assistance manual - ravamerica · 2019-06-29 · screen wheel balancers technical assistance manual...

SCREEN WHEEL BALANCERS

ASSISTANCE MANUAL

FOR TEST AND CALIBRATION

Screen wheel balancers TECHNICAL ASSISTANCE MANUAL GB

Page | 2


Page | 3

SUMMARY

1.0 INTRODUCTION 4

2.0 USER MENU 5

2.1 Options menu 5

2.1.1 List of the available options 6

2.1.2 Lower weight limit 7

2.1.3 Setting adhesive weight dimensions and static threshold percentage 8

2.1.4 User management 9

3.0 SERVICE MENU 10

3.1 Display of error codes list 11

3.2 Machine ADVANCED calibration 11

3.2.1 Mandrel “Ø” calibration 12

3.2.2 Weight measurement sensors calibration 12

3.2.3 Gauge calibration 13

3.2.3.1 Distance-diameter caliper calibration 13

3.2.3.2 Calibration of external data gauge (optional) 18

3.2.4 Calibration of phonic wheel 20

3.3 OPTIONAL calibrations

3.3.1 Mobile laser calibration

3.3.2 Touch monitor calibration

3.4 Test menu 21

3.4.1 Motor Test 21

3.4.2 Weight measurement sensors test 23

3.4.3 Encoder sensor test 24

3.4.4 Wheel dimensions measurement test 25

3.4.5 Input/Output signals test 26

3.5 Hardware configuration menu

4.0 ERROR SIGNALS 28

4.1 Trouble shooting 28

5.0 COMPONENTS REPLACEMENT

5.1 CPU board replacement

5.2 Readout board replacement

5.3 PC board replacement

5.4 Replacement of weight measurement sensors del peso (piezoelectric)

5.5 Encoder sensor replacement

6.0 CONNECTION DIAGRAM 29

6.1 Electrical diagram

6.2 Pneumatic diagram


Page | 4

1.0 INTRODUCTION

The task of this manual is to instruct fully the installer about the calibration and the functional tests of

wheel balancing equipment.

The instructions concerning use and maintenance, destined to the final user, have been gathered in the

special manual, supplied with the machine.

SETTING and STANDARD CALIBRATION pages are available in the special dedicated section, which can be

entered through the code 1234, the same as the one indicated in the use and maintenance manual that

comes along with the machine.

Warning! TEST procedure and ADVANCED CALIBRATION can be found in a special section, which can be

entered through the code 4324 for the specialized staff of technical service only.

IMPORTANT! This password is strictly confidential and must not be spread to other people.


Page | 5

2.0 USER MENU

From the main page press the button to move to the next screen page and the button to

access the user menu. On the monitor, the following screen appears where you can enter the password.

Fig.1

The user login password is: 1234.

After entering the correct password you will see the following screen:

Fig.2

KEY

1 - Options menu push-button

2 - STANDARD calibrations menu push-button

2.1 Options menu

Press button to display the monitor screen to enable/disable the options as shown below:

Fig.3

1 2


Page | 6

To enable / disable individual functions simply highlight the icon using the buttons and/or and

press the button .

Pressing the button may involve, besides, the change in the unit of measure from "mm" to "inch" and

vice versa (where applicable) or access to a sub-screen for values settings values (see Par. 15.1.1 or 15.1.2).

After you select/deselect the desired options, exit the menu by pressing push-button .

2.1.1 List of the available options

Enables/disables the spin/protection carter.

Enables/disables the distance/diameter detection caliper.

Enable/disable the display of static threshold after each spin.

It allows you to set the thresholds for each of the balancing mode weights (see Par. 15.1.1).

Enable/disable the lock function for caliper arm in position.

It allows you to change the unit of measurement of the weights from grams to ounces and vice versa.

It allows to enable/disable the width function detected by GAR305 or by GAR307.

Enable/disable ECO-WEIGHT function.

Enable/disable the positioning of weights at "6 o'clock".

Enable/disable the pneumatic brake after the spin.

