Status information from top to bottom, balancer model and software revision, date and time, screen name, balancer status (i.e. adapter compensation active, loaded user), error messages. Status Area Main Screen Function Key Area Figure 4-2 BALANCER SETUP On the initial installation the balancer should be setup for the customer preferences i.e. ounce/gram, day/ month/year, time, etc. Press the “Function” key (F1) Figure 4-X Start = No Function Stop = Stop the Main Shaft Escape = No Function Help = Go to Help Screen F1 = Go to Function Screen / Enter Service Mode User Calibration / Text Editor F2 = Adapter compensation function or if adapter compensation is active; switch off. The unbalance of an adapter can be temporarily compensated with this function. If the adapter compensation is active it is indicated by the adapter compensation icon in the status area. (Operator Manual) F3 = No Function F4 = Go to Balancing Function (Operator Manual) F5 = No Function F6 = Optimization menu (Operator Manual) Figure 4-3 Effective Page 4-4 01/2005 CHAPTER 4 SYSTEM IV FUNCTION SCREEN Start = No Function Stop = Stop the Main Shaft Escape = Back to Introduction Screen Help = Go to Help Screen F1 = User Calibration F2 = Go to text editor F3 = No Function F4 = No Function F5 = Used to toggle selected Function F6 = Used to change selected Function While pressing and holding in the “F6” key rotate the shaft. The green indicator arrows in the “Main Screen” area will either move up or down depend- ing on the direction of the shaft rotation. Once the indicating arrow reaches the function to be changed release the “F6” key. Press and hold the “F5” key to toggle the function. The indicator arrow at the bottom of the “Main Screen” area indicates additional information. The two “--” marks at the top of the Main Screen area indicates that there is no information above the selected function. Figure 4-4 FUNCTION DESCRIPTION Setting factory default modes of operation. • Set to 1 for changing all setting to factory defaults and settings. Saving modes of operation in permanent memory. Saving the user settings in the non volatile memory. The saved setting are now active after the next power on. • 0: do not save • 1: save settings After successful write to the non volatile memory the display board speaker sounds the typical Snap-on “TüDüLü”. Language selection. • The English Language is the first one on the list. The volume of audible signals. • 0 ... 100: selectable from 0 (off) to 100 (loud), 50 is default. Resolution of unbalance amount readings. The resolution of the unbalance display. • Normal: rough, default • Fine: fine Suppression of minor unbalance readings. The used threshold can be changed with C8. Below these threshold the unbalance value is set to zero. • off • on, default Effective 01/2005 Page 4-5 CHAPTER 4 SYSTEM IV Setting threshold value for unbalance suppression. Threshold value for suppression of minor unbalance readings. • 3.5 ... 20.0 grams, 3.5 grams is default • 0.25 ... 2.00 ounces, 0.25 ounces is default All unbalance values below the threshold are set to zero if suppression of minor unbalances is enabled. If the right, left and static unbalance values are set to zero the OK segment is on. If the ALU mode is not normal the unbalance values are transformed to the normal ALU mode to check the values. Measurement units of the unbalance amount readings. • grams, default • ounces Number of revolutions for a measurement run. Note that a decrease of the number of revolutions for a measurement run causes lower accuracy of the measurement results. • 5 ... 25: Number of revolutions for a measurement run, 10 is default. Starting a measuring run by closing the wheel guard. This feature works not in the user codes, service codes, optimization and minimization. • off, default • on Automatic braking when wheel guard is raised. • off: no automatic braking, motor is switched off. • on: braking to standstill, default. Releasing of the power clamping device. The power clamp system can be locked. This can be used if a special clamping device is in use. • off: no lock, default • on: locked Actuation direction of pedal for clamping/releasing. The functionality of the power clamp foot pedal can be changed. • raise: raise pedal for clamping, default • press: press pedal for clamping Three lines for changing the date. • Day: dd.—.— • Month: —.mm.— • Year: —.—.yy Two lines for changing the time. • Hour: hh:— • Minute: —:mm The balancer has counters to count the measured runs. The counters are displayed in three lines: • number of measurement runs / number of measurement runs with OK • number of measurement runs since last calibration / number of clamping. • number of optimization and minimization / number of measurement runs in service mode Effective Page 4-6 01/2005 CHAPTER 4 SYSTEM IV Screensaver timeout (0=disable) • Amount of time for screensaver to activate while unit is sitting idle (default 20) CUSTOMER CALIBRATION The JBC VPI System IV balancer features a user calibration program which requires only a few minutes to complete. Perform this procedure when the balancer has been moved, disturbed, or whenever accuracy is questioned. Occasional field calibra- tion will ensure years of reliable service. 1. Press and release the “Function” key (F1) from the “Intro Screen”. (Figure 4-5) Figure 4-5 2. Press and release the “Calibration” key (F1). (Figure 4-6) Figure 4-6 Effective 01/2005 Page 4-7 CHAPTER 4 SYSTEM IV 3. With nothing mounted on the shaft lower the wheel guard and press the “SPIN” key. The balancer should spin and come to a complete stop. (Figure 4-7) Figure 4-7 4. After the balancer comes to a stop raise the wheel guard and screw the calibration slug into left side of the flange plate. Lower the wheel guard and press the “SPIN” key. The balancer should spin and come to a complete stop. Once the shaft stops the display should display “OK” and the speaker sounds the Snap-on “TüDüLü”. (Figure 4- 8) Calibration Complete Figure 4-8 Effective Page 4-8 01/2005 CHAPTER 4 SYSTEM IV ENTERING SERVICE MODE 1. From the Introduction Screen press the “FUNC- TION” key (F1) to enter in to the Function Menu. (Figure 4-9) Figure 4-9 2. By pressing the F6 key 3 times successively the “SERVICE” key (F4) will become active. (Figure 4- 10) Figure 4-10 3. By pressing the F4 key the service program will become active. (Figure 4-11) Figure 4-11 Effective 01/2005 Page 4-9 CHAPTER 4 SYSTEM IV C CODES By pressing and holding the “C-CODE” key (F1) and rotating the main shaft the user can select the desired C-Code. Once the desired C-Code is displayed in the C-Code identifier window the technician needs to simply release the “C-Code” key (F1). After each C-Code change it is recommended that the technician save the change by use of the “C90” code. There are many C-Codes available however there are very few that are required to diagnosis and repair the System IV balancer. Many codes are written for engineering purposes and are not valid for field use. C Description 28 Display and clear error codes Figure 4-12 43 Reset counters 47 Select machine model 55 Indication the line voltage 56 Indication of the circuit state of the wheel guard switch 57 Indication of temperature 59 Indication of the residual unbalance compensated for using code C84 60 Motor: Indication of RPM of main shaft 74 Indication of position counter and basic incremental encoder test 75 Display values from AD converter 76 Indication of the voltages used by the 2 step motor control 80 Calibration of the inner SAPE gauge arm and the AutoStopSystem 81 Measuring the adaptor flange and the zero plane. 82 Calibration of the outer SAPE. 83 Calibration of the unbalance measurement with wheel/test rotor. 84 Compensation of unbalance of main shaft 85 Copy content of serial EEPROM (EEP) from micro-controller EEP to incremental encoder EEP. 86 Copy content of serial EEPROM (EEP) from incremental encoder EEP to micro-controller EEP. 90 Saving the adjustments data 92 Display of actual distance and diameter of inner SAPE. 110 Indication of the operating voltages supplied by the power supply module. C28 DISPLAY AND CLEAR ERROR CODES The last 10 different malfunction codes are written into the error memory so that they can be called up and reported by the operator of the wheel balancer e.g. for remote diagnosis of malfunctions. The most recent malfunction code is written into memory location 1 and the previous error codes are shifted to the higher memory locations. Displays the internal error code (6 digits). NOTE: MAKE SPECIAL NOTE OF DIAGNOSTIC CODES THAT RELATE TO A SPECIFIC COMPO- NENT. REPEATED DIAGNOSTIC CODES POINT TO THE FAILED COMPONENT. Use the “Enter” key (F4) to proceed to the next error message (reading Err1 -Err10). If no error occurred, “—” is displayed. Clearing the entire error memory (step 2): Press the Acknowledgment key to proceed to step 2. Use the option selection to choose “1” and acknowledge with the “Enter” key (F4). Effective Page 4-10 01/2005 CHAPTER 4 SYSTEM IV C43 RESET COUNTERS This C-Code is used to reset all balancer counters. The following counters are reset. This code will not clear any error codes that have been set into memory. • Total number of measuring runs • Number of measuring runs where balance quality was considered OK • Number of optimizations and minimizations • Number of measuring runs in service mode • Number of measuring runs since the last calibration 0: No reset of counters 1: Reset of counters C47 SELECT MACHINE MODEL This balancer is sold world wide under different brands and model numbers. The only model available in the domestic market in the USA. is the “Sys IV” balancer. If changes are made by accident all factory calibration procedures will need to be performed. It is advised that no changes be made to the software settings. C55 INCOMING LINE VOLTAGE Measured line voltage going into the electronic box. The correct voltage is 230VAC ± 10%. If the balancer is has a step-up transformer installed so that the unit can be plugged into 115VAC the incoming voltage is what is measured after the transformer. C56 CIRCUIT STATE OF THE WHEEL GUARD This test function can be used to determine the angle at which the wheel guard switch trips. With the wheel guard in the open (up) position the reading should be 000. Slowly lower the wheel guard to the closed (down) position, the reading will change once to 100 indicating the position of a closed wheel guard. C57 VIBRATORY TEMPERATURE SENSOR Measures the vibratory temperature, unit measures in centigrade (°C) C60 MOTOR RPM Once this code is called up “---” is read out in the right display. As soon as measured data is available, the current speed is read out. The correct value is 190 ± 10. C74 POSITION COUNTER AND BASIC INCREMENTAL ENCODER TEST Once this code is called up, the angular position and incremental encoder status register are display continu- ously. For a short test turn the main shaft at least 2 turns in both directions, the status register then must show 23F. For detailed status information see below. Angular position: As long as the incremental encoder has not yet synchronized with the zero reference, the angular location reading is “- - -”. After synchronization the angular position is display as a value in a range between 0 and 511. -00 after switching power on (main shaft not moved at all), or after pressing the Special function key -07 after 2 turns backward Æ A- and B channel signals are OK, but there is no synchronisation in back- ward direction. -0b after 2 turns forward Æ A and B channel signals are OK, but there is no synchronisation in forward direction. -1b after 2 turns forward backward Æ A and B channel signals are OK, synchronisation in forward rotation is OK as well. -1F after 2 turns in each direction à A and B channel signals are OK, but synchronisation was made in forward direction only C74 Continued on next page Effective 01/2005 Page 4-11 CHAPTER 4 SYSTEM IV -27 after 2 turns backward Æ A and B channel signals are OK, synchronisation in backward direction is OK as well -2F after 2 turns in each direction Æ A and B channel signals are OK, but synchronisation was made in backward direction only. 23F Incremental encoder was rotated by more than 2 turns in each direction and performs properly. >-40 Synchronisation error in forward direction >-80 Synchronisation error in backward direction Comments If this test fails (no 23F) please check • the cabling of the opto electronic – micro-controller • the connectors of the cable • clean the incremental encoder sleeve C75 DISPLAY VALUES OF A/D CONVERTER AD input Channel Description AdC 0 0.0 REF-AD Reference voltage of external AD converter AdC 1 1.0 fLED-CW LED current control AdC 2 2.0 fSON-TMP Temperature ultrasonic unit AdC 3 3.0 fBAL-TMP Temperature of transducer/vibratory system AdC 4 4.0 fANA3 Motor current AdC 5 5.0 fANA2 Power interface board multiplexer channel Y AdC 6 6.0 fANA1 Power interface board multiplexer channel X AdC 7 7.0 fPOT free AdC 8 8.0 fPOt-WHO Width potentiometer AdC 9 9.0 fPOT-OFS Distance/extraction potentiometer AdC 10 10.0 fPOT-DIA Diameter/angle potentiometer AdC 11 11.0 RF1V23 Internal reference voltage of analogue unit potentiometer AdC 12 12.0 VCC-W ½ voltage of +5V supply AdC 13 13.0 fLINE-V Mains voltage control AdC 14 14.0 AIR Input of voltage amplifier in front unbalance channel AdC 15 15.0 AIL Input of voltage amplifier in rear unbalance channel AdC 16 5.0 VCSSw* 0.793 * supply voltage to external switches AdC 17 6.0 free AdC 18 5.1 VBrCur* Coil current of solenoid brake AdC 19 6.1 free AdC 20 5.2 VDisp* Supply voltage of display board AdC 21 6.2 VAssStat* Voltage on capacitor of AutoStopSystem AdC 22 5.3 VRimSens* Identification of rim material AdC23 6.3 VRelCur* Coil current of relay AdE 1 AE1 External AD converter (rear transducer) AdE 2 AE2 External AD converter (front transducer) * via multiplexer on the power interface C80 CALIBRATION OF DISTANCE, DIAMETER AND AUTO STOP SYSTEM NOTE: THIS FUNCTION MUST BE PERFORMED IF C-CODE 47, 85 & 86 IS INITIATED OR IF SOFTWARE IS INSTALLED OR UPGRADED. Effective Page 4-12 01/2005 CHAPTER 4 SYSTEM IV 1. With the Distance gauge in the home position check the voltage reading in the right hand display window, the correct value is 4.30VDC ± .05. See Distance SAPE Potentiometer installation in Chapter 3 if adjust- ments is needed. 