Extraordinary maintenance

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M 0535 - 1GB

Extraordinary maintenance M

Check that the ruler used for measuring the DISTANCE of the wheels reads 185 mm as measurement of the distance from the adapter plane. If the graduated strip is replaced, position it with the line indicating 185 at the ﬁxed index limit (reading point) when the prod coincides with the adapter plane.

Reading point: 185 mm Adapter plane

2 - Autodiagnostics

In Setup, selecting diagnosis gives:

DISPLAY TEST

- All the LEDs and the displays should light up simultaneously.

- On the right-hand display the current position of the wheel is indicated with a number from 0 to 127. Turning the wheel in the direction of rotation, the number displayed should increase. Turning the wheel in the opposite direction of rotation the number displayed should decrease. With one full turn of the wheel the number zero should appear only once.

- Control parameter

END OF AUTODIAGNOSTICS

CANCEL AUTODIAGNOSTICS IN ANY PHASE.

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2

4 6 5 3

2

1 3 - Piezo sensor assembly

ASSEMBLY INSTRUCTIONS

Problems of excessive compensation and out-of-phase sometimes depend on a fault in the piezo measurers.

To replace them, proceed as follows:

1. Remove the weight shelf.

2. Remove nuts 1 and 2 with relative cup springs and washers.

3. Back-off screws 3, 4, 6 and 5 then disassemble the various parts.

4. Reassemble the various parts without tightening the nuts being careful to follow the correct sequence.

N.B.: Mount the piezo units in accordance with the position of the coloured wires shown in the drawing.

5. Keeping the spindle perfectly aligned, tighten the nuts 5 and 6 with a spanner, and nuts 3 and 4 by hand (by half a turn with the spanner if necessary).

6. Reﬁt the washers, cup springs and nuts 1 and 2. Tighten the nuts fully in order to fully regain the elasticity of the cup springs, then loosen them by half a turn. This will automatically ensure correct preloading on the piezo (a torque wrench can be used set to 400 kg. cm.).

7. Cover the piezo units with a generous layer of silicone.(N.B.: For correct operation, insulation of the piezo crystals should be greater than 2000 Mohm).

8. Reassemble the various parts.

9. Again carry out the automatic calibration.

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M 0535 - 5GB 4 - Trouble shooting logic sequence

Is the position sensor working?

( see AUTODIAGNOSTICS

)

^NO

YES

Replace the position sensor board

N.B. : Do not remove the mounting brackets.

Replace the computer board

NO

YES

NO

Disconnect CN1 on the computer board.

Again replace the fuse and switch on.

Is the fuse working? NO YES

Replace the computer board

YES

NO

Check that on the CN2 the imput voltage (12/24 V DC) is available and that there is no damage in the wiring.

If everything is OK, replace the power supply board.

Is there a voltage of 8.5 Vac across points 1 - 3 and the earth 2 on CN3 (computer)?

Is the fuse on the power supply

board in a good state? Replace the power

supply board

Replace the fuse and switch on

Is the fuse working?

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5 - Functioning and accuracy test

If faults or inaccuracies are encountered which are not readily identiﬁed, it may be useful to perform the function and precision check.

PRELIMINARY CONTROLS

· Carefully clean the ﬂange and cones

· Spring cover sliding

· Shaft terminal locking

TEST OF PROPER ENCODER FUNCTIONING 1. Cleaning the encoder

Remove the snap cover on the chuck side.

Insert a tool until it touches the phase disc (use a soft brush to prevent damaging the decals).

Slowly turn the wheel by hand several times to allow the tool to remove any residual dust.

Never force the tool on the phase generator.

After cleaning, close the snap cover.

2. Positioning the encoder card

It is recommended to position the encoder card in the following cases:

- If replacing the encoder card;

- If replacing, cleaning or generally working on the encoder decals;

- In the event of repeated errors 1,2,11,12,13,14,15,16,17,18 detected by the wheel balancer during the unbalance measurement phase;

- In the event of unjustiﬁed unbalance oscillation.

Before running the encoder test, ALWAYS check that there is a maximum distance of 1 mm between the decal and the encoder card and that the retaining nuts of the encoder card are adequately tightened.

Use a wheel of average dimensions.

Press:

[MENU]

[-] The word [Setup] appears

[ENTER] The word [Diagn.] appears

[MENU]+[HOME]+[MENU] Press in sequence in maximum 5 sec.

[+] The word [Enc.] appears

[ENTER] The word [Start] appears

Perform a manual spin after which the following results must be obtained for the encoder to function properly:

[ 32] [ 32] Number of encoder pulses A/B

[Min.] [0.15] The number displayed must be in a range of 0.12%0.25.

[xxx] [xxx] The number shown on the left-hand display must be higher by as much as possible than the right-hand number and both values must be as far as possible away from 0.

MEANING OF ENCODER TEST ERRORS

Err. 1 No reset signal. 1. Check the connection cable between the encoder card and the CPU board.

