John Bean, Blackhawk, Hofmann, Kansas Jack - JBC VPI ......Once the balancer reaches balancing speed...

Service Manual

JBC VPI SYSTEM I, II, III, IVSNAPON LOW DIGITALBFH 1000 / 800 /800b /800c

EEWB504A, EEWB503A, EEWB502A,EEWB516A, EEWB304A, EEWB519A,EEWB526A, EEWB526B, EEWB526C

Snapon LowDigital

VPI System IV

December, 2007

VPI System II

VPI System I

VPI System III

All information contained or disclosed in this documentis considered confidential and proprietary by Snap-onEquipment Company. All manufacturing, use, repro-duction, and sales rights are reserved by Snap-on ToolsCompany and the information contained herein shallnot be used in whole or in part without the expresswritten consent of Snap-on Tools Equipment.

SNAP-on® is a registered trademark of Snap-on Incorporated.

TABLE OF CONTENTS

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Table of Contents

INTRODUCTIONGENERAL........................................................................................................................................................... IFUNCTIONAL DESCRIPTION.............................................................................................................................. I

BASIC BALANCER OPERATION.................................................................................................................. IWEIGHT APPLICATION ................................................................................................................................ IALLOY MODES............................................................................................................................................ IALU-S MODE ............................................................................................................................................... IDISPLAY / CONTROL PANEL ...................................................................................................................... I

GENERAL SPECIFICATIONS AND MACHINE FEATURES ................................................................................ IIMAJOR FEATURES .................................................................................................................................... IISPECIFICATIONS........................................................................................................................................ II

IMPORTANT SAFETY INSTRUCTIONS ............................................................................................................. IIILOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE ..................................................................................... IVELECTRICAL SAFETY PRECAUTIONS ............................................................................................................ IVSERVICE GUIDELINES / HANDLING STATIC SENSITIVE PCB’S ..................................................................... V

CHAPTER 1 AC/DC POWER DISTRIBUTIONLOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE ................................................................................... 1-1ELECTRICAL REQUIREMENTS...................................................................................................................... 1-1AC THEORY OF OPERATION ........................................................................................................................ 1-2

AC DISTRIBUTION.................................................................................................................................... 1-2DRIVE MOTOR......................................................................................................................................... 1-2

DC THEORY OF OPERATION ........................................................................................................................ 1-2PROCESSOR BOARD ............................................................................................................................. 1-2ENCODER BOARD .................................................................................................................................. 1-2DISTANCE POTENTIOMETER (SYSTEM I,II,III,IV SOT LOW DIGITAL) ..................................................... 1-2DIAMETER POTENTIOMETER (SYSTEM II,III,IV SOT LOW DIGITAL) ...................................................... 1-2WIDTH POTENTIOMETER (SYSTEM III,IV) .............................................................................................. 1-3TRANSDUCERS ....................................................................................................................................... 1-3DISPLAY BOARD ..................................................................................................................................... 1-3KEYPAD................................................................................................................................................... 1-3AUTO STOP LOCK SWITCH (VPI III, IV) .................................................................................................. 1-3ELECTROMAGNETIC BRAKE.................................................................................................................. 1-3EMBEDDED PCB (SYSTEM IV, BFH) ...................................................................................................... 1-3

TROUBLESHOOTING ..................................................................................................................................... 1-4PROCESSOR PCB......................................................................................................................................... 1-7KEYPAD SCHEMATIC (VPI SYSTEM III) ........................................................................................................ 1-7KEYPAD SCHEMATIC (VPI SYSTEM I, II) ...................................................................................................... 1-8KEYPAD SCHEMATIC (SNAPON LOW DIGITAL) ........................................................................................... 1-8EMBEDDED PC (JBC SYSTEM IV) .............................................................................................................. 1-10

CHAPTER 2 THEORY OF OPERATIONFUNCTIONAL DESCRIPTION.......................................................................................................................... 2-1TERMINOLOGY JBC SYSTEM IV ................................................................................................................... 2-2TERMINOLOGY JBC SYSTEM III ................................................................................................................... 2-3TERMINOLOGY JBC SYSTEM I, II ................................................................................................................. 2-4TERMINOLOGY SNAPON LOW DIGITAL ....................................................................................................... 2-5BALANCER COMPONENTS ........................................................................................................................... 2-6

MAIN PROCESSOR PCB......................................................................................................................... 2-6POWER SUPPLY PCB ............................................................................................................................ 2-6KEYPAD................................................................................................................................................... 2-6