2. Pull the distance gauge out from the home position and rest the arm on the vibratory tube. Check the voltage reading in the left hand display window, the correct value is 4.00VDC ± .10. See Diameter SAPE Potentiometer installation in Chapter 3 if adjustments is needed. 3. Press the “ENTER’ key (F6) to proceed to the next step. (Figure 4-13) Figure 4-13 Effective 01/2005 Page 4-13 CHAPTER 4 SYSTEM IV 4. Fully extend the distance gauge and press the “ENTER” key (F6) to store the value and proceed to the next step. (Figure 4-14) Figure 4-14 5. Place the large pancake portion of the calibration slug down on the bell housing and pull the distance arm out and rest it on the pancake portion of the calibration slug. Press the “ENTER” key (F6) to store the value and proceed to the next step. (Figure 4-15) Figure 4-15 Effective Page 4-14 01/2005 CHAPTER 4 SYSTEM IV 6. Raise the gauge arm, and touch the tip of the calibration slug. Press the “ENTER” key (F6) to store the value and proceed to the next step. (Figure 4-16) Figure 4-16 7. Step 5 has no function. Press the “ENTER” key (F6) to proceed to the next step. (Figure 4-17) Figure 4-17 Effective 01/2005 Page 4-15 CHAPTER 4 SYSTEM IV 8. Pull the distance gauge out slowly at least 3 times until the “Auto Lock” clamps and locks the distance gauge, after which return it to the home position. Repeat this process 3 consecutive times, the software will then advance to step 7. Watch the “Status Area” if the arm is pulled out to quickly or to slowly the balancer will flash an “H26” or “H28” code. (Figure 4-19) Figure 4-19 9. Pull out the gauge arm 7 times with increased constant speeduntil it clamps. After each clamping hold the gauge arm for at least 1 second in the clamped position before repeating the procedure. When the gauge arm has been pulled out and clamped 7 times, the reading will automatically advance to C ---. (Figure 4- 20) Figure 4-20 CALIBRATION COMPLETE STORE FACTORS USING C90 Effective Page 4-16 01/2005 CHAPTER 4 SYSTEM IV C81 MEASURING ADAPTOR FLANGE AND ZERO PLANE 1. Place the calibration weight against the backing collar. Press the “ENTER” key (F6) to store values. Store the new values using C90. (Figure 4-21) Figure 4-21 C82 WIDTH GAUGE ARM ADJUSTMENT / CALIBRATION 1. Read the values of the potetiometer with the width gauge arm in the home position. The voltage reading should be 4.35VDC ± 0.05. Press the “ENTER” key (F6) to store the value. See Chapter 3 if adjustments are required. (Figure 4-22) Figure 4-22 Effective 01/2005 Page 4-17 CHAPTER 4 SYSTEM IV 2. Touch the tip of the width gauge to the outer face of the backing collar, the value should be greater than 0.15. Press the “ENTER” key (F6) to store this value. (Figure 4-23) Figure 4-23 3. Screw the calibration weight into the threaded hole on the outside of the backing collar. Touch and hold the tip of the width gauge to the tip of the calibration weight. Press the “ENTER” key (F6) to store this value. (Figure 4-24) Figure 4-24 CALIBRATION COMPLETE STORE FACTORS USING C90 Effective Page 4-18 01/2005 CHAPTER 4 SYSTEM IV C83 CALIBRATION OF UNBALANCE MEASUREMENT This test can be done either using a Pruefrotor or Tire and Wheel assembly. If a tire and wheel assembly, is used a 3.50oz (100gr) or 3.00oz (85gr) weight is required to accurately calibrate the balancer. NOTE: FOR INSTRUCTIONAL PURPOSES THE PRUEFROTOR IS USED. 1. Mount the Pruefrotor on the balancer shaft and enter in the parameters of the Pruefrotor using the balance screen. (Figure 4-25) Figure 4-25 2. Enter the “Service” routine and select C83. Press the “START” button to begin the mea- suring run. (Figure 4-26) Figure 4-26 3. If a Pruefrotor is used, screw the 100 gram weight on the left side of the Pruefrotor if the value displayed is not “100” in step 2 press and hold the “ENTER VALUE” key (F4) and rotate the shaft until the custom weight is displayed. Press the “ENTER” key (F6) to enter the value of the test weight and to proceed to step 3. Press the “START” button to begin the measuring run. (Figure 4-27) Figure 4-27 Effective 01/2005 Page 4-19 CHAPTER 4 SYSTEM IV 4. Remove the 100 gram calibration weight and insert it into the right hand plane of the Pruefrotor. Press the “START” key to begin the measuring run. (Figure 4-28) Figure 4-28 5. Step Number 5 has not been programmed. Press the “ENTER” key (F6) to advance to the next step. (Figure 4-29) Figure 4-29 6. The ambient transducer temperature is displayed for 1 second. (Figure 4-30) Figure 4-30 Effective Page 4-20 01/2005 CHAPTER 4 SYSTEM IV 7. Remove the 100 gram weight, lower the hood and press the “START” button to begin a measuring run. (Figure 4-31) Figure 4-31 8. Insert the calibration weight that is supplied with the balancer on the left side of the backing plate. Press the “START” button to begin a measuring run. (Figure 4-32) 9. Store the new factors using C90. 10. Must complete C84 after this function CALIBRATION COMPLETE Figure 4-32 C84 EMPTY SHAFT COMPENSATION 1. Remove all accessory items from the Main Shaft. (Figure 4-33) 2. Lower the hood and press the “START” button to begin the measuring run. 3. Store the new factors using C90. CALIBRATION COMPLETE Figure 4-33 Effective 01/2005 Page 4-21 CHAPTER 4 SYSTEM IV C88 ANGULAR UNBALANCE POSITION 1. Mount the Pruefrotor on the balancer shaft and enter in the parameters of the Pruefrotor using the balance screen. Press the “START” button to begin the measurement run. (Fig- ure 4-34) Figure 4-34 2. Attach the 100 gram weight to outside of the Pruefrotor and press the “START” button. (Figure 4-35) Figure 4-35 3. After the shaft comes to a complete stop rotate the shaft to locate the 100 gram weight at “BOTTOM DEAD CENTER” position. Press the “ENTER” key (F6) to save the data. (Figure 4-36) 4. Store the new factors using C90. CALIBRATION COMPLETE Figure 4-36 Effective Page 4-22 01/2005 CHAPTER 4 SYSTEM IV C90 SAVING ADJUSTMENT DATA All calibration data must be saved into memory before powering down the unit. Any data that is not saved will be lost if the power is recycled. 1. Press and hold the “ENTER VALUES” key (F4) and rotate the shaft to change the selec- tion window from “0” to “1”, release the key. (Figure 4-37) Figure 4-37 Effective 01/2005 Page 4-23 CHAPTER 4 SYSTEM IV FIELD PROGRAMMING THE BALANCER 1. Turn off balancer. 2. Place EEPROM in micro-controller socket with flat end at bottom of socket close to large blue connec- tor. Notched end is 3 spaces short of other end of socket. (Figure 4-38) 3. Turn on balancer. 4. Three audible beeps accompanied by three flashes of the led on the micro-controller board indicate that program is loading. 5. A continuous sequence of beeps and flashes indicates that program loading is complete. 6. Turn off balancer. 7. Remove EEPROM and turn on balancer. 8. The normal startup procedure will be performed. 9. Perform service codes in the following order; • C47 - Select machine model • C80 - Calibration of inner SAPE gauge arm • C81 - Measurement of flange to zero plane distance • C82 - Calibration of outer gauge arm • C83 - Basic calibration of vibratory system • C84 - Measurement of residual main shaft unbalance • C88 - Adjustment of 12 h position • C90 - Saving calibration data The machine is now ready for use. Figure 4-38 Effective Page 4-24 01/2005 CHAPTER 5 BFH SERIES INTRODUCTION The BFH/Optima Series system is a wheel balancing machine equipped with three optical scanners. Two scanners capture images of the wheel rim profiles (inner and outer), so that the co-ordinates of optimum positions for application of the balancing weights can be calculated automatically and without user inputs. The scanners are also used to obtain geometrical data about rim deformations, deviation of the rim edges from its axis of rotation (Rim Runout). The third scanner provides geo- metrical data about tire deformations, deviation of the tire from its axis of rotation (Tire Runout). Such data is used for advanced diagnosis of the wheel as well as to provide the user with indications on how to proceed in order to minimize the effects of such deformations. THEORY OF OPERATION The BFH/Optima Series system is based on distance measuring devices (range finders) based on the principle of LASER triangulation. This device comprises a LASER source, a lens and a linear optical image sensor (a CCD – charge coupled device). The beam of coherent light emitted by the LASER source hits the object whose distance is to be measured. The beam of light is diffused (scattered) in a plurality of light rays from the surface of the object and the rays are concentrated by the lens in a spot on the sensitive surface of the linear optical image sensor. The position of the spot on the sensor is determined by a digital analysis of the electrical signal produced by the sensor. The distance between the object and the LASER source may be calculated. In practice, a calibration procedure is performed and a polynomial interpolation of a suitable degree is used. Specifically, the BFH/Optima system implements cubic spline interpolation with shape preserving characteristics. The complete process is as follows: 1. Laser power – exposure time settling. The system is able to set the optimum values of laser power and CCD exposure time according to the ambient light, amount of reflected light, and reflectivity of objects. 2. Background subtraction. Two successive readings are taken: in the first the laser source is off, in the second is on. Complete sensor readouts are kept in the computer’s memory. The difference of the acquired data provide an image of the CCD sensor without effects due to ambient light. 3. Detecting the position of the light peak on the linear optical image sensor. 4. Calculating the distance to the object by means of polynomial interpolation. Effective 10/2007 Page 5-1 BFH / OPTIMA Profiling In the BFH/Optima Series system, the distance measuring devices (range finders) are rotated in a plurality of known positions by a stepper motor, so that they constitute optical scanners. The scanners, detecting the distances from a known position of a plurality of points on the object to be explored (the wheel rim) allows the spatial co-ordinates of each point detected to be obtained. For each scanner, the complete process is as follows: 1. Measuring the distance to the point hit. 2. Saving the distance measured at point 1 and the position of the distance measuring device at point 1. 3. Moving the laser range finder to the next known position. 