It allows to modify the unit of measurement of the distance for weights fitting point from the

machine from mm to inches and vice versa.

Enable/disable the LED-light.

Enable/disable the dynamic residues in the ECO-WEIGHT function.

Enable/disable the functions of motorbike wheel balancing.

Enable/disable the encoder mounted on the spin motor.

It allows you to change the unit of measurement of the rims width from mm to inches and vice versa.

It allows you to change the unit of measurement of the rims width from mm to inches and vice versa.

Enable/disable the RUN-OUT functions.

Enable/disable the functions of machine printing.

It allows the setting of the retrieval of the measures by eye: readout of measures printed on the rim

and the graduated scale of the distance-diameter caliper.

NOTE: it is activated only if distance-diameter caliper is disabled.


Page | 7

Enable/disable the use of the manual caliper to measure rim width.

NOTE: it is activated only if distance-diameter caliper is disabled.

It allows you to change the unit of measurement of the rim diameter from mm to inches and vice

versa.

Enable/disable the weights positioning laser function (GAR308).

Enable/disable the repositioning of the wheel at the end of the spin.

Enable/disable user function.

Option already enabled on machine delivery.

Option enabled only if mounted on the machine.

2.1.2 Lower weight limit

Correction weight below a certain limit is normally shown equal to zero.

This limit, defined as lower weight limit, can be set from 1 gr to 10 gr.

At the end of the spin however, by pressing the button , the weight can be displayed with max

resolution of 1 g, not considering the set lower limit.

Fig.4

KEY

1 - Lower weight limit in the DYNAMIC program

2 - Lower weight limit in the ALU-STATIC program

3 - Weights display resolution (default value 5 gr)

4 - Weight % reduction in ECO-WEIGHT function (default value 100)

THE LOWER LIMIT FOR DYNAMIC WHEEL BALANCING MODE IS SET AT 5 gr, THE LOWER

LIMIT FOR ALL THE OTHER MODES IS SET AT 7 gr.

1

2

4

3


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2.1.3 Setting adhesive weight dimensions and static threshold percentage

To ensure the balancing machine precisely calculates the dimensions and total adhesive weights, set the

height (thickness) and width of the adhesive weights at your disposal.

Fig.5

To carry out this setting, press the icon . You will see the following screen:

Fig.6

KEY

1 - Weight thickness/height (pre-set at 4 mm)

2 - Weight width (pre-set at 19 mm)

From this screen page, change the size values of weights using the buttons and .

1

2

THE BLUE-COLOURED-VALUE IS THE ACTIVE FIELD AND THE MODIFIABLE ONE.


Page | 9

2.1.4 User management

The "User Management" function is disabled on machine delivery. To enable it, proceed as described in

par. 2.1.1. After enabling, the icon will be displayed on every page (Fig.7 ref.1).

The wheel balancers can be used simultaneously by 4 different users.

Fig.7

Fig.8

Press the button shown on the monitor (Fig.7 ref.2) or selecting the field (Fig.8 ref.1) and next press

the push-button to display the screen page below:

Fig.9

KEY

A - Program used in the last carried out spin

B - Acquired measurements for the last carried out spin

1 2

1

A

B


Page | 10

Press any of the available numbers on the buttons at the bottom of the page to select the corresponding

user.

The system stores the data relating to the last performed spin according to the different operators.

You can recall the desired user each time the program displays the specific button (Fig.7 ref.2 and Fig.8

ref.1). The measurements stored for each user are lost when the machine is switched off.

User management is valid for any wheel balancer function.

3.0 SERVICE MENU

From the main page “Home” press the button to move to the next screen page and the button to

access the user menu. On the monitor, the following screen appears where you can enter the password.

Fig.10

The service login password is: 4324.

After entering the correct password you will see the following screen:

Fig.11

KEY

1 - Push-button for display of error codes list

2 - ADVANCED calibrations menu push-button

3 - Test menu push-button

4 - Hardware configuration menu push-button

5 - ?????????? push-button

Press push-button to enter the second page of the service menu.