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DISPLAY PCB .......................................................................................................................................... 2-6TEMPERATURE SENSOR ....................................................................................................................... 2-6DRIVE MOTOR......................................................................................................................................... 2-6TRANSDUCERS ....................................................................................................................................... 2-6SAPE (SEMI-AUTOMATIC-PARAMETER-ENTRY) ................................................................................... 2-7ENCODER................................................................................................................................................ 2-7VIBRATORY SYSTEM.............................................................................................................................. 2-8ELECTROMAGNETIC BRAKE.................................................................................................................. 2-8AUTO STOP LOCK SWITCH (JBC SYSTEM III, IV) .................................................................................. 2-8

CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCEGENERAL....................................................................................................................................................... 3-1SHAFT IMBALANCE, WHEEL ADAPTER TO SHAFT REMOUNT TEST ......................................................... 3-1BALANCER DIAGNOSTICS (TROUBLESHOOTING) ....................................................................................... 3-1TROUBLESHOOT USING CORRECT DIAGNOSTICS PROCEDURES ............................................................ 3-2TOOLS REQUIRED WHEN SERVICING THE Y2K BALANCERS ................................................................... 3-2FUNCTIONS OF SNAPON / JBC VPI BALANCERS ...................................................................................... 3-3

SERVICE CODES .................................................................................................................................... 3-3F/P CODE DESCRIPTIONS OF THE BALANCER........................................................................................... 3-4

F/P 1 TOGGLE FINE WEIGHT MODE ...................................................................................................... 3-4F/P 2 RIM WIDTH INCH / MILLIMETER .................................................................................................... 3-4F/P 3 GRAM / OUNCE ............................................................................................................................. 3-4F/P 4 CALIBRATION WITH ADAPTER OR DISABLE ADAPTER COMPENSATION .................................. 3-4F/P 7 TOGGLE MILLIMETER AND INCH FOR DIAMETER ....................................................................... 3-4F/P 12 READ COUNTERS ....................................................................................................................... 3-4F/P 14 USER CALIBRATION PROCEDURE ............................................................................................. 3-5F/P 18 ALU-S MODE ................................................................................................................................ 3-6F/P 19 ALU-S ONE PLANE BALANCING MODE ...................................................................................... 3-6F/P 21 KERNEL SOFTWARE .................................................................................................................. 3-6F/P 28 KERNEL ERROR MESSAGES ..................................................................................................... 3-6F/P 36 TOGGLE ANGLES OF LEFT AND RIGHT WEIGHTS. ................................................................... 3-6F/P 43 RESETTING THE COUNTERS ...................................................................................................... 3-6F/P 44 READ OR RESET PRODUCTIVITY OF USER .............................................................................. 3-6F/P 50 READ OUTPUT VOLTAGE OF THE DISTANCE POTENTIOMETER OF SAPE ............................. 3-7F/P 51 READ OUTPUT VOLTAGE OF THE DIAMETER POTENTIOMETER OF SAPE ............................. 3-7F 52 READ OUTPUT VOLTAGE OF THE WIDTH POTENTIOMETER ....................................................... 3-7F/P 53 DISPLAY TEST ............................................................................................................................. 3-7F/P 55 CHECK AC AND DC VOLTAGES .................................................................................................. 3-7F/P 59 DISPLAYS THE UNBALANCE OF THE BARE SHAFT .................................................................. 3-7F/P 60 READ SHAFT RPM ...................................................................................................................... 3-7F/P 63 CONTINUOUS BALANCING .......................................................................................................... 3-7F/P 64 DISPLAYS THE TRANSDUCER OUTPUT ..................................................................................... 3-7F79 CALIBRATION OF WIDTH SAPE ....................................................................................................... 3-8F/P 80 SAPE GAUGE CALIBRATION....................................................................................................... 3-9F/P 83 FACTORY CALIBRATION PROCEDURE ..................................................................................... 3-11F/P 84 EMPTY SHAFT CALIBRATION PROCEDURE ............................................................................ 3-13F/P 85 COPY CONTENTS OF MAIN PCB TO ENCODER ...................................................................... 3-13F/P 86 COPY CONTENTS OF ENCODER TO MAIN PCB - BK 1.21 ...................................................... 3-13F/P 90 MATCH BALANCE ...................................................................................................................... 3-13F/P 91 OPTIMIZATION ............................................................................................................................ 3-13F/P 92 SPLIT WEIGHT ........................................................................................................................... 3-13F/P 93 CHANGE MODEL SETTING........................................................................................................ 3-13F/P 94 SPOKE MODE ........................................................................................................................... 3-14F/P 95 CLEAN & RESET EEPROM 1 & 2 .............................................................................................. 3-14F/P 97 STICKY AT TOP STOP AT TOP ................................................................................................... 3-14F99 SAPE-2 ACCURACY TEST ............................................................................................................. 3-15