4. Repeating steps 1 – 4 until the scan is complete. Based on these co-ordinates, it is possible to identify positions on the rim profile which are useful, and even in a certain sense optimum, for the application of balancing counterweights. The co-ordinates of these positions are calculated automatically and without contact. The complete weight position detection process is as follows: 1. Scan rim contour to determine typical rim parameters 2. Compare current rim pattern with a set of stored rim patterns 3. Select the best match stored rim pattern 4. Pick pre-established weight locations associated with the best match pre-established rim pattern 5. Calculate weight amount and display 6. Allow the user to modify suggested weight location by moving the laser pointer 7. “Learn” from experience Effective Page 5-2 10/2007 BFH / OPTIMA Rim Runout Measurement - Rim- Tire Matching / Optimization It is known that the vibrations produced by a motor vehicle wheel as it turns are caused, by the following: 1. Uneven distribution of weights on the tire 2. Uneven distribution of weights on the rim 3. Geometrical deformation of the tire 4. Geometrical deformation of the rim 5. Uneven tire elasticity (variation in stiffness) The BFH/Optima system allows the identification of geometrical deformations in the rim, that is to say, deviation of the rim axis from its axis of rotation: Radial and Lateral Runout. The scanner devices are rotated to a known position so that the LASER beam hits the surface of the rim at a predetermined point. The rim is rotated about the wheel balancer shaft and a plurality of distance measurements are taken at known rim angles of rotation. The operation is repeated for at least one other known distance measuring device position. On the basis of the data gathered in this way, a calculation process defines the eccentricity (Radial Runout) and angle (Lateral Runout) of the rim axis relative to the axis of rotation. This data can be used to provide the user an indication of the quality of the rim examined. It is also used to provide the user with indications on how to position the tire relative to the rim in order minimize the effects of such deformations. In fact, the system allows the measurement of geometrical data relative to tire deformations, deviation of the tire axis from its axis of rotation. The distance measuring device is moved by rotation and translation to a known position so that the LASER beam hits the surface of the tire at a predetermined point. The wheel is rotated about the wheel balancer axis and a plurality of distance measurements are taken at known wheel angles of rotation. On the basis of the data gathered in this way, a calculation process defines the eccentricity – Radial Runout – of the wheel axis relative to the axis of rotation. A calculation process defines the eccen- tricity of the tire only, based on the measurements taken respectively on the rim and on the entire wheel by means of vector subtraction. This data, together with the data about the imbalance and the data about the rim geometrical deformations, allows a complete wheel diagnosis and provides the user with more accurate indications. Moreover, a suit- able optimization algorithm provides indications on how to position the tire relative to the rim in order to minimize the concurrent effects of such deformations in accordance with appropriate criteria. Typically, the tire is rotated with respect to the rim opposing the peak (maximum) of the tire radial runout with the minimum of the rim radial runout, thus minimizing the radial runout of the assembled wheel. Effective 10/2007 Page 5-3 BFH / OPTIMA BFH/OPTIMA SERIES MAJOR COMPONENTS This section identifies the major components for the BFH/Optima Series balancer. All descriptions and AC/ DC theory of other components can be found in earlier chapters of this service manual. CAMERA PROCESSOR BOARD The Camera Processor board is the liason between the three Scanner / CCD assemblies and the Main Processor PCB inside the Ebox. J6/7/8/9 Pin # Direction Name Description 1 Digital Out Q3 Stepper Motor Phase B 2,5 Power Out Un Common Power Supply 3 Digital Out Q4 Stepper Motor Phase D 4 Digital Out Q2 Stepper Motor Phase C 6 Digital Out Q1 Stepper Motor Phase A J10 Pin # Direction Name Description 1 Power Out +5Vdc Digital Power Supply (5V) 2 Digital In Zpos3 Motor 3 Zero Position 3,4 dGnd Digital Ground J11 Pin # Direction Name Description 1 Digital In PH-A Encoder Phase A 2,4 dGnd Digital Ground 3 Digital In PH-B Encoder Phase B J12 Pin # Direction Name Description 1,2,4,6 Power In External 5V power supply 3,5,13,14 External Ground 7,8,9,10 NC Not Connected 11 Digital In IIC-SCif External IIC Serial Clock 12 Digital I/O IIC-SDif External IIC Serial Data J13 Pin # Direction Name Description 1,2,3 Power In External Motor Power Supply 4,5,6 External Motor Ground Effective Page 5-4 10/2007 BFH / OPTIMA J14,15,16 Pin # Direction Name Description 1,18,20 Digital Ground 2 Analog In OSx OS CCD signal 3 Analog In DOSx DOS CCD signal 4,12 Power Out +5Vd 5V Digital Power Supply 5 Digital Out FRMstx Frame Start Signal 6 Out LPx Laser Pointer Switch 7 Digital Out RSTx Reset signal 8,10 Power Out +3.3Vd 3.3V Digital power supply 9 Digital In AUXoutx Auxialiary Digital out 11 Digital In CONVstx Conversion start signal 13 Digital I/O SDA IIC serial data 14,16 Digital Out E0/1 IIC EEPROM address configuration 15 Digital Out SCL IIC serial clock 17 Digital In Zposx Scanner home position signal 19 Digital Out LASERx Laser modulation signal J10 J9 J8 J7 J6 Rear Rear Rear Outside Inside Encoder Scanner Scanner Scanner Scanner Zero Motor Motor Motor Motor Drive J13 J16 Motor Rear Power CCD J12 PCB Power J15 Outside CCD J11 Power Clamp Encoder J14 Inside CCD ELECTRONIC BOX The BFH/Optima is equipped with an electronic box somewhat like the Y2k balancers. Additional compo- nents have been added to the power supply pcb to operate the “Power Clamp” and the “Power Clamp switch”. The box is backwards compatible but the older Ebox will not work in the BFH/Optima balancer. Effective 10/2007 Page 5-5 BFH / OPTIMA SCANNER / LASER / CCD The BFH/Optima is equipped with 3 Scanner assemblies. Each of these assemblies are installed and cali- brated as complete assemblies. A role call is performed with each one on boot up. There are no serviceable components on these assemblies with the exception of the manufactures mechanical adjustments. DO NOT ATTEMPT TO MAKE ADJUSTMENTS OTHER THAN THE ZERO REFERENCE STATED LATER IN THIS MANUAL. Each scanner assembly has a zero stop that has minor adjustment. The rear scanner assembly and the outside scanner assembly are identical and can be swapped. However, the inside scanner assembly has a different mounting bracket and cannot be interchanged with the other two assemblies. For troubleshooting purposes the units can be swapped at board level. Should any of these assemblies require replacement the balancer will flag an E360 error code and force a scanner calibra- tion. POWER SUPPLY PCB The Power Supply PCB receives 230VAC power from the Electronic box. This voltage can be measured using a Digital Volt Meter at J1 pins 1 and 2 on the Power Supply PCB. The AC power passes through on-board bridge rectifiers converting the power to 9VDC which is used to power all of the (4) Scanner Motors. This 9VDC can be measured at J2 pins 1,2 and 3. Pins 4,5 and 6 are ground connections. This voltage must be adjusted after the installation of the Power Supply PCB. Follow the procedure below to measure and adjust the output voltage to the scanner motors. 1. Remove the weight tray 2. Place the positive lead of the Digital Volt Meter on Pin 1 (Red wire) and the negative lead of the Digital Volt Meter on Pin 6 (Black wire). 3. Use a small pocket screwdriver and adjust the pot to obtain a voltage reading between 9 - 9.5 VDC. Adjustment Pot Pin 6 Pin 1 Effective Page 5-6 10/2007 BFH / OPTIMA POWER CLAMP ASSEMBLY The BFH/Optima series balancer is equipped with a power clamp that eliminates the need for a standard or quick clamp nut. The Power Clamp is activated by lifting up on the foot pedal mounted on the balancer. The vibratory system has an optical sensor mounted on the shaft that senses variation on a visible encoder disk. The opti switch looks to see if the shaft is spinning before operating the power clamp. The power clamp will not open or close if the shaft is spinning. The large pulley drives the power clamping jaws while the magnetic brake is engaged and is holding the shaft. Should the clamping jaws be engaged during the event of a power failure there is a manual overide to disengage the power clamp so the wheel/tire assembly can be removed. Manual Overide Wheel and Tire Removal Procedure 1. On the front of the balancer, remove the plug from the access holes. 2. Insert a large screwdriver into the access hole approximately 6 inches. 3. Slowly turn the Wheel and Tire assembly CW until the “Manual Stops” make contact with the screw- driver. 4. Continue to turn the Wheel and Tire assembly until the power clamp cup reaches the end of the shaft. 5. Once power is resumed simply lift up on the foot pedal to re-engage the power clamp mechanism. Access Hole Manual Stops Effective 10/2007 Page 5-7 BFH / OPTIMA SELF TEST DURING START UP The BFH/Optima performs a start-up routine when power is applied. A series of self diagnostic tests is conducted after the machine has been turned on. If a test is not successful: a series of audible signals is given, or an error code is displayed. A three-tone signal is given once, the machine is operative. In case there is a functional error, it must be acknowledged by pressing the STOP or ESC key to proceed. Listed below are the steps that the balancer performs along with possible “E Codes”, “C Codes”, or “H Codes that could occur. This is for informational purposes. 1. Communication between microcontroller and embedded PC (Blue screen) Service Codes: No service code available Communication between micro-controller and embedded PC is not OK (check connecting cable). This can also indicate a bad connection to the keyboard. Check cabling between embedded PC and proces- sor or cable to switches on the front panel. 2. Check availability of keyboard (E 300) Service Codes : No service code available The microcontroller was not able to detect a keyboard. Check cabling between microcontroller and keyboard. 3. Check content of permanent memories (E 145) Service Codes: C85, C86 to copy content of permanent memory Contents of both permanent memories are different, but both contain valid data. If the trouble signalled by the error code is not remedied (using service codes C85 or C86), the machine will remain in service code mode. It will be necessary to perform a manufatures calibration (C83, C84, C88) 4. Check model information (E 900) Service Codes : C47 to set model The stored machine model is not known. If the trouble signalled by the error code is not remedied (using service codes C47), the machine will remain in service code mode. 5. Check keyboard (E 89) Service Codes : No service code available One of the keys F1 to F6, HELP, ESC, START supplies a key code. The machine will proceed with the next step only if the trouble is remedied. 6. Check pedal switches (E 89) Service Codes : C56 to check the pedal switches. C75, AdC16 to check voltage to external switches. (See “C75”) One or, if available, both pedal switches are actuated. The user can now remedy the trouble. Press STOP or ESC key to check the pedal switch once again and to delete the error code reading. If the trouble cannot be remedied, the pedal is made inoperative. 7. Check BFH/Optima Calibration (E 360) Service Codes : All codes available for this model The BFH/Optima hardware requires wheel profiler position calibration. When the camera controller board is replaced on the machine, the software detected that calibration data is missing. Calibration procedure C122 is required to calibrate the actual position of the laser scanners with respect to the balancer reference plane. Effective Page 5-8 10/2007 BFH / OPTIMA 8. Check BFH/Optima Hardware (E 361) Service Codes: All codes available for this model Wheel profiler is not present or responding during the self test. The balancer controller board was not able to communicate with the camera controller board during start-up test. Possible causes: •The camera controller board is missing or dead. •The cable connecting the balancer controller board and the camera controller board is un plugged, damaged or missing. 9. Check BFH/Optima Hardware (E 362) Service Codes : All codes available for this model Main camera board self test failed. Balancing is not possible since wheel data cannot be scanned. Problem during power up. Switch power off and on again. Possible camera board failure. 10. Check BFH/Optima Inner Scanner (E 363) Service Codes : All codes available for this model Left side scanner self test failed or CCD not calibrated or zero mark not detected. Balancing is not possible since wheel data cannot be scanned. 11. Check BFH/Optima Outer Scanner (E 364) Service Codes : All codes available for this model Right side scanner self test failed or CCD not calibrated or zero mark not detected. Balancing is not possible since wheel data cannot be scanned. 12. Check BFH/Optima Rear Scanner (E 365) (Excluding 800) Service Codes : All codes available for this model Rear scanner self test failed or CCD not calibrated or zero mark not detected. Wheel data can be scanned, balancing is possible. Runout measurement of the wheel is not possible. 