IF THE FUNCTION "USER MANAGEMENT" IS DISABLED THE PUSH-BUTTON IS NOT

DISPLAYED.

1 2 3 4

5


Page | 11

3.1 Display of error codes list

Press (Fig.11 ref.1) to display on monitor the following screen page that shows the meaning of the

error codes generated by the machine.

Fig.12

3.2 Machine ADVANCED calibration

Press the button (Fig.11 ref.2) to display the following screen page on the monitor

Fig.13

KEY

1 - Mandrel “ø” calibration

2 - Weight measurement sensors calibration

3 - Gauge calibration

4 - Phonic wheel calibration

1 2 3 4


Page | 12

3.2.1 Mandrel “Ø” calibration

Press the button to display the following screen page on the monitor:

Fig.14

After making sure that the mandrel is unloaded (no wheel or mounted accessories) and in the case of

closed pneumatic mandrel, press the button and close the guard.

The spindle will rotate for a few minutes until you see the screen below:

Fig.15

The machine has reset all its measuring fields, press the push-button to return to calibration page.

3.2.2 Weight measurement sensors calibration

Press the button to display the following screen page on the monitor

Fig.16

ASSEMBLE A BALANCED WHEEL ON THE SPINDLE AND PERFORM THE SPINDLE Ø

CALIBRATION PROCEDURE DESCRIBED IN PAR. 20.3 (WITH WHEEL MOUNTED).


Page | 13

- Set the size of the rim on the mandrel using the distance-

diameter caliper arm and the external data gauge (if present) or manual caliper.

- Press the button and close the guard to the perform the 1st spin of the wheel without weights.

- At the end, on the monitor will appear the following screen, saying that

you should apply a weight of 100 g to the "12 o'clock" outer rim.

Fig.17

- Apply the weight and position it perfectly to the "12 o'clock".

- Press the button and close the guard to the perform the 2nd spin (100 g weight

placed on the outside wheel).

- At the end, on the monitor will appear the following screen, saying that you should apply a weight of 100

g previously applied on the outer side and apply it on the inside of the rim.

Fig.18

- Turn manually the wheel until you have the weight of 100 g on the outer side at "12 o'clock".

- Press the brake pedal and hold it down during the whole the following

operation to avoid unexpected rotation of the spindle.

- Remove the weight from 100 g from the outside of the wheel and apply it on the inner side at "12

o'clock".

- Close the guard to perform the 3rd spin of the wheel (100 g weight placed on the inside wheel).

APPLY THE WEIGHT AT A POINT IN WHICH BOTH SIDES OF THE RIM THERE IS THE

POSSIBILITY OD APPLYING A CLIP WEIGHT OF 100 gr.


Page | 14

At the end of the rotation, the video screen below will be displayed to indicate the operation is finished.

Fig.19

3.2.3 Gauge calibration


Fig.20

KEY

1 - Distance-diameter caliper calibration

2 - Calibration of external data gauge

3.2.3.1 Distance-diameter caliper calibration


Fig.21

1 2

WHEN THE OPERATION IS CONCLUDED, REMOVE THE WHEEL FROM THE MANDREL AND

PERFORM A COMPLETE CALIBRATION PROCEDURE Ø MANDREL. (see par. 3.2.1)


Page | 15

- Place the gauge (Fig.22 ref.1) on the mandrel flange (Fig.22 ref.2).

Fig.22

- The following screen will appear on the monitor to indicate the measured values:

Fig.23

- The value on the right hand of the symbol "scale" (Fig.23 ref.1) must be equal to the

value positioned above the gauge (Fig.23 ref.2) ± 1 mm.

- Press push button . The following screen will appear on the monitor:

Fig.24

1

2

2 1


Page | 16

- Place the gauge as shown in the following figure

Fig.25

- Press push button . Wait a few seconds until you see the following screen

Fig.26

- Place the gauge against the mandrel in the lower part of it but on a smaller diameter

than before as indicated on the image on the monitor.