2. Check positioning of the encoder card.

3. Clean the encoder decal.

4. Replace the encoder card 5. Replace the CPU board

Err. 2 Encoder test speed not reached. 1. Check positioning of the encoder card.

3. Replace the encoder card 4. Replace the CPU board

Err. 4 Incorrect direction of rotation. 1. Check the encoder card connection cable.

Err. 33 Rising edge fault detected for ENCA. 1. Check positioning of the encoder card.

Err. 34 Falling edge fault detected for

ENCB. 1. Check positioning of the encoder card.

Err. 35 Falling edge fault detected for

ENCA. 1. Check positioning of the encoder card.

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M 0535 - 7GB Err. 36 Rising edge fault detected for ENCB. 1. Check positioning of the encoder card.

Err. 37 Detected irregular behaviour of the ENCA falling edge with respect to the reset rising edge.

3. Move the encoder card up or down.

Err. 38 Detected irregular behaviour of the ENCB falling edge with respect to the reset rising edge.

3. Move the encoder card up or down.

HOME [HOME] button pressed during test. 1. Repeat the test.

3. Encoder count test Press:

[MENU]

[-]

[ENTER] The word [dIAgn.] appears

[ENTER] Conﬁrm

After a brief LED and display test, the wheel position appears on the right-hand display, which must vary in the range 0%127 in a full turn.

WHEEL BALANCING MACHINE CALIBRATION (see SELF CALIBRATION)

· Use a wheel with steel rim of average dimensions e.g. : 6” x 14” (± 1”)

· Set precise measurements (input by hand if necessary)

· Perform self-calibration CHECKING MACHINE OSCILLATION

After running autocalibration, press [HOME] to return to the standard measuring frame.

Without locking the wheel, measure the machine oscillation as follows:

[MENU]

[-]

[ENTER]

[MENU]+[HOME]+[MENU] Press in sequence in maximum 5 sec.

The words [Lan] [ci] appear

[ENTER] Conﬁrm.

The letters [t.L.] [ 10] appear, perform a manual spin.

Spin the wheel each time the word [START] appears; at the end of the cycle, the maximum oscillation is displayed (max. permitted +/- 2 g).

[ENTER] The following appears [Ini] [~120]: indicates the average unbalance measurement start speed in rpm.

[ENTER] The following appears [End] [~100]: indicates the average unbalance measurement end speed in rpm.

N.B.: The difference between the unbalance measurement start and end speed must never be more than 30 rpm.

[ENTER] End of test.

[HOME] Return to the standard measuring frame

If you wish to run more than 10 automatic spins, when [t.L.] [10] appears press the buttons [+]/[-] to select the desired number in the range 5%999.

CHECKING MACHINE CALIBRATION

With the wheel perfectly balanced, apply 100 g ﬁrst on the outside and then on the inside.

The wheel balancer must measure:

FI=0 FE=100 Weight F.E. = position = 12 o’clock FI=100 FE=0 Weight F.I. = position = 12 o’clock Max. permitted tolerance 100 g = 5%.

CHECKING THE FLANGE

When the wheel is perfectly balanced, tip over by 180° and measure the unbalanced values.

MAX ERR =

Above all for this check, it is advisable to use a sample wheel with known max. unbalanced errors caused by centering which, for metal wheels, are less than 10 gr.

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I E

a b h

I E

aI

aE dI dE

0 Calibro

aI

aE

dE dI

0 Calibro

6 - Wheel measurement and setting on the wheel balancer

The need for ever more accurate calibration and the use of the ALU buttonsmakes it important to deﬁne how the rims must be measured and how the wheel balancer interprets the data set. Hence we indicate how the set dimensions are automatically changed in order to obtain the distances of the correction planes which are deﬁned as through-planes for the centres of gravity of the correction weights.

Let us consider a typical rim: The measurement “l” given as rim width by the manufacturer differs from the distance measured between the correction planes for the rim thickness and the physical dimensions of the counterweight whose centre of gravity is at distance “h” from the resting point on the edge of the rim. The wheel balancer automatically corrects the set measurement by adding 2 x h = 6 mm to the measurement. The measurement “b” made with the gauge is normally more accurate even if very similar to the measurement “l” known by the user. The two measurements differ only by the thickness of the plate, usually about 2 mm per side. This minimal difference allows obtaining accurate calibration by indifferently setting the inside width “l” or the outside width “b” of the rim. It is a good rule to add 1/4 inch to the value given by the rim manufacturer. As regards the ALU functions, the machine performs the following approximations in addition to systematic correction of the centre of gravity of the counterweight as seen above.

0 gauge

NOTE : I = INSIDE E = OUTSIDE

a = a preset + ¾”

b = b preset - 1 ½”

dl = d preset - 1”

dE = d preset - 1”

a = a preset b = b preset - ¾”

dl = d preset dE = d preset - 1”

a = a preset + ¾”

b = b preset - ¾”

dE = d preset

a = aI preset - 8 mm b = aE - aI

dE = d preset - 2”

a = aI preset b = aE - aI - 5 mm dl = d preset dE = d preset - 2”

0 gauge

Extraordinary maintenance