13. Hardware tests C1- --- - If an error occurs during the hardware test. The four hyphens replace the digits 0 to 9 and the letters A to F which all characterize an error/defect. Refer to all Error Codes in Appendix A The following test are performed: A. Power supply voltage (235V) B. 5V line C. Incremental encoder (Current of optoelectronic LED) D. Transducer signal available E. Auto Stop System (Voltage for relay on Motor Control Board) A. Hardware test - common errors C10F02 - Test returned with an error. No valid test results available C10F07- Test function reported an unkown error C10F18- Test timed out. No valid test results available B. Hardware test - Power supply voltage C10800 C10801 C10804 Service Codes: C55 to check line voltage. If the line voltage is below or above a limit the error code is displayed. (See “C55”) Effective 10/2007 Page 5-9 BFH / OPTIMA C. Hardware test - 5V line C10810 C10811 Service Codes: C110 to check 5V voltage. If the 5V voltage is below or above a limit the error code is displayed. D. Hardware test - Current of optoelectronic LED C10705 C10706 C10707 C10708 Service Codes: C75, AdC1 to check LED If the current / voltage is below or above a limit the error code is displayed. E. Hardware test - Transducer signals C10410 C10420 C10430 Service Codes: C103/C104 to check transimpedance and signal amplifiers and transducer values. If no signals from the transducers are detected the error code is displayed. F. Hardware test - Auto stop system C10380 C10381 C10382 C10383 Service Codes: C75, Adc21 to check voltage on capacitor of the auto stop system. If the voltage is below or above a limit or the recharging time is above a limit the error code is dis- played. 14. Hardware test disturbed H 82 Service Codes : All codes available for the model A self test was disturbed (e.g. wheel was rotated during the transducer test) The code is displayed for 3 seconds, then measurement is repeated (10 times maximum), or aborted using the STOP or ESC key. 15. Power clamp service interval expired E93 All codes available for this model. After a successful boot up the following screen will appear on the display. Effective Page 5-10 10/2007 BFH / OPTIMA DISPLAY DESCRIPTION The Display of the BFH/Optima Series balancer is divided into three parts. Each of these parts display different information throughout the use of the balancer. • Main Screen: Main information screen for the user interface. • Function Key area: Six function keys F1 to F6, the functionality of the keys can change in every screen. Represents the function of the keys on the keyboard. • Status Area: Status information from top to bottom, balancer model and software revision, date and time, screen name, balancer status (i.e. adapter compensation active, loaded user), error messages. Status Area Main Screen Function Key Area BALANCER SETUP On the initial installation the balancer should be setup for the customer preferences i.e. ounce/ gram, day/month/year, time, etc. Press the “Function” key (F1) Start = No Function Stop = Stop the Main Shaft Escape = No Function Help = Go to Help Screen F1 = Go to Function Screen / Enter Service Mode User Calibration / Text Editor F2 = Adapter compensation function or if adapter compensation is active; switch off. The unbal- ance of an adapter can be temporarily compen- sated with this function. If the adapter compensa- tion is active it is indicated by the adapter com- pensation icon in the status area. (Operator Manual) F3 = No Function F4 = Go to Balancing Function (Operator Manual) F5 = No Function F6 = Optima menu (Operator Manual) Effective 10/2007 Page 5-11 BFH / OPTIMA FUNCTION SCREEN Start = No Function Stop = Stop the Main Shaft Escape = Back to Introduction Screen Help = Go to Help Screen F1 = User Calibration F2 = Go to text editor F3 = No Function F4 = No Function F5 = Used to toggle selected Function F6 = Used to change selected Function While pressing and holding in the FUNCTION DESCRIPTION Balancer operating mode. Saving the operating mode setting in the non volatile memory. The saved setting are now active after the next power on. • 0: manual (The BFH/Optima must be set to the manual mode before running any C-Codes.) • 1: profiling • 2: optima Setting factory default modes of operation. • Set to 1 for changing all setting to factory defaults and settings. Saving modes of operation in permanent memory. Saving the user settings in the non volatile memory. The saved setting are now active after the next power on. • 0: do not save • 1: save settings After successful write to the non volatile memory the display board speaker sounds the typical Snap-on “TüDüLü”. Language selection. • The English Language is the first one on the list. The volume of audible signals. • 0 ... 100: selectable from 0 (off) to 100 (loud), 50 is default. Resolution of unbalance amount readings. The resolution of the unbalance display. • Normal: rough, default 5 gram / .25 ounces • Fine: fine 1 gram / .05 ounces Effective Page 5-12 10/2007 BFH / OPTIMA Suppression of minor unbalance readings. The user threshold can be changed with C8. Below this threshold the unbalance value is set to zero. • off • on, default Setting threshold value for unbalance suppression. Threshold value for suppression of minor unbalance readings. • 3.5 ... 20.0 grams, 3.5 grams is default • 0.25 ... 2.00 ounces, 0.25 ounces is default All unbalance values below the threshold are set to zero if suppression of minor unbalances is enabled. If the right, left and static unbalance values are set to zero the OK segment is on. If the ALU mode is not normal the unbalance values are transformed to the normal ALU mode to check the values. Measurement units of the unbalance amount readings. • grams, default • ounces Number of revolutions for a measurement run. Note that a decrease of the number of revolutions for a measurement run can cause an in-accuracy of the measurement results. • 5 ... 25: Number of revolutions for a measurement run, 10 is default. Starting a measuring run by closing the wheel guard. This feature does not work in the user codes, service codes, optimization and minimization. • off, default • on Automatic braking when wheel guard is raised. • off: no automatic braking, motor is switched off. • on: braking to standstill, default. Releasing of the power clamping device. The power clamp system can be locked. This can be used if a special clamping device is in use. • off: no lock, default • on: locked Actuation direction of pedal for clamping/releasing. The functionality of the power clamp foot pedal can be changed. • raise: raise pedal for clamping, default • press: press pedal for clamping Three lines for changing the date. • Day: dd.—.— • Month: —.mm.— • Year: —.—.yy Two lines for changing the time. • Hour: hh:— • Minute: —:mm Effective 10/2007 Page 5-13 BFH / OPTIMA The balancer has counters to count the measured runs. The counters are displayed in three lines: • number of measurement runs / number of measurement runs with OK • number of measurement runs since last calibration / number of clamping. • number of optimization and minimization / number of measurement runs in service mode Screensaver timeout (0=disable) • Amount of time for screensaver to activate while unit is sitting idle (default 20) CUSTOMER CALIBRATION The BFH/Optima balancer features a simple user calibration program. Perform this procedure when the balancer has been moved, disturbed, or whenever accuracy is questioned. Occasional field calibration will ensure years of reliable service. 1. Press and release the 2. Press and release the 3. With nothing mounted on the shaft lower the Effective Page 5-14 10/2007 BFH / OPTIMA wheel guard and press the 4. After the balancer comes to a stop raise the wheel guard and screw the calibration slug into left side of the flange plate. Lower the wheel guard and press the Calibration Complete Effective 10/2007 Page 5-15 BFH / OPTIMA ENTERING SERVICE MODE 1. From the Introduction Screen press the 2. By pressing the NOTE: BEFORE PERFORMING ANY “C-CODES” ON THE BFH/OPTIMA BALANCER THE TECHNICIAN MUST FORCE THE BAL- ANCER INTO THE MANUAL MODE. SEE “BALANCER OPERATING MODE” UNDER “FUNCTION DESCRIPTION EARLIER IN THIS CHAPTER. 3. By pressing the Effective Page 5-16 10/2007 BFH / OPTIMA C CODES By pressing and holding the C Description 28 Display and clear error codes 43 Reset counters 47 Select machine model 55 Indication of the line voltage 56 Indication of the circuit state of the wheel guard switch and both foot pedal switches 57 Indication of temperature 59 Indication of the residual unbalance compensated for using code C84 60 Motor: Indication of the RPM of main shaft 74 Indication of the position counter and basic incremental encoder test 75 Display values from AD converter 76 Indication of the voltages used by the 2 step motor control 80 Geodata arm adjustment and calibration (Hofmann Optima only) 81 Geodata arm calibration (Hofmann Optima only) 83 Calibration of the unbalance measurement with wheel/test rotor. 84 Compensation of unbalance of main shaft 85 Copy content of serial EEPROM (EEP) from micro-controller EEP to incremental encoder EEP. 86 Copy content of serial EEPROM (EEP) from incremental encoder EEP to micro-controller EEP. 88 Calibration of the 12 o’clock position for positioning the weights on the wheel. 90 Saving the adjustments data 98 Display angular position of power clamp pulley, incremental encoder test. 110 Indication of the operating voltages supplied by the power supply module. 120 Enable / Disable the laser pointer 122 Calibration of the Scanner / Laser / CCD assemblies (Inner, Outer and Rear). 123 Manufacturing diagnostic and mechanical adjustment test. C28 DISPLAY AND CLEAR ERROR CODES The last 10 different malfunction codes are written into the error memory so that they can be called up and reported by the operator of the wheel balancer e.g. for remote diagnosis of malfunctions. The most recent malfunction code is written into memory location 1 and the previous error codes are shifted to the higher memory locations. Displays the internal error code (6 digits). NOTE: MAKE SPECIAL NOTE OF DIAGNOSTIC CODES THAT RELATE TO A SPECIFIC COMPO- NENT. REPEATED DIAGNOSTIC CODES POINT TO THE FAILED COMPONENT. Use the “Enter” key (F4) to proceed to the next error message (reading Err1 -Err10). If no error occurred, “— ” is displayed. Clearing the entire error memory (step 2): Press the Acknowledgment key to proceed to step 2. Use the option selection to choose “1” and acknowledge with the “Enter” key (F4). Effective 10/2007 Page 5-17 BFH / OPTIMA C43 RESET COUNTERS This C-Code is used to reset all balancer counters. The following counters are reset. This code will not clear any error codes that have been set into memory. • Total number of measuring runs • Number of measuring runs where balance quality was considered OK • Number of optimizations and minimizations • Number of measuring runs in service mode • Number of measuring runs since the last calibration 0: No reset of counters 1: Reset of counters C47 SELECT MACHINE MODEL This balancer is sold world wide under different brands and model numbers. To validate any software upgrades. Enter C47, press the C55 INCOMING LINE VOLTAGE Measured line voltage going into the electronic box. The correct voltage is 230VAC ± 10%. C56 CIRCUIT STATE OF THE WHEEL GUARD This test function can be used to determine the angle at which the wheel guard switch trips. With the wheel guard in the open (up) position the reading should be 000. Slowly lower the wheel guard to the closed (down) position, the reading will change once to 100 indicating the position of a closed wheel guard. By pressing down on the foot pedal the value should change to “010”, by pulling up on the foot pedal the value should change to “001”. C57 VIBRATORY TEMPERATURE SENSOR Measures the vibratory temperature, measurement displayed in Celcius. C60 MOTOR RPM Once this code is called up “---” is displayed in the right display. As soon as measured data is available, the current speed is displayed. The correct value is 190 ± 10 RPM. C74 POSITION COUNTER AND BASIC INCREMENTAL SHAFT ENCODER TEST Once this code is called up, the angular position and incremental encoder status register are display continu- ously. For a short test turn the main shaft at least 2 turns in both directions, the status register then must show 23F. For detailed status information see below. Angular position: As long as the incremental encoder has not yet synchronized with the zero reference, the angular location reading is “- - -”. After synchronization the angular position is display as a value in a range between 0 and 511. -00 after switching power on (main shaft not moved at all), or after pressing the Special function key -07 after 2 turns backward Æ A- and B channel signals are OK, but there is no synchronisation in back- ward direction. -0b after 2 turns forward Æ A and B channel signals are OK, but there is no synchronisation in forward direction. -1b after 2 turns forward/ backward