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SERVICING THE BALANCER ....................................................................................................................... 3-16CONTROL PANEL REMOVAL & REPLACEMENT.................................................................................. 3-16MAIN PROCESSOR REPLACEMENT .................................................................................................... 3-17TO ACCESS THE INSIDE OF THE MACHINE ........................................................................................ 3-18POWER SUPPLY BOX........................................................................................................................... 3-18TRANSDUCER REMOVAL ..................................................................................................................... 3-19INSTALLATION OF TRANSDUCER ......................................................................................................... 3-19ENCODER REMOVAL............................................................................................................................ 3-20VIBRATORY MEMBER REMOVAL......................................................................................................... 3-20VIBRATORY INSTALLATION ................................................................................................................... 3-20DIAMETER SAPE / POTENTIOMETER VPI II, III, IV & SOT LD .............................................................. 3-21DIAMETER SAPE / POTENTIOMETER ADJUSTMENT .......................................................................... 3-21SAPE GAUGE ....................................................................................................................................... 3-21DISTANCE SAPE / POTENTIOMETER VPI III, IV ................................................................................... 3-22DISTANCE SAPE / POTENTIOMETER INSTALLATION VPI III, IV ........................................................... 3-22WIDTH SAPE / POTENTIOMETER INSTALLATION ................................................................................ 3-23ELECTRIC BRAKE PEDAL ADJUSTMENT ............................................................................................. 3-23ELECTROMAGNETIC MOTOR BRAKE ADJUSTMENT .......................................................................... 3-23MOTOR REMOVAL ................................................................................................................................ 3-24HOOD SWITCH / CAM / SPRING ........................................................................................................... 3-25

CHAPTER 4 JBC SYSTEM IVGENERAL....................................................................................................................................................... 4-1SELF TEST DURING START UP ..................................................................................................................... 4-1DISPLAY DESCRIPTION................................................................................................................................. 4-4BALANCER SETUP ........................................................................................................................................ 4-4FUNCTION SCREEN ...................................................................................................................................... 4-5FUNCTION DESCRIPTION .............................................................................................................................. 4-5CUSTOMER CALIBRATION ............................................................................................................................ 4-7ENTERING SERVICE MODE .......................................................................................................................... 4-9C CODES ..................................................................................................................................................... 4-10

C28 DISPLAY AND CLEAR ERROR CODES.......................................................................................... 4-10C43 RESET COUNTERS ........................................................................................................................ 4-11C47 SELECT MACHINE MODEL ............................................................................................................ 4-11C55 INCOMING LINE VOLTAGE ............................................................................................................. 4-11C56 CIRCUIT STATE OF THE WHEEL GUARD ...................................................................................... 4-11C57 VIBRATORY TEMPERATURE SENSOR ......................................................................................... 4-11C60 MOTOR RPM .................................................................................................................................. 4-11C74 POSITION COUNTER AND BASIC INCREMENTAL ENCODER TEST ............................................. 4-11C75 DISPLAY VALUES OF A/D CONVERTER ....................................................................................... 4-12C80 CALIBRATION OF DISTANCE, DIAMETER AND AUTO STOP SYSTEM ......................................... 4-12C81 MEASURING ADAPTOR FLANGE AND ZERO PLANE ................................................................... 4-17C82 WIDTH GAUGE ARM ADJUSTMENT / CALIBRATION ..................................................................... 4-17C83 CALIBRATION OF UNBALANCE MEASUREMENT ........................................................................ 4-19C84 EMPTY SHAFT COMPENSATION .................................................................................................. 4-21C88 ANGULAR UNBALANCE POSITION ................................................................................................ 4-22C90 SAVING ADJUSTMENT DATA ......................................................................................................... 4-23FIELD PROGRAMMING THE BALANCER.............................................................................................. 4-24

CHAPTER 5 BFH SERIESINTRODUCTION .............................................................................................................................................. 5-1THEORY OF OPERATION .............................................................................................................................. 5-1BFH/OPTIMA SERIES MAJOR COMPONENTS ............................................................................................ 5-4

CAMERA PROCESSOR BOARD ............................................................................................................. 5-4ELECTRONIC BOX ................................................................................................................................... 5-5SCANNER / LASER / CCD ....................................................................................................................... 5-6

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POWER SUPPLY PCB ............................................................................................................................ 5-6POWER CLAMP ASSEMBLY .................................................................................................................. 5-7

SELF TEST DURING START UP ..................................................................................................................... 5-8DISPLAY DESCRIPTION............................................................................................................................... 5-11BALANCER SETUP ...................................................................................................................................... 5-11FUNCTION SCREEN .................................................................................................................................... 5-12FUNCTION DESCRIPTION ............................................................................................................................ 5-12CUSTOMER CALIBRATION .......................................................................................................................... 5-14ENTERING SERVICE MODE ........................................................................................................................ 5-16C CODES ..................................................................................................................................................... 5-17