- Press push button . On the monitor the next screen page will be displayed

Fig.27


Page | 17

Measure the exact diameter of a rim (see Fig.28) and place it on the screen on the monitor by pressing the

or buttons.

Fig.28

- Fit the measured wheel on the balancer and lock it on the mandrel.

- Move the gauge ferrule (Fig.29 ref.1) onto the inner edge of the wheel upwards (see Fig.29).

Fig.29

- Press button to end the operation. On the monitor the next screen page will be displayed, press

the push-button to save and quit the calibration.

Fig.30

The calibration of the distance-diameter caliper is finished.

1


Page | 18

3.2.3.2 Calibration of external data gauge


Fig.31

Move the tip of the width measuring device (Fig.32-34 ref.1) in in line with the mandrel edge (Fig.32-34

ref.2), In case of a pneumatic locking mandrel, move the tip just next the upper edge of the closed mandrel

(Fig.33-35).

GAR 307 with SCREW mandrel GAR 307 with PNEUMATIC mandrel

Fig.32 Fig.33

GAR 305 with SCREW mandrel GAR 305 with PNEUMATIC mandrel

Fig.34 Fig.35

TO PERFORM THIS CALIBRATION, THE MANDREL MUST BE UNLOADED (NO WHEEL OR

ACCESSORIES MOUNTED ON IT) AND WITH CLOSED PNEUMATIC MANDREL.


Page | 19

Press button . On the monitor the next screen page will be displayed:

Fig.36

Move the tip of the width measuring device (Fig.37-38 ref.1) in line with the outer surface of the flange

(Fig.37-38 ref.2).

GAR 307 GAR 305

Fig.37 Fig.38

Press button .

At the end of the operation, the following screen will appear on the monitor, press button to save and

quit the calibration.

Fig.39

The calibration of the external data gauge is finished.


Page | 20

3.2.4 Calibration of Phonic wheel

Press the button , to enter the calibration of phonic wheel, then press and close the guard to

start the calibration spin.

During program running, are displayed the various screen pages as the ones shown in the following images

(Fig. 40-41-42).

The speed rotation indicated on the monitor (Fig.40-41-42 ref.1) should be of 100.00 ±2 rev/min, on the

contrary the calibration will not be completed and trouble shooting should be performed.

Fig.40 Fig.41 Fig.42

At the end of the operation, the following screen will appear on the monitor, press button to save and


Fig.43

The calibration of the phonic wheel is finished.

1 1 1


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3.3 OPTIONAL calibrations

For the machines equipped with mobile laser pointer and/or touchscreen are also available the following

optional calibrations.

From the user Menu page (par. 2.0 page 5) press button (Fig.2 ref.2) to display the following screen

page

Fig.44

KEY

1 – Mobile laser calibration

2 - Touch monitor calibration

3.3.1 Mobile laser calibration

Press the button (Fig.44 ref.1) to display the following screen page on the monitor:

Fig.45

Mount the small wheel (13”/14” diameter) onto the mandrel and apply an adhesive weight in any point inside the rim.

At the end of the operation press push button .

On the monitor the next screen page will be displayed:

1 2

TO PERFORM THIS CALIBRATION, YOU NEED TWO WHEELS WITH A WIDE RIM DIAMETER

DIFFERENCE, A SMALL ONE MEASURING 13”/14”, AND A LARGE ONE MEASURING 18”/19”.


Page | 22

Fig.46

Turn the wheel manually (if necessary) to let the weights fitting gripper of the caliper come into contact

with the previously applied weight (see Fig.47).

Fig.47

Keep the caliper in position and press push button . On the monitor the next screen page will be

displayed:

Fig.48

Use the buttons or (or the equivalent ones on the keyboard in case of machines without touch

screen) and by manually rotating the wheel too, make the laser pointer hit the reference point previously

taken, as showed in Fig. 49.


Page | 23

Fig.49

When the button is pressed the measure is displayed and the monitor will show the following screen

page:

Fig.50

Replace the small wheel (13”/14”) with the large one (18”/19”) and repeat the previously described operations.