Æ A and B channel signals are OK, synchronisation in forward rotation is OK as well. -1F after 2 turns in each direction A and B channel signals are OK, but synchronisation was made in forward direction only -27 after 2 turns backward Æ A and B channel signals are OK, synchronisation in backward direction is OK as well Effective Page 5-18 10/2007 BFH / OPTIMA -2F after 2 turns in each direction Æ A and B channel signals are OK, but synchronisation was made in backward direction only. 23F Incremental encoder was rotated by more than 2 turns in each direction and performs properly. >-40 Synchronisation error in forward direction >-80 Synchronisation error in backward direction Comments If this test fails (no 23F) please check • the cabling of the opto electronic – micro-controller • the connectors of the cable • clean the incremental encoder sleeve C75 DISPLAY VALUES OF A/D CONVERTER NOTE: SOME OF THESE CODES ARE NOT USED IN THE BFH/OPTIMA SOFTWARE. AD input Channel Description AdC 0 0.0 REF-AD Reference voltage of external AD converter AdC 1 1.0 fLED-CW LED current control AdC 2 2.0 fSON-TMP Temperature ultrasonic unit AdC 3 3.0 fBAL-TMP Temperature of transducer/vibratory system AdC 4 4.0 fANA3 Motor current AdC 5 5.0 fANA2 Power interface board multiplexer channel Y AdC 6 6.0 fANA1 Power interface board multiplexer channel X AdC 7 7.0 fPOT free AdC 8 8.0 fPOt-WHO Width potentiometer (not used) AdC 9 9.0 fPOT-OFS Distance/extraction potentiometer (not used) AdC 10 10.0 fPOT-DIA Diameter/angle potentiometer (not used) AdC 11 11.0 RF1V23 Internal reference voltage of analogue unit potentiometer AdC 12 12.0 VCC-W ½ voltage of +5V supply AdC 13 13.0 fLINE-V Mains voltage control AdC 14 14.0 AIR Input of voltage amplifier in front unbalance channel AdC 15 15.0 AIL Input of voltage amplifier in rear unbalance channel AdC 16 5.0 VCSSw* 0.793 * supply voltage to external switches AdC 17 6.0 free AdC 18 5.1 VBrCur* Coil current of solenoid brake (not used) AdC 19 6.1 free AdC 20 5.2 VDisp* Supply voltage of display board AdC 21 6.2 VAssStat* Voltage on capacitor of AutoStopSystem AdC 22 5.3 VRimSens* Identification of rim material (not used) AdC23 6.3 VRelCur* Coil current of relay AdE 1 AE1 External AD converter (rear transducer) AdE 2 AE2 External AD converter (front transducer) * via multiplexer on the power interface Effective 10/2007 Page 5-19 BFH / OPTIMA Page left blank intentionally Effective Page 5-20 10/2007 BFH / OPTIMA Page left blank intentionally Effective 10/2007 Page 5-21 BFH / OPTIMA Page left blank intentionally Effective Page 5-22 10/2007 BFH / OPTIMA C83 CALIBRATION OF UNBALANCE MEASUREMENT This test must be done using a Pruefrotor. NOTE: THIS TEST REQUIRES THE USE OF A PRUEFROTOR. ALL TESTS MUST BE DONE WITH THE BALANCER IN THE MANUAL MODE. AFTER ALL TEST ARE DONE THE BALANCER MUST BE SWITCHED BACK INTO THE PREFERRED OPERATING MODE. ALSO CHECK THE VCC VOLTAGE “C110” AND ADJUST IF NECESSARY BEFORE ANY CALIBRATION IS DONE. 1. Mount the Pruefrotor on the balancer shaft and enter in the parameters of the Pruefrotor using the balance screen. 2. Enter the “Service” routine and select C83. Press the 3. After the spin cycle completes, screw the 100 gram weight on the left side of the Pruefrotor and press the Effective 10/2007 Page 5-23 BFH / OPTIMA 4. Remove the 100 gram calibration weight and insert it into the right hand plane of the Pruefrotor. Press the 5. Step Number 5 has not been programmed. Press the 6. The ambient transducer temperature is displayed for 1 second. Effective Page 5-24 10/2007 BFH / OPTIMA 7. Remove the Pruefrotor. Install the small and medium cone on the shaft. Remove the pressure cup from clamping nut and clamp both cones on the shaft. Lower the hood and press the 8. Insert the calibration weight that is supplied with the bal- ancer on the left side of the backing plate. Press the 9. Store the new factors using C90. NOTE: MUST COMPLETE C84 AFTER THIS FUNCTION CALIBRATION COMPLETE Effective 10/2007 Page 5-25 BFH / OPTIMA C84 EMPTY SHAFT COMPENSATION NOTE: THIS PROCEDURE REQUIRES THE USE OF A SPECIAL CALIBRATION RING (EAM0033D53A). DO NOT ATTEMPT THIS PROCEDURE WITHOUT IT. THE BALANCER MUST BE IN THE MANUAL MODE FOR THIS PROCEDURE. 1. Mount the Small Cone, Medium Cone and the clamping sleeve on the shaft. 2. Lower the hood and press the 3. After the spin cycle completes remove the clamping sleeve and install the 4mm calibration ring (EAM0033D53A) between the Medium Cone and the clamping sleeve. Press the 4. Store the new factors using C90. CALIBRATION COMPLETE Effective Page 5-26 10/2007 BFH / OPTIMA C88 WHEEL WEIGHT POSITIONING 1. Mount the Pruefrotor on the balancer shaft and enter in the parameters of the Pruefrotor using the balance screen. Press the 2. Attach the 100 gram weight to outside of the Pruefrotor and press the 3. After the shaft comes to a complete stop rotate the shaft to locate the 100 gram weight at “BOTTOM DEAD CENTER” position. Press the 4. Store the new factors using C90. CALIBRATION COMPLETE Effective 10/2007 Page 5-27 BFH / OPTIMA C90 SAVING CALIBRATION DATA All calibration data must be saved into memory before powering down the unit. Any data that is not saved will be lost if the power is recycled. 1. Press and hold the 2. Press the CALIBRATION DATA SAVED C98 POWER CLAMP ENCODER Once the code is called up the reading should display “---”. After the incremental encoder has identified zero reference, the angular location is displayed in a range between 0 and 63. Use of this C code and meaning are identical with C code 74. If this test should fail (no 23F) check the following: • Cables of the opto switch • Connectors on cable • Clean the incremental encoder tape. Effective Page 5-28 10/2007 BFH / OPTIMA C110 VCC VOLTAGE The operating voltage of the processor is +5.23 VDC ± .25 volts. If the voltage is out of range the balancer may experience a reset problem or it may display 81118b indicating that the voltage is to high or 81018b indicating that the voltage is below the acceptable range. A small adjustment on the balancer power supply can be made. Follow the procedure below to bring the voltage within the acceptable range. Before adjust- ing the output voltage of the power supply observe the voltage reading using C110 and record this reading. Place a DVM on the input power leads on the embedded PC, the acceptable voltage is +5.10 ± .05 A differ- ence of .20 volts between the output (power supply pcb) and input (embedded PC) may indicate a problem with a connection or cable. Repairs must be made before attempting the voltage adjustment below. 1. Remove the weight tray. ! 2. Remove the cover from the power supply. HIGH VOLTAGE PRESENT 3. Power up the unit. 4. Enter the service menu and press Pot Adjustment 6. Verify the voltage reading at the embedded PC connection to ensure that it is acceptable. C120 ENABLE / DISABLE LASER POINTER 0 = Disable laser pointer 1 = Enable laser pointer This feature will turn the laser on/off during the ALU-S mode. It is recommended that the laser should be enabled. Effective 10/2007 Page 5-29 BFH / OPTIMA C122 SCANNER / LASER / CCD CALIBRATION Before the Scanner assemblies can accurately obtain the data needed to balance the wheel and tire assem- bly they must be calibrated. The calibration information is stored on the CCD / Scanner PCB. This informa- tion is stored automatically after completing the calibration. It is recommended that a check of scanner adjustments be made using the C123 procedure before calibrating the scanner assemblies. NOTE: THE BALANCER MUST BE IN THE MANUAL MODE AND ALL PRUEFROTOR PARAMETERS ENTERED BEFORE CONTINUING THIS PROCE- DURE . AT LEAST TWO REVOLUTIONS OF THE SHAFT SHOULD BE MADE SO THAT THE SHAFT ENCODER CAN LOCATE HOME REFERENCE. THIS CAN BE DONE BY QUICKLY ROTATING THE SHAFT UNTIL THE ENCODER READS. 1. Mount the Pruefrotor as shown in the figure on the right, making sure the the orientation of the Pruefrotor is turned correctly. Failure to do so will fail the calibration procedure. 2. Using a small magnetic torpedo level, turn the shaft until the Pruefrotor is in the verticle posi- tion. 3. Press the 4. Slowly rotate the shaft clockwise 20° (153.2). The display will quickly show “LOCK” and the magnetic brake of the balancer will engage. The inner scanner will scan the inside profile of the Pruefrotor DO NOT MOVE THE SHAFT UNTIL INSTRUCTED. After the scanner completes the profile a beep will sound. NOTE: LOWER THE HOOD FOR THE FOL- LOWING STEPS. Effective Page 5-30 10/2007 BFH / OPTIMA 5. Slowly rotate the shaft clockwise 70° (223.2). Once again the “LOCK” will display and the magnetic brake will engage. The outside scanner will begin to take an outside profile of the Pruefrotor The laser light will move from the balancer shaft out to the end of the Pruefrotor (See the red arrow to the right). After the profile has been taken a beep will sound. At this point it is possible to proceed two different ways providing you have a “T” calibration tool, UI 2.9 (or higher) AWP 0.71 (or higher). If the balancer has the software and tool to accomodate the “T” fixture proceed to step 6b. 6. Slowly rotate the shaft clockwise 5° (228.2). Once the correct position is reached the “LOCK” will be displayed and the magnetic brake will engage and lock the shaft. The rear scanner will begin to travel and make a com- plete cycle from the left to the right and back to the left. The scanner is determining the location of the face of the bell housing and the runout profile of the Pruefrotor. 7. The balancer will emit a tone after completing the calibration procedures and an “END” will be displayed for step 5. Perform a C90 to store the new calibration factors. 6b. Unclamp the Pruefrotor and clamp the “T” fixture on the shaft with the reference hole (yellow arrow) away from the balancer. Using a torpedo level, vertically level the “T” fixture. Press 7b. Slowly rotate the “T” fixture -85 degrees (CCW) until “LOCK” appears and engages the magnetic brake. Hold that position until the brake locks and “CAL” appears on the screen. The rear scanner assembly will engage and travel across the back. When the scan is complete the brake WILL NOT release. Firmly grab the “T” fixture and press NOTE: IF AN “ERROR” OCCURS DURING CALIBRA- TION REPEAT EACH STEP CAREFULLY. SHOULD AN ERROR OCCUR A SECOND TIME MAKE SURE EACH SCANNER IS ADJUSTED CORRECTLY USING C123. CALIBRATION COMPLETE C123 DIAGNOSTIC FUNCTIONS When troubleshooting the BFH/Optima series balancer it is recommended that the technician use the diagnostic informa- Effective 10/2007 Page 5-31 BFH / OPTIMA tion that is available on screen in both the C122 and C123 functions. Information from each scanner / laser assembly is reported on screen and is color coded for easy diagnostics. When the balancer is initially powered up the unit will run a self diagnostic test of all internal components. Each of these test are outlined in the service manual (TEEWB519A). After running the internal diagnostic test the software initiates a self test of all 3 scanner and laser assemblies along with the AWP board. If there are any failures to report the technician can determine the failed component using C123. Some failures reported are easily repaired with minor adjustments and calibration and other failures may require scanner replacement. The information on C122 and C123 is broken into 3 categories: 1. Diagnostic bits - Self diagnostic test on CCD, EEP (memory), Cal (calibration) and ZMarks (home reference). If a Diagnostic bit is in red the unit will display an error code on boot up. 2. Status Flags - Status flags are used to indicate that a command has been issued to a device and the device has responded to the command. This does not mean that the component is functioning correctly. 