C28 DISPLAY AND CLEAR ERROR CODES.......................................................................................... 5-17C43 RESET COUNTERS ........................................................................................................................ 5-18C47 SELECT MACHINE MODEL ............................................................................................................ 5-18C55 INCOMING LINE VOLTAGE ............................................................................................................. 5-18C56 CIRCUIT STATE OF THE WHEEL GUARD ...................................................................................... 5-18C57 VIBRATORY TEMPERATURE SENSOR ......................................................................................... 5-18C60 MOTOR RPM .................................................................................................................................. 5-18C74 POSITION COUNTER AND BASIC INCREMENTAL SHAFT ENCODER TEST ................................. 5-18C75 DISPLAY VALUES OF A/D CONVERTER ....................................................................................... 5-19C83 CALIBRATION OF UNBALANCE MEASUREMENT ......................................................................... 5-23C84 EMPTY SHAFT COMPENSATION .................................................................................................. 5-26C88 WHEEL WEIGHT POSITIONING ..................................................................................................... 5-27C90 SAVING CALIBRATION DATA .......................................................................................................... 5-28C98 POWER CLAMP ENCODER ........................................................................................................... 5-28C110 VCC VOLTAGE .............................................................................................................................. 5-29C120 ENABLE / DISABLE LASER POINTER ......................................................................................... 5-29C122 SCANNER / LASER / CCD CALIBRATION .................................................................................... 5-30C123 DIAGNOSTIC FUNCTIONS ............................................................................................................ 5-32ACCESSING THE DIAGNOSTIC FEATURES ......................................................................................... 5-32DIAGNOSITC BITS (SHOWN IN BLACK) ................................................................................................ 5-35STATUS FLAGS (SHOWN IN BLUE) ...................................................................................................... 5-36ANALOG INPUTS: (SHOWN IN GREEN) ............................................................................................... 5-36C123 MECHANICAL SCANNER / LASER / CCD ADJUSTMENT ............................................................ 5-37

CCD / LASER / SCANNER INSTALLATION ................................................................................................... 5-39INNER SCANNER INSTALLATION .......................................................................................................... 5-39OUTER SCANNER INSTALLATION......................................................................................................... 5-40HOOD ADJUSTMET ............................................................................................................................... 5-40OUTER SCANNER INSTALLATION CONTINUED .................................................................................... 5-41REAR SCANNER INSTALLATION ........................................................................................................... 5-42REAR SCANNER DRIVE BELT .............................................................................................................. 5-43

FIELD PROGRAMMING THE CAMERA PROCESSOR PCB ........................................................................ 5-44REMOVING THE BELL HOUSING ................................................................................................................ 5-45IMPORTANT BALANCER INFORMATION ..................................................................................................... 5-46QUALIFYING THE BALANCER ..................................................................................................................... 5-46

CHAPTER 6 BFH800B6INTRODUCTION .............................................................................................................................................. 6-1SETUP AND CALIBRATION ............................................................................................................................ 6-1

CALIBRATION OF WHEEL GUARD POTENTIOMETER ........................................................................... 6-2C122 CAMERA AND SONAR CALIBRATION ............................................................................................ 6-4BFH800B SPECIFIC COMPONENTS ....................................................................................................... 6-6

APPENDIX A CODESKERNEL CODES ........................................................................................................................................... A-1H CODES SYSTEM IV................................................................................................................................... A-7E CODES SYSTEM IV................................................................................................................................... A-7

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INTRODUCTION

GENERAL

The BFH, VPI SYSTEM & SOT Low Digital balancers are designed to compute static and dynamic imbalanceof 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 thestatus 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 stateand displays dashes on the 7 segment LED’s. The unit is now ready for parameter inputs and can takemeasurements.

FUNCTIONAL DESCRIPTION

BASIC BALANCER OPERATIONOnce the balancer reaches balancing speed (>200 RPM System III, IV, BFH >90 RPM System I, II, SOT LowDigital) the balancer display will show “Spn”, calculation is done at this time. Once the weight imbalance andlocation is known the balancer will reverse polarity sending 230VAC via a relay on the Power Supply Board tothe motor bringing the shaft to a stop. Imbalance amounts and corrective weight locations will be shown onthe display.

WEIGHT APPLICATIONRotate the wheel until the center green LED in the right hand row of LEDs illuminates. Apply the correctiveweight at top dead center (12 o'clock position) on the right side of the wheel. Repeat this process for