At the end of the calibration will appear the following screen page press the push-button to save and


Fig.51

The calibration of the mobile laser is finished.


Page | 24

3.3.2 Touch monitor calibration


Fig.52

Press the intersection of the lines that appear on the monitor.

The points on which you need to press will be 4 and positioned near the corners of the monitor.

The calibration of the monitor is finished.

Fig.53

IT IS EXTREMELY IMPORTANT TO PRESS ON THE CENTRE OF THE INTERSECTIONS, IT IS

RECOMMENDED THE USE OF A SPECIAL NIB (see Fig.53)


Page | 25

3.4 Test menu


Fig.54

KEY

1 - Motor test

2 - Weight measurement sensors test

3 - Encoder sensor test

4 - Wheel dimensions measurement sensors test

5 - Input/Output signals test

3.4.1 Motor test


Fig.55

KEY

1 - Counter-clockwise direction motor rotation

2 - Clockwise direction motor rotation

3 - Test, continuous cycle with start and motor braking

The number that appears on the top left indicates the total amount of spins performed by the machine

1 2 3 5 4

1 3 2

TO PERFORM TESTS THAT HAVE EFFECTIVE CONTROL VALUE CARRY OUT THE FOLLOWING

PROCEDURES WITH A 14”/15” WHEEL ASSEMBLED ON THE SHAFT.


Page | 26

Press the buttons and (Fig.55 ref.1-2), and close the wheel cover guard, to start the motor

rotation respectively clockwise and counter-clockwise, on the monitor is displayed the following screen

page that allows the motor correct functioning.

Fig.56

100.00 rev/min is the machine nominal speed (Fig.56 ref.1), on the right side are listed the values measured

during the spin in progress, recorded average speed (Fig.56 ref.3), maximum reached speed (Fig.56 ref.2)

and the minimum one (Fig.56 ref.4).

Press the button (Fig.55 ref.3), and close the wheel cover guard, to activate the continuous cycle; this

test allows to test the motor and brake good functioning, under stress the machine will perform

autonomously consecutive spins made of: start-up, measurement, braking and rest (5 sec).

On the screen , on the top left (Fig.57 ref.1) is reported the progressive number of the performed cycles.

By means of this test you can check that the motor does not overheat and that the brake is in service even

under stress.

Fig.57

Measure the wheel unbalance before carrying out a test cycle and check it again at the end of it, to control

the quality of the measurement that should not vary considerably between the first and the second check.

1

2

3

4

1


Page | 27

3.4.2 Weight measurement sensors test


Fig.58

KEY

1 - Selection of signals amplification scale A - Outer sensor detected value (RH)

2 - Sensors control with shaft moving B - Inner sensor detected value (LH)

3 - Sensors control with calibration instrument C - Outer sensor values graph (RH)

D - Inner sensor values graph (LH)

E – Selected amplification scale

For a correct operation the weight measurement sensors values must be 2050 ±50 and their difference

must not exceed 20.

A and B = 2050 ±50

Δ max = 20

Press on the shaft to make the outer sensor value go down to the lower value of the scale (about 11) and to

make the inner one rise to the maximum value of the scale (about 4090).

The push-buttons 1, 2 and 3 (Fig.58) activate functions that are used only during the factory control or by

part of the hardware and software development unit; therefore they are not required for the normal check

of the sensors functioning.

1 3 2

A C

E

D B


Page | 28

3.4.3 Encoder sensor test


Fig.59

The encoder sensor must read the black and white "windows", reported on the adhesive in the inner side

of the main shaft drive pulley.

On the pulley there are two scales made of 256 points each, plus a single black notch inside that marks the

Zero point.

To check the encoder sensor correct functioning, turn the shaft manually and check that, at each complete

revolution, the value “C” (Fig.59) covers the 256 points readout (255 + 0), the value “D” (Fig.59) will be 0 when it is next to the Zero point notch , and will go back to 1 as soon as it is shifted.

The values A and B (Fig.59) indicate the exact readout of the two scales; 1 corresponds to the readout of a

black "window" while 0 corresponds to a white "window".