3. Analog Inputs - There are eight A/D converter channels checked. Normal Analog errors reflect AWP failures. When analyzing data from C122 / C123 diagnostic screen the scanner and laser assemblies are identified as: Inside Camera Outside Camera Rear Camera Rear Slide Car CCD0 (camera) CCD1 (camera) CCD2 (camera) EEP0 (memory) EEP1 (memory) EEP2 (memory) Mot0 (motor) Mot1 (motor) Mot2 (motor) Mot3 (motor) Zmark0 (motor home) ZMark1 (motor home) ZMark2 (motor home) ZMark3 (motor home) ACCESSING THE DIAGNOSTIC FEATURES 1. From the Introduction Screen press the 2. By pressing the NOTE: BEFORE PERFORMING ANY “C-CODES” ON THE BFH/OPTIMA BALANCER THE TECHNI- CIAN MUST FORCE THE BALANCER INTO THE MANUAL MODE. Effective Page 5-32 10/2007 BFH / OPTIMA 3. By pressing the 4. Press and hold the Effective 10/2007 Page 5-33 BFH / OPTIMA MainPw(0) MainAdc(36) MainEEP(4) MainCal(8) Z0Fail(12) Z0Mark(28) Ch0:X.XX CCD00(1) EEP0Ack(33) EEP0Chk(5) EEP0Cal(9) Z1Fail(13) Z1Mark(29) Ch1:X.XX CCD1(2) EEP1Ack(34) EEP1Chk(6) EEP1Cal(10) Z2Fail(14) Z2Mark(30) Ch2:X.XX CCD2(3) EEP2Ack(35) EEP2Chk(7) EEP2Cal(11) Z3Fail(15) Z3Mark(31) Ch3:X.XX Las0Ena(45) Las0Pw(37) Las0Pwm(41) Mot0Pw(20) Mot0Chk(16) Mot0Ena(24) Ch4:X.XX Las1Ena(46) Las1Pw(38) Las1Pwm(42) Mot1Pw(21) Mot1Chk(17) Mot1Ena(25) Ch5:X.XX Las2Ena(47) Las2Pw(39) Las2Pwm(43) Mot2Pw(22) Mot2Chk(18) Mot2Ena(26) Ch6:X.XX Busy(44) MsEnc(40) MotorPw(32) Mot3Pw(23) Mot3Chk(19) MoteEna(27) Ch7:X.XX Effective Page 5-34 10/2007 BFH / OPTIMA DIAGNOSITC BITS (SHOWN IN BLACK) Diagnostic bits, 0 (failure) is displayed in RED, 1 (ok) is GRAY. Note: Diagnostics bits will produce an error code. Bit Shown label Meaning Notes 0 MainPw Analog/logic power supply 1 CCD0 Inner CCD signals 2 CCD1 Outer CCD signals 3 CCD2 Rear CCD signals2 4 MainEEP Main board EEPROM memory valid 5 EEP0Chk Inner EEPROM memory valid 6 EEP1Chk Outer EEPROM memory valid 7 EEP2Chk Rear EEPROM memory valid 2 8 MainCal Cameras calibration (E360,C122) 9 EEP0Cal Inner scanner factory calibration 10 EEP1Cal Outer scanner factory calibration 11 EEP2Cal Rear scanner factory calibration 2 12 Z0Fail Inner motor home mark detection 13 Z1Fail Outer motor home mark detection 14 Z2Fail Rear motor home mark detection 2 15 Z3Fail Rear shift motor home mark detection 2 16 Mot0Chk Inner motor missing steps 17 Mot1Chk Outer motor missing steps 18 Mot2Chk Rear motor missing steps 2 19 Mot3Chk Rear shift motor missing steps 2 20 Mot0Pw Inner motor current sink / power check 1 21 Mot1Pw Outer motor current sink / power check 1 22 Mot2Pw Rear motor current sink / power check 1 - 2 23 Mot3Pw Rear shift motor current sink / power check 1 - 2 32 MotorPw External motor power supply 1 33 EEP0Ack Inner EEPROM memory ACK 34 EEP1Ack Outer EEPROM memory ACK 35 EEP2Ack Rear EEPROM memory ACK 2 36 MainAdc Camera board A/D converter check 37 Las0Pw Inner laser current sink / power check 1 38 Las1Pw Outer laser current sink / power check 1 39 Las2Pw Rear laser current sink / power check 1 - 2 40 MsEnc Shaft encoder zero mark detection 3 41 Las0Pwm Inner laser modulation 1 42 Las1Pwm Outer laser modulation 1 43 Las2Pwm Rear laser modulation 1 - 2 Notes: 1. Available only on new camera boards (EAP0204G50B), default to 1 on former boards. 2. Obviously fails on any BFH/Optima without the rear scanner. (this unit does not have a rear scanner and camera assembly) 3. Valid after runout measurement only. Effective 10/2007 Page 5-35 BFH / OPTIMA STATUS FLAGS (SHOWN IN BLUE) Status Bits, 0 (disable) is displayed in GRAY, 1 (enable) is BLUE. Bit Displayed Meaning 24 Mot0Ena Inner motor power enable 25 Mot1Ena Outer motor power enable 26 Mot2Ena Rear motor power enable 27 Mot3Ena Rear shift motor power enable 28 Z0Mark Inner motor home mark 29 Z1Mark Outer motor home mark 30 Z2Mark Rear motor home mark 31 Z3Mark Rear shift motor home mark 44 Busy Firmware ready/busy status 45 Las0Ena Inner laser power enable 46 Las1Ena Outer laser power enable 47 Las2Ena Rear laser power enable ANALOG INPUTS: (SHOWN IN GREEN) For Analog Values, normal data is GREEN, out of range is RED. Ch Analog input Valid range 0 5.00 V power supply 4.80 V ÷ 5.60 V 1 -5.00 V analog power supply -5.60 V ÷ -4.80 V 2 3.30 V logic power supply 3.00 V ÷ 3.60 V 3 9.00 V external motor power supply 8.00 V ÷ 12.00 V 4 AUX 0 external input 0 V ÷ 4.096 V 5 AUX 1 external input 0 V ÷ 4.096 V 6 Laser current sink 0 V ÷ 4.096 V 7 Motor current sink 0 V ÷ 4.096 V Effective Page 5-36 10/2007 BFH / OPTIMA C123 MECHANICAL SCANNER / LASER / CCD ADJUSTMENT If the BFH/Optima balancer fails any part of the C122 camera calibration it may be necessary to adjust one or more of the cameras. If any of the Scanner assemblies require replacement it will also be necessary to check the mechanical adjustment before calibration. 1. Access the service menu and program the balancer to run C123. 2. Step 1 accesses and avtivates the inside laser and “motor 0”. Press the 3. Looking down at the anchor tab just under the main shaft a laser light will be illuminated. The figure to the right shows the direction of travel. The scanner must stop somewhere between the two black illustrated lines. See “Inside Scan- ner Adjustment” for procedure. 4. Press the 5. Step 2 accesses and runs the outside scanner test “motor 1”. The Pruefrotor must be mounted on the shaft to verify the accuracy of this test. NOTE: THE HOOD OF THE BALANCER MUST CLOSE TO THE CORRECT HEIGHT BEFORE ANY ADJUST- MENTS ARE MADE. SEE “HOOD ADJUSTMENT” FOR THIS PROCE- DURE. Effective 10/2007 Page 5-37 BFH / OPTIMA 7. Press the 8. Press the 9. Press the If the laser line does not scan the prefered area, adjust the hex screw on the back of the assem- bly to move the laser to the correct position. Hex adjustment screw Effective Page 5-38 10/2007 BFH / OPTIMA 10. Press the 11. Remove the Pruefrotor from the shaft. Press the CCD / LASER / SCANNER INSTALLATION Should any of the scanner assemblies require replacement it will be necessary to make some mechanical adjustment before calibrating the unit (C83, 84, 88 and 122) and returning it to service. These adjustments should run parallel with the C123. The ribbon cable that feeds the CCD must have some slack at the scanner assembly. This can be tested by manually pressing on the scanner assemblies. A small amount of play is necessary and they should return to the home postion. INNER SCANNER INSTALLATION 1. Power down the unit. 2. Remove the 4 phillip screws that secure the shield. Effective 10/2007 Page 5-39 BFH / OPTIMA 3. It may be necessary to manually swing the scanner assembly downward to access the bolts that secure the assembly to the vibratory. 4. Remove the two Socket Head Cap Screw that secure the assembly to the vibratory. DO NOT DROP THE SCANNER ASSEMBLY. 5. Disconnect all cables and reverse this procedures for installation. OUTER SCANNER INSTALLATION 1. Power down the unit. 2. Remove the 4 phillip screws that secure the shield. 3. Firmly hold the scanner assembly and remove the 2 Socket Head Cap Screw (1 and 2) that secure the scanner assembly to the hood frame. 4. Disconnect all cable assemblies and reverse the procedure for installation. NOTE: IF A CABLE IS REPLACED AND A ZIP TIE IS CUT OR SILICON ADHESIVE BOND IS BRO- KEN IT IS VERY IMPORTANT TO REINSTALL THESE SECURING FEATURES. HOOD ADJUSTMET Before making any adjustments to the outside scan- ner it is recommended that the hood be checked for the proper height in the closed position. Failure to do so could cause the outside scanner to fail during a C122 calibration. 5. Measure the distance from the ground to the center of the shaft and record this distance. Measure distance between the ground and the center of the adjustment screw labeled (3) in the figure above. If the measurements are different the hood must be adjusted to match the two measurements. 6. Loosen the Hex screw on the back side of the hood block. Loosen the jam nut (yellow). Using a wrench turn the adjustment screw (red) until while monitoring the height between the ground and the screw mentioned in step 5. Effective Page 5-40 10/2007 BFH / OPTIMA OUTER SCANNER INSTALLATION CONTINUED The HOME reference and the orientation of the projected laser can only be adjusted using the mounting screws listed below. NOTE: DO NOT TAMPER WITH THE SCANNER ASSEMBLY. THE SCANNER ASSEMBLY COMES CALIBRATED FROM THE FACTORY. 7. Mount a Pruefrotor on the balancer shaft and secure. Program the balancer for step 2 of C123. Verify that the laser light moves horizontally from left to right. The illustrations below show the direction that the laser line moves using the adjustments screws. Each direction of movement can and will effect the other adjustments. In most cases the number (1 & 2) adjustment screw is the only needed movement after replacement of a scanner. Secure all screws. 8. If the number 1 & 2 adjustment screw do not bring the laser within specification it may be necessary to adjust all adjustment screws. Before doing so it is recommended to level the scanner in two locations before any adjustments are made. Doing so will bring the scanner very close to specs and only a small amount of adjustment will be necessary. Level the scanner in the two locations indicated. 9. Using the adjustment points below will adjust the projected scanner light in the following orientation. 1 - 2 4 3 4 - 5 Effective 10/2007 Page 5-41 BFH / OPTIMA REAR SCANNER INSTALLATION 1. Remove the rear cover from the Slide Car. 2. Remove the philip screws from the scanner box. 3. Remove the front glass from the scanner box. 4. Remove the (1) Hex screw securing the scanner assembly and disconnect all wires. 5. Special attention must be spent when installing the rear scanner assembly. The scanner bracket and the mounting bracket must be aligned parallel with each other. 6. Install the protection glass onto the scanner box assembly. 7. Program step 4 of C123. 8. Look at the reflection of the laser back on the scanner. The reflection should come close to being on top of the original light source. NOTE: AFTER ANY CHANGES AND OR ADJUSTMENTS TO EACH OF THE 3 SCANNERS THE BALANCER MUST BE CALIBRATED. FAILURE TO CALIBRATE THE BALANCER WILL YIELD ERRORS. Effective Page 5-42 10/2007 BFH / OPTIMA REAR SCANNER DRIVE BELT The belt that drives the rear scanner inside the housing is a one piece cog belt. Over time the belt may be come hard and brittle and require replacement. The belt will come as a single belt that needs to simply be cut. The rear scanner assembly moves across the back of the balancer using a drive motor mentioned earlier. The drive motor has a cog gear mounted that drives the scanner assembly. 1. Loosen the two Phillips sheet metal screws and remove the broken or damaged drive belt. 2. Remove the rear cover of the rear drive assembly. 3. Using a pair of scissors cut the new drive belt and install the one end of the belt with the cog side facing down. 4. Feed the belt through the drive assembly. It may be necessary to loosen the motor to feed the belt through. Once the belt is installed lift up on the drive motor, this will tighten the belt and not allow it to slip off the gear drive. 5. Tighten each end that secures the belt. DO NOT OVER TIGHTEN THE SCREWS SECURING THE BELT, THIS MAY CUT THROUGH THE BELT. 6. Snip the remaining excess and retest the rear drive. Effective 10/2007 Page 5-43 BFH / OPTIMA FIELD PROGRAMMING THE CAMERA PROCESSOR PCB The BFH/Optima has two processors that can be programmed. The main processor which is inside of the Electronic box and the Camera Controller PCB. Each processor is programmed using the EEprom socket on the Main Processor PCB. Programming the main Processor is mentioned earlier in this manual. The camera processor PCB is flashed in the same manner. 1. Turn off balancer. 2. Place EEPROM in micro-controller socket with flat end at bottom of socket close to large blue connector. The notched end is 3 spaces short of other end of socket. 3. Turn on balancer. 4. The following is a sequence of events that will take place; three light audible beeps accompanied by 3 green light flashes on the Camera PCB followed by 1 red flash followed by 3 more green flashes followed by a constant flicker of the red LED. (Location Circled Below). 5. A continuous sequence of tones will sound from the keyboard indicating that the program loading is com- plete and the red LED will stop flashing. 6. Turn off the balancer. 7. Remove EEPROM and turn on the balancer. 8. The normal startup procedure will be performed. NOTE: IF A NEW COMPACT FLASH IS INSTALLED ON THE EMBEDDED PC IT WILL BE NECES- SARY TO PERFORM A “C47” AFTER INSTALLTION. FAILURE TO DO SO WILL NOT DIS- PLAY ANY NEW GRAPHICS OR FEATURES THAT WERE INSTALLED. 9. Perform service codes in the following order; • C123 - Verify all scanner are profiling correctly • C122- Calibration of all 3 scanner assemblies. The machine is now ready for use. Effective Page 5-44 10/2007 BFH / OPTIMA REMOVING THE BELL HOUSING It may be necessary to remove the bell housing from the vibratory member to either clean or replace it. Follow the process below. 1. Un-plug the balancer from the power source. 2. It may be necessary to remove the weight tray. Using a 13mm wrench slightly loosen the 2 bolts securing the bell housing to the main shaft. 3. Turn the main shaft and the bell housing opposite direction to line the Hex Head Cap Screw with the keyhole. 4. Using a rubber mallet tap the face of the bell housing to break taper of the shaft. 5. Pull the bell housing out away from the balancer. 6. Hold the main shaft and turn the bell housing clockwise, un-screwing and separating the two shafts. 7. When installing a new bell housing or re- installing the old bell housing make sure that both tapered portions are clean and free from any dirt particles. Failure to do so may cause damage to both pieces and separation may be impossible. 8. Always make sure that the bell housing is fully screwed onto the main shaft before aligning the key holes. This can be accomplished by pulling the bell housing away from the bal- ancer and making sure that the bell housing is fully screwed onto the main shaft. Effective 10/2007 Page 5-45 BFH / OPTIMA IMPORTANT BALANCER INFORMATION Before calling technical support it will be necessary to know what revision of balancer is being serviced. Follow the steps below to enter the “Info” screen. 1. From the Introduction Screen press the “FUNCTION” key (F1) to enter in to the Func tion Menu. 2. By pressing the F6 key 3 times successively the “INFO” key (F3) will show. 3. By pressing the F3 key the “INFO” will become active. 4. Make note of the following line items: User Interface - Revision Number and Date (Revision may not change however date may. Balancer Kernel - Revision Number and Date Display - Revision Number and Date Optima - AWP, Version Number QUALIFYING THE BALANCER The BFH/Optima is a very precision piece of equipment. In order for each scanner to accurately measure tire and wheel profiles each scanner must be adjusted and calibrated within manufactures specification. Below is a step by step procedure that can easily be followed to qualify the BFH/Optima . Each of these procedures should be checked on every service call. These steps will validate each component, should a failure of a component occur the balancer will not pass one of these test and it will be necessary to complete a more in depth analysis. 1. Change the balancer to manual mode (Page 5-12) 2. Check C55 for the proper supply VAC in. 3. Check C110 for proper voltage +5.23 VDC ± .05 4. Check that the proper voltage is being supplied to the embedded PC+5.00 VDC ± .25 volts. (See adjustment) 5. 9 volt camera power supply - The output voltage of the camera power supply is 9.25 VDC ± .25 (See adjustment) 6. C83 - Manufactures vibratory calibration. (Pruefrotor required) 7. C84 - Empty shaft calibration. (4mm Calibration ring required) 8. C88 - Top Dead Center (TDC) wheel weight positioning. (Pruefrotor required) 9. C123 - Mechanical adjustment of all three camera assemblies. 10. C122 - Calibration of all three camera assemblies. (Pruefrotor required) 11. Change from Manual Mode back to customers preference. NOTE: RUN A C90 PROCEDURE AFTER STEPS 4,5& 6. Effective Page 5-46 10/2007 Snap-on Diagnostic 309 Exchange Ave Conway, AR 72032 U.S.A. EEWB519A 07/2006 REV D. Rod Harrison David Cullum Rod Harrison AC / DC POWER DISTRIBUTION 1-1 5-47/48 Page left blank intentionally BFH800c CHAPTER 6 BFH800C INTRODUCTION The BFH800c is a redesign of the of the original BFH800. The BFH800c maintains the accuracy of it’s prede- cessor using a sonar measuring device on the outside of the hood guard instead of the CCD camera used in the original BFH800. This chapter outlines and explains the diferences in the calibration procedure. The trouble- shooting procedure used in the earlier BFH series balancer is also used in the new BFH800c. A few new service codes have also been added in Appendix A. SETUP AND CALIBRATION Follow the C83, C84 and C88 outlined in the Chapter 5 before performing a C122 on the 800c. The following setup and calibration procedures must be followed in order for the balancer to profile and diagnose any correc- tion needed to balance a tire and wheel assembly correctly. Failure to follow the setup will introduce errors in the balancer that will result in comebacks. The BFH800b incorporates a potentiometer that monitors the state of the hood guard. The potentiometers measures the speed of the wheel guard as it closes so that it can accurately profile the outside of the wheel. If the potentiometer should get out of adjustment the balancer would display an error icon to the user indicating that the sonar was not able to accurately profile the wheel when the guard was closed thus forcing the user to manually enter the tire and wheel parameters. The output of the potentiometer can be located using the diag- nostic flag screen in C123. Below is a captured screen poining out the additional diagnostice flags while servicing a BFH800b. Ch 4: Potentiometer Wheel Guard Status Sonar Information Effective 07/2007 Page 6-1 BFH800c CALIBRATION OF WHEEL GUARD POTENTIOMETER 1. With the wheel guard closed measure from the ground to the center of the sonar on the outside of the wheel guard. The measurement should be between 32.375 and 32.625. Adjust the hood guard bolt as shown in figure 1 to bring the sonar device to the correct height. Figure 1 Figure 2 2. Check the Hood Shock for the proper tension 3. Using the C56 feature adjust the hood cam so that the hood switch will remain in the open position (000) until the hood is almost fully closed. At that point the value should read (100). Tighten the 2 set screws once the correct adjustment is obtained. Effective Page 6-2 07/2007 BFH800c 4. Using the C123 dianostic screen refer to the potentiometer voltage on Channel 4. The value must be between .5V - 1.8V. If the values are not correct gently separate the gear mounted on the potentiometer with the large gear and turn the potentiometer until the correct value is reached. Gently release the potentiometer bracket and make sure that the teeth on both gears meet correctly. Gear Separation Wheel Guard Closed Ch 4: Set at 1.32V 5. Raise the wheel guard to it’s most open position. Channel 4 value should be at least 2V above what it was in the closed state. It may be necessary to adjust the hood guard bolt shown in Figure 4 to achieve the required voltage. Wheel Guard Open Ch 4: Set at 3.43V 6. Press Effective 07/2007 Page 6-3 BFH800c C122 CAMERA AND SONAR CALIBRATION Before the Scanner and Sonar can accurately obtain the data needed to balance the wheel and tire assembly they must be calibrated. The calibration information is stored on the CCD / Scanner PCB. This information is stored using C90 after completing the calibration. NOTE: THE BALANCER MUST BE IN THE MANUAL MODE AND ALL PRUEFROTOR PARAMETERS ENTERED BEFORE CONTINUING THIS PROCEDURE . AT LEAST TWO REVOLUTIONS OF THE SHAFT SHOULD BE MADE SO THAT THE SHAFT ENCODER CAN LOCATE HOME REFERENCE. THIS CAN BE DONE BY QUICKLY ROTATING THE SHAFT UNTIL THE EN- CODER READS. 1. Mount the Pruefrotor as shown in the figure on the right, making sure the the orientation of the Pruefrotor is turned correctly. Failure to do so will fail the calibra- tion procedure. 2. Using a small magnetic torpedo level, turn the shaft until the Pruefrotor is in the verticle position. 3. Press the 4. Slowly rotate the shaft clockwise 20° (153.2). The display will quickly show “LOCK” and the magnetic brake of the balancer will engage. The inner scanner will scan the inside profile of the Pruefrotor DO NOT MOVE THE SHAFT UNTIL INSTRUCTED. After the scanner completes the profile a beep will sound. Lower the hood for the following step. Effective Page 6-4 07/2007 BFH800c 5. Remove the Pruefrotor from the shaft and install the Sonar Calibration tool (EAA0344G09A). Slowly rotate the calibration fixture (Figure A below) clockwise until a reading between 284 - 304mm appears on the sonar diagnostic flag. Press the 6. The balancer will emit a tone after completing the calibration procedures and an “END” will be displayed for step 5. Perform a C90 to store the new calibration factors. Sonar Reading Wheel Guard Closed Figure A Figure B Between 284 - 304 Between 234 - 254 Effective 07/2007 Page 6-5 BFH800c BFH800B SPECIFIC COMPONENTS 12 Volt DC Power Supply 120 VAC Input 12VDC Output Inner Scanner AWP Processor Motor 12Volt Input Keyboard Input Encoder Input Inner Scanner Potentiometer Sonar Effective Page 6-6 07/2007 BFH800c Sonar and Cable Assembly Sonar Sonar Assembly Cable Effective 07/2007 Page 6-7 BFH800c Effective Page 6-8 07/2007 APPENDIX A CODES KERNEL CODES A complete error code consists of 6 hexadecimal digits. Prefix Digit 6 Digit 5 Digit 4 Digit 3 Digit 2 Digit 1 0X Module ID Priority ID Error ID Digital Display Left Display Right Display Module ID: 2-digit hexadecimal value and indicates the software module which detected the error. Priority ID: Represents the kind of error (message only, critical error). Error ID: Determines the kind of the fault. Module ID Description 21 Time Service 22 I2C bus device driver 23 Serial device driver 24 Sound device driver 25 External AD converter 26 Internal AD converter 27 Temperature measurement 28 Piezo transducer 29 Incremental encoder Main shaft 2A Incremental encoder belt disc 2B Relay management 2C Hand-spin brake 2D Electromagnetic brake 2E main supply line 2F motor 30 Supervisor 31 Watchdog timer 41 Auto stop system 42 Data conditioning 43 Rim data management 44 Sape device 45 Display device 46 Keyboard device 47 Brake device 48 Motor device 49 Drive (Motor & Brake) 4A Power clamp 4B Incremental potentiometer 4c Rim light 61 Balancing algorithm 62 Balancing calibration 63 Behind the spokes placement 64 Effective 10/2007 Page A-1 APPENDIX A CODES 81 Command language (Commands coming from the UI) 82 Calculator 83 Message Server (Message service from BK to UI) 84 Message Server (User messages from BK to UI) 85 Sleep command 86 Balancing Kernel : Test statemachine (eg selftest during startup) A1 Event system A2 User management A3 State machine A4 complex data type A5 Persistent objects A6 Pipe device A7 Power on time counter (-> time stamp for error recording) A8 Counter for total spins / in service-, in user mode C1 Self test C2 User interface C3 User interface Priority ID Description 0 Critical error (will be recorded in user mode) 1 Warning message 2 For information only 3 All of above, but will not be recorded in the error record (persistent objects p30 to p39) Error ID Limits Description F01 Not complete F02 Invalid job Mod 2D, Brake : Module gets invalid event. Mod 49, Drive system : Internal error, command not valid in actual mode of operation Mod 66, Meas Control : Internal error. Module gets invalid user event. command not valid in actual mode of operation Mod C1, Self-test : Self-test failed, see error record for more information (kernel register err0,...err9 or User interface: C28). F03 Out of memory F04 Out of range Mod 27, Temperature: Out of Range F05 Buffer full F06 Channel not found F07 Not found Mod 41, ASS : Time client not found Mod 44, SAPE : Time service not found during unregister Mod C1, Self-test : Self-test failed, result of test invalid F08 Already exists F09 In use Mod 44, SAPE : AWP already in use Mod 49, Drive system : Internal error, command not valid in actual mode of operation Many “490F09” errors in the error record indicates a malfunction of the pedal. F0A End of file F0B Drive full Effective Page A-2 10/2007 APPENDIX A CODES Error ID Limits Description F0C Bad name F0D Xmit error Mod C3, User Interface : Communication Error between balancing kernel and user interface (BK <- UI). Machine should be restarted. This error can be caused by a bad connection of the RS232-E serial line. Check external and internal cabling. F0E Format failed F0F Bad parameter Mod 41, ASS : Invalid time specified Mod 44, SAPE : Bad parameter during calling time service Mod 81, cmd : Parameter of a kernel command is bad. Such an error can occur as a result from a hardware malfunction. F10 Bad medium F11 Error in expression Mod C3, User Interface : Communication Error between balancing kernel and user interface (BK -> UI). This error can be cleared by pressing STOP or Escape. This error can caused by a bad connection of the RS232-E serial line. Check external and internal cabling. F12 Overflow Mod 41, ASS : Too many time clients Mod 44, SAPE : Overflow (e.g. invalid time period) F13 Not implemented F14 Read only F15 Bad line F16 Bad data type F17 Not running (still not initialised) This error can occur after a measuring run, if the incremental encoder of the power clamp is not able to detect the reference mark (810F17). check the incremental encoders with C54, C74 (main shaft) and C98 (powerclamp) F18 Timeout Mod 31, Watchdog: Recorded during start-up: Watchdog causes last reset. Check error record (C28). Mod 42, Data cond. : Can’t get data from external AD converter This error can caused by a malfunction of the incremental encoder. Check C74 and C54. A malfunction of the micro-controller board Check C75 if ADE1 and ADE2 displays valid results. Mod 44, SAPE : Communication timeout (No answer from AWP) Mod C1, Self-test : Self-test failed, test function does not response (timed out) F20 Access denied Mod 49, Drive system : Access denied : e.g. Use of the clamp device if it is not available (not a power clamp machine?) - Requested action not allowed 50 UT_CMPLX_ERROR_MatrixSingular 60 ERR_VOLTAGE_ZERO 61 ERR_VOLTAGE_BELOW_LIMIT 63 ERR_VOLTAGE_ABOVE_LIMIT 64 ERR_VOLTAGE_really_HIGH 100 Keyboard : No time client available Effective 10/2007 Page A-3 APPENDIX A CODES Error ID Limits Description 101 ERROR_KEYB_NO_HARDWARE_AVAILABLE 102 ERROR_KEYB_ORDER_BUSY 120 Display (Digital) : No Hardware