The fact that the two scales are not aligned on the same axis allows a higher precision, as a mater of fact

the machine can identify 512 points instead of only 256.

According to the position of the pulley, the values will be indicated as shown in the examples of Fig.60.

Fig.60

D C

A

B


Page | 29

3.4.4 Wheel dimensions measurement test


Fig.61

KEY

A - Distance encoder analogical signal E - Distance encoder precise value

B - Diameter potentiometer analogical signal F -Diameter potentiometer precise value

C - Width potentiometer analogical signal G - Width potentiometer precise value

D - Run-out potentiometer analogical signal H -Run-out potentiometer precise value

“A” and “E” (Fig.61) show the data relating to the encoder, which measures the wheel distance, the two values must coincide between them and with the value indicated on the scale divided into millimetres that

is on the gauge; in rest position both values must be set to 0.

If the sensor operates correctly, the value increases with the extraction of the gauge and decreases with

the opposite movement.

“B” and “F” (Fig.61) show the data relating to the potentiometer that measures the wheel diameter.

If the potentiometer operates correctly, the value increases with the lifting of the gauge and decreases with

the opposite movement.

Make sure that value “B” (Fig.61) never reaches ZERO in its whole readout range, from the upper contact point (Fig.62 ref.POS.1) to the lower contact point (Fig.62 ref.POS.2), on the contrary proceed with the

mechanic adjustment of the potentiometer position and with a new calibration.

Fig.62

N.B.: in case of mechanic adjustment place the potentiometer so that the “B” value (Fig.61) is approximately 100 next to the upper contact point (Fig.62 ref.POS.1).

F

E

H

G

B

A

D

C

MAKE SURE THAT VALUE “B” (Fig.61) NEVER REACHES ZERO IN ITS WHOLE READOUT RANGE.


Page | 30

“C” and “G” (Fig.61) show the data relating to the potentiometer that measures the wheel width.

If the potentiometer operates correctly, the value increases with the shifting inwards of the gauge and

decreases with the opposite movement.

In rest position the bit value should be about 200. The potentiometer should be brought to the same value

when replaced.

“D” and “H” (Fig.61) show the data relating to the potentiometer that measures the wheel run-

out/roundness.

If the potentiometer operates correctly, the value increases with the lowering of the feeler pin against the

wheel and decreases with the opposite movement.

3.4.5 Input/Output signals test


Fig.63

KEY

A - Board input signal 1 - wheel cover guard micro

2 - pneumatic blocking micro pedal

3 - Empty

4 - micro GAR303 (green push-button)

B - Board output signal 1 - closes pneumatic locking

2 - opens pneumatic locking

3 - engage/disengage pneumatic brake

4 - engage/disengage LED-light

5 - engage/disengage laser

6 - engage/disengage the gauge locking in position

C - Push-buttons for the selection of the outputs

B

A

TO CHECK THE GAUGES CORRECT FUNCTIONING, CARRY OUT TESTS WITH A WHEEL WITH

WELL-KNOWN DIMENSIONS MOUNTED ON THE MACHINE SHAFT.

THE VALUE DETECTED FROM A POTENTIOMETER OR FROM AN ENCODER MUST BE

CONTINUOUS AND LINEAR, SUDDEN JUMPS FROM A VALUE TO ANOTHER ARE USUALLY

INDICATING FAULTS.

C


Page | 31

To check the input signals activate one of the switches of point “A” (Fig.63 ref.A1-A2-A3-A4), if it is working

correctly, the relevant indicator will pass from to , on the contrary if there is a fault the indicator will

stay green .

Examples:

Lower the wheel cover guard; if the micro switch is working correctly, the indicator (Fig.64 ref.A) will turn

red.

Fig.64

To check the outputs press the relevant push-buttons (Fig.63 ref.C), at the same moment the chosen

control should activate and the relevant indicator should turn red.

Examples:

To check the LED-light functioning press the push-button (Fig.65 ref.B), at this point, if everything is correct,

the LED-light will turn on and the relevant indicator (Fig.65 ref.A) will go from to .

Fig.65

A

A

B


Page | 32

3.5 Hardware configuration menu

In case of application of a new accessory or the loss of the mechanical configuration of the CPU board,

proceed with the hardware setting of the machine/board.

Press the push-button (Fig.12 ref.4) and then scroll the pages by means of the push-buttons and

to display the following screen pages:

Fig.66

Through the push-buttons and you can scroll the parameters (the green-lighted is the currently

selected one) and through the push-button you can set it as each case requires.

Parameter Description State/possible

selections

Gauge1Type Lateral gauge for the detection of the rim width

NONE

GAR262

GAR264

GAR266

GAR301

GAR302

GAR303

GAR304

GAR305

GAR306

GAR307

LaserBlade Fixed blade laser, it indicates the position of the

adhesive weight at "6 o'clock" with a luminous line.

1 - Present/Assembled

0 - Absent

LaserSpot Mobile laser that indicates the position of the

adhesive weight with a luminous point.


0 - Absent

PneumEquipment Pneumatic locking of the wheel on the mandrel. 1 - Present/Assembled

0 - Absent

PneumBreak Tyre wheel braking system 1 - Present/Assembled

0 - Absent

Illum Lighting system of the wheel inner side. 1 - Present/Assembled

0 - Absent

Gauge0Lock System locking in position the fitting device of the

adhesive weight


0 - Absent

PrintEnabled Printer 1 - Present/Assembled

0 - Absent

UltraSound Run-out detection system (Sonar) 1 - Present/Assembled

0 - Absent


Page | 33

4.0 ERROR SIGNALS

During wheel balancer operation, if wrong commands are given by the operator or device faults occur, an

error code or symbol may appear on the monitor screen.

Press the key to return to the previous program page.

Below is a troubleshooting chart.

4.1 Trouble shooting

Error Cause Remedy

1

- The protection guard is open

- The guard micro does not work

- Close the protection guard

- Check the micro and its connections.

- Replace the micro.

- Replace the board .

The cycle can in any case be performed, cutting out the

micro, by pressing the GREY and GREEN keys

simultaneously. This operation must be performed in max safety

conditions, without moving anything close up to the rotating parts.

2 Encoder sensor does not read

May be due to faulty position encoder or encoder not fitted

correctly. Or else the motor is faulty or has not started

because something is preventing its rotation.

3 Calibration overcoming

During the calibration procedure, the machine detects

excessive weight.

- The weight may not have been fitted properly.

- The data acquisition board may be faulty.

- The measurement sensors may be faulty.

4 Wheel speed stability out of

tolerance

- Check the position encoder functioning.

- Check the position encoder correct assembly.

5 Encoder calibration error

Repeat the phonic wheel calibration (page 20).

- Check the position encoder functioning.


6 Encoder samples not sufficient - Check the position encoder functioning.


7 Mandrel calibration error

During the “zero mandrel” calibration procedure, the machine detects excessive weight.

- The rotation of empty shaft may be unbalanced.



8 Piezo calibration values out of

tolerance

During the “zero mandrel” calibration procedure, the machine detects insufficient weight.

- The weight may not have been fitted properly.




Page | 34

Error Cause Remedy

9 Wheel rotations not completed During the calibration procedure, the spin is not completed

because the key has been pressed (STOP).

10 Pneumatic mandrel open

During the balancing procedure, the pneumatic mandrel is

open. Close the mandrel before starting the spin. If

necessary, switch the machine off and on. If the error

continues, the micro on the pedal or the acquisition board

could be faulty.

11 Incorrect gain calibration

During the diameter potentiometer calibration procedure,

the machine detects an out-of-range value.

- Check the measurement rod correct position.


- The diameter measurement sensor may be faulty.

12 Distance/diameter caliper value

not released

During the balancing operation, the gauge is not in idle

position. Turn the machine off and on with the gauge in

correct idle position.

If the error persists:

- The distance sensor may be faulty.

- The diameter sensor may be faulty.

- The acquisition board may be faulty.