available 130 Bad parameter for the frequency of beep command 131 Bad parameter for the volume of beep command 132 Bad parameter for the sound file of beep command 133 Bad parameter for the repetition of a beep 134 Sound file corrupted 140 RS232-E : Wrong parameter for ioctl call. 141 RS232-E : Input buffer overrun occurred 142 RS232-E : Transmission error 143 FIFO_KORRUPT 144 FIFO_WRONG_ACTION 145 FIFO_EMPTY_READ 146 FIFO_FULL_WRITE 147 FIFO_STRING_ENDE 148 PIPE_NO_COMPLETE_MESSAGE_AVAILABLE 149 SER_WRONG_ACTION 14A SER_NO_HARDWARE 14B SER_ERR_RESET_FIFO 14C SER_ERRORCODE_EXISTS 160 ERROR_PO_INIT_READORDER_FAILED 161 ERROR_PO_INCORRECT_DATA_OR_HEADER_SIZE 162 ERROR_PO_EEPROM_IS_FULL 163 ERROR_PO_I2C_WRITE_ORDER 164 ERROR_PO_NO_TIMECLIENT_AVAILABLE 165 ERROR_PO_ORDER_IS_BUSY 166 ERROR_PO_ORDER_IS_FULL 167 ERROR_PO_PRODUCTION_READ_WRONG_TYPE 168 ERROR_PO_EEP1_EEP2_ARE_DIFFERENT 169 ERROR_PO_CRC_EEP1_ERROR 16A ERROR_PO_CRC_EEP2_ERROR 16B ERROR_PO_ORDER_HAS_FAILED 16C ERROR_PO_NOT_AVAILABLE 16D ERROR_PO_CRC_EEP1_EEP2_ERROR 180 ERROR_I2C_QUEUE_FULL 181 I2C_ERROR_ORDER_NOT_FOUND 182 I2C_ERROR_ORDER_TOO_BIG 183 I2C_ERROR_ORDER_BUSY 184 I2C-Bus : No order in I2C queue 185 I2C-Bus : No active order in I2C queue 186 I2C_ERROR_TOO_MANY_SOP 187 I2C_bad_SDA 188 I2C_bad_SCL 189 I2C_busy 18A I2C_no_Acknowledge 18B No Acknowledge from device 18C I2C_ERROR_NO_ACK_FROM_START 18D I2C_ERROR_NO_ACK_FROM_STOP 18E I2C_ERROR_NO_ACK_FROM_SEND1 18F I2C_ERROR_NO_ACK_FROM_SEND2 190 2C_ERROR_NO_ACK_FROM_RECEIVE Effective Page A-4 10/2007 APPENDIX A CODES Error ID Limits Description 191 ERROR_I2C_SYNCHRONOUS_ORDER_TIMEOUT 192 ERROR_I2C_ASYNCHRONOUS_ORDER_TIMEOUT 193 ERROR_I2C_ORDER_HAS_FAILED 201 ERROR_DS_USER_BREAK 202 Drive system : Timeout during speed up - hand-spin only! speed does not settle after start command 203 ERROR_DS_SPEED_NOT_REACHED 204 Drive system : Speed slows down during measuring - speed falls below limit while measuring 205 Drive system : Wheel speeds up in reverse turn - Hand-spin only! main shaft rotating backwards on start command 206 Drive system : No acceleration during speed up or braking detected 1. Motor 2. Belt mounted? 3. Incremental encoder main shaft 207 Drive system : Slip detected (speed up to fast) 1. Wheel not clamped strong enough 2. no wheel or wheel mass to low 208 Drive system : Speed limit exceeded - speed exceeds security limit (mainly wheel guard open and drive management set to high speed) 210 Drive system : Clamping device got stuck in clamped position 211 Drive system : Clamping device got stuck in unclamped position 212 Drive system : Displacement limit exceeded during (un)clamping 213 Drive system : Belt disc rotates backward after clamping. 214 Drive system : Main shaft rotates during clamping (e.g. EMB defective?) 215 Drive system : Clamp device is locked 216 Drive system : Time limit for clamping process exceeded 300 Motor over-current detected by hardware. Over-current-LED on the power inter- face board will be cleared on the next activation of the motor 350 0.05 V First Potentiometer : Voltage below measuring range (AD value : 0..10) 351 4.45 V First Potentiometer : Voltage above measuring range (AD value : 1014..1024) 360 0.05 V Second Potentiometer : Voltage below measuring range (AD value : 0..10) 361 361 4.45 V Second Potentiometer : Voltage above measuring range (AD value :1014..1024) 370 0.05 V Third Potentiometer : Voltage below measuring range (AD value : 0..10) 371 4.45 V Third Potentiometer : Voltage above measuring range (AD value : 1014..1024) 380 4.50 V ASS : Voltage magnet below limit - off state. 381 1.00 V ASS : Operating Voltage magnet below limit - on state. 382 2.00 V ASS : Operating voltage magnet above limit - on state. 383 0.5 s ASS : Operating Voltage magnet recharging time above limit 400 During measuring run : Data conditioning can’t get proper speed information. 401 During measuring run : User break. (Measuring run stopped by user) 402 During measuring run : Temperature information invalid, 20°C used instead. 403 During measuring run : Can’t perform transducer correction. 405 Channel 1 - channel 2 Phase shift too big Effective 10/2007 Page A-5 APPENDIX A CODES Error ID Limits Description 410 Transducer 1, No signal 411 Transducer 1, transimpedance to low 412 Transducer 1, RC time constant out of range 415 Transducer 1, transimpedance amplifier; idle voltage out of range 416 Transducer 1, DC amplifier; idle voltage out of range 418 Transducer 1, amplifier saturation 419 Transducer 1, Transfer function out of range 420 Transducer 2, No signal 421 Transducer 2, transimpedance to low 422 Transducer 2, RC time constant out of range 425 Transducer 2, transimpedance amplifier; idle voltage out of range 426 Transducer 2, DC amplifier; idle voltage out of range 428 Transducer 2, amplifier saturation 429 Transducer 2, Transfer function out of range 430 Transducer 1&2, No signal 431 Transducer 1&2, transimpedance to low 432 Transducer 1&2, RC time constant out of range 435 Transducer 1&2, transimpedance amplifier; idle voltage out of range 436 Transducer 1&2, DC amplifier; idle voltage out of range 438 Transducer 1&2, amplifier saturation 439 Transducer 1&2, Transfer function out of range 500 BL_BAL_ERROR_NoConverge 501 BL_BAL_ERROR_ResultInvalid 502 BL_BAL_ERROR_TooMuchLoops 510 BL_BAL_ERROR_NoCalUser 511 BL_BAL_ERROR_FailCalUser 512 BL_BAL_ERROR_SideCalUser NOTE: C1 = FRONT TRANSDUCER 560 c1 value too low, if a user calibration tool assumed C2 = REAR TRANSDUCER 561 c2 value too low, if a user calibration tool assumed 565 c1 value too low, if a 100g weight and calibration rotor assumed 566 c2 value too low, if a 100g weight and calibration rotor assumed 570 c1 value too high, if a calibration rotor only assumed 571 c2 value too high, if a calibration rotor only assumed 580 -30°C Temperature below -30°C or hardware fault. 581 100°C Temperature above 100°C or hardware fault. 585 0.23 V Temperature Input near to ground Voltage. 586 4.05 V Temperature Input near to reference Voltage. 601 Internal error : To many event sinks 602 Internal error : Cannot register event sink 603 Internal error : Invalid event level 701 ERROR_IEMS_INV_PARAM 702 Incremental encoder not initialised. Software is not able to detect the reference mark. 703 Incremental encoder : Counter - reference mark mismatch 705 2.50 V Opto electronic, No voltage on shunt resistor 706 4.30 V Opto electronic, VCC on shunt resistor 707 16 mA Opto electronic, Current through LED below limit 708 20 mA Opto electronic, Current through LED above limit Effective Page A-6 10/2007 APPENDIX A CODES Error ID Limits Description 710 Hand-spin with electromagnetic released brake - main shaft rotates backwards 800 170 V Line voltage below limit 801 265 V Line voltage above limit 804 275 V Line voltage much too high 810 5.10 V VCC below limit 811 5.35 V VCC above limit 820 5.00 V Keyboard/display voltage below limit 821 5.35 V Keyboard/display voltage above limit 830 4.50 V External voltage (pedal) below limit, see keyboard module 831 External voltage (pedal) above limit, see keyboard module 900 Power fail detected 950 OPTIMA hardware main board fault detected 951 OPTIMA hardware inner scanner fault detected 952 OPTIMA hardware outer scanner fault detected 953 OPTIMA hardware rear scanner fault detected 9FF ERROR_SELFTEST e01 ASA: Status of an activated order has changed due to network manager or shop management software activities. H CODES SYSTEM IV H# Internal code(s) Description H0 Wheel running conditions cannot be improved by optimisation H1 Further optimisation not recommended but feasible H2 Weight minimisation is recommended, optimisation can achieve no further improvement H20 The correction plane cannot be re-located using the gauge arm H21 Indexing position does not match correction plane H22 0x492215 Unclamping of power clamp device is disabled H26 The gauge arm was pulled out too quickly (normal operation, ASS calibra- tion) H28 NEW : The gauge arm was pulled out too slowly (ASS calibration) H80 0x810510 No provision was made for readjustment H82 Self test disturbed during execution H90 0x492203 - Acceleration during start or stop too slow - Measuring speed not reached H91 0x492204 Speed variations during measuring run E CODES SYSTEM IV E# Internal code(s) Description E1 Rim dimensions entered incorrectly E2 Wheel guard is not closed E3 Gauge arm not in home position E4 Outer gauge arm not in home position E5 Range of electrical unbalance compensation exceeded (residual adapter unbalance) E6 Calibration weight not attached to flange E7 No balancing mode for this wheel type E8 Valve position was not entered E9 Optimisation was carried out incorrectly Effective 10/2007 Page A-7 APPENDIX A CODES E Description E10 Wheel guard is not open, wheel may not be clamped / unclamped E12 Pedal is operated, measuring run not possible E13 The clearance of the solenoid brake is too wide. E14 The power clamping device is not clamped E15 Corrective terms for readjustment are out of range E16 Calibration weight attached erroneously to flange E17 Wheel slipped on adapter E28 Wrong direction of rotation (hand spin) E29 Speed too high (hand spin ?) E30 Run-out measurement failed E31 Rim only mounted during geometric matching when rim and tyre expected. E32 The user selected to proceed with a bare rim measurement but the machine actually detects that a complete wheel is on the machine. Mount a bare rim. E83 Vibration of the machine disturbed the unbalance measurement E85 Power clamp service interval expired E88 The rotating speed of the main shaft exceeds the safety limit E89 Key contact or pedal switch closed E92 The inner gauge arm for distance and rim diameter is defective E93 The outer gauge arm for rim width is defective E101 ASA: Status of an activeted order has changed due to network man ager or shop management software activities. E141 Check sum of EEPROM 1 is wrong E144 Check sums of both EEPROMs are wrong E145 Contents of the EEPROMs are different E300 The micro-controller was not able to detect a keyboard.Check cabling between micro-controller and keyboard. E341 Check sum of EEPROM 2 is wrong E360 OPTIMA hardware wheel profiler position calibration required E361 OPTIMA wheel profiler is not present or is not responding during self test E362 OPTIMA main camera board power on self test failure E363 OPTIMA left side scanner self test fail or CCD not calibrated or zero mark not detected E364 OPTIMA right side scanner self test fail or CCD not calibrated or zero mark not detected E365 OPTIMA rear scanner self test fail or CCD not calibrated or zero mark not detected E366 OPTIMA main camera board memory self test failure E367 OPTIMA motor power supply missing or out of range E368 OPTIMA main camera board A/D converter failure E369 OPTIMA main shaft encoder zero mark detection failure or missing cable E370 OPTIMA inner CCD signals failure E371 OPTIMA inner scanner memory not responding E372 OPTIMA inner scanner memory not valid E373 OPTIMA inner scanner not calibrated E374 OPTIMA inner motor current sink or power supply failure E375 OPTIMA inner scanner zero mark not detected E376 OPTIMA inner motor missing steps E377 OPTIMA inner laser current sink or power supply failure E378 OPTIMA inner laser modulation failure Effective Page A-8 10/2007 APPENDIX A CODES E Description E380 OPTIMA outer CCD signals failure E381 OPTIMA outer scanner memory not responding E382 OPTIMA outer scanner memory not valid E383 OPTIMA outer scanner not calibrated E384 OPTIMA outer motor current sink or power supply failure E385 OPTIMA outer scanner zero mark not detected E386 OPTIMA outer motor missing steps E387 OPTIMA outer laser current sink or power supply failure E388 OPTIMA outer laser modulation failure E390 OPTIMA rear CCD signals failure E391 OPTIMA rear scanner memory not responding E392 OPTIMA rear scanner memory not valid E393 OPTIMA rear scanner not calibrated E394 OPTIMA rear motor current sink or power supply failure E395 OPTIMA rear scanner zero mark not detected E396 OPTIMA rear motor missing steps E397 OPTIMA rear laser current sink or power supply failure E398 OPTIMA rear laser modulation failure E400 OPTIMA pull index user calibration failure E404 OPTIMA rear shift motor current sink or power supply failure E405 OPTIMA rear shift scanner zero mark not detected E406 OPTIMA rear shift motor missing steps E812 The drive pulley was not readjusted by 180º relative to the main shaft E900 No model selected E901 Machine not calibrated E990 Internal error (message server : message buffer overflow(1) Machine halts. E991 Internal error (message buffer overflow(2) Machine halts. E992 Internal error (synchronous receive time-out) Machine halts. Effective 10/2007 Page A-9 APPENDIX A CODES Effective Page A-10 10/2007 309 Exchange Avenue Conway, AR 72032 TEEWB502A (REV F) 12/2007 © 2007 Snap-on Incorporated Printed in U.S.A.