13 Distance/diameter caliper value

not released

During the balancing operation, the gauge is not in idle

position. Turn the machine off and on with the gauge in

correct idle position.

If the error persists:

- The distance sensor may be faulty.

- The diameter sensor may be faulty.

- The acquisition board may be faulty.

14 Firmware Error

15 Run-out samples not sufficient

17 External data gauge enabled

27 Rotate the wheel to make a

complete rotation

28 Piezo calibration error

29 Distance out of tolerance level

31 Distance and diameter caliper

released

32 Parameters format incompatible

100 Board reboot

101 Board boot failure

102 FW version incompatible

103 Time-out expired

107 Configuration error

108 Damage Error


Page | 35

5.0 COMPONENTS REPLACEMENT

5.1 CPU board replacement

Remove the protection guard to access the board. Before removing the faulty board, disconnect the two

cables from the transformer (for machines with 90W motor, Fig.67), or the two cables, red and black, from

the power card, observing the + and - signs (for machines with 200W motor, Fig.68).

!! Pay attention to the cables position since they will have to be reconnected in the same way !!

Fig.67 Fig.68

Replace the CPU board and plug in all the cables previously disconnected.

Fig.69 Fig.70

SHUT-DOWN THE WHEEL BALANCER BEFORE PERFORMING THE OPERATIONS DESCRIBED

BELOW.

FOR THE MODELS WITH READ-OUT BOARD CODE 18327C (Fig.69), CONNECT THE 24V AND

0V CLAMPS AS SHOWN IN FIG.70

FOR THE MODELS WITH PC BOARD CODE 19611 (Fig.71), CONNECT THE 5V AND 0V

CLAMPS AS SHOWN IN FIG.72


Page | 36

Fig.71

Fig.72

Start the machine and a screen page similar to the one in Fig.73 will appear

Fig.73

Press the push-button to confirm that the CPU board has been replaced and transfer and save the

data of the PC or read-out board.

After the confirmation, the home page logo will be displayed, at this stage the machine is ready to operate.

5.2 Readout board replacement

Remove the protection guard to access the board. Before removing the defective board unplug all the

cables.

Fig.74

Replace the board and plug in all the cables previously disconnected.

Remove in case the bond on the keyboard pin and connect the cable as indicated in Fig. 75.


BELOW.


Page | 37

Fig.75


Press the push-button to shift the red “X” towards right in order to cross the board below the monitor as in Fig.76

Fig.76

Press the push-button to confirm that the read-out board has been replaced and transfer and save the

data of the CPU board.


5.3 PC board replacement

Remove the protection guard to access the PC board (Fig.71). Before removing the defective board unplug

all the USB touch, HDMI and serial cables.

Replace the defective board with a new one and reconnect all cables.


Press the push-button to shift the red “X” towards right in order to cross the board below the monitor as in Fig.76

Press the push-button to confirm that the PC board has been replaced and transfer and save the data

of the CPU board.



BELOW.


Page | 38

5.4 Software and Firmware update

Through a computer with access to internet, open the manufacturer's site and enter Technical Support

page to download the last software version.

De-compact the downloaded .zip file, at this stage we will have a folder named V02.03.15, copy the folder

onto a pen-drive.

Remove the guard to enter the PC board (Fig.71) or the read-out board (Fig.69) and insert the pen-drive

with the software in one of the USB port of the board as in Fig.77 and Fig.78.

Fig.77 Fig.78

Turn on the machine and wait for all the files to be copied, at the end a screen page similar to the one of

Fig.79 will be displayed.

Fig.79

Remove the pen-drive from the USB port and wait for the machine restart.

The pen-drive must be emptied and once the unloaded software is copied by the Technical

Support, you must rename the folder with the following name: PyEQ.


Page | 39

Once the restart is over, turn off the machine and wait for all the LEDs on the board to turn off. Restart

again and check that everything is functioning correctly.

Mount the protection guard again.

assistance manual - ravamerica · 2019-06-29 · screen wheel balancers technical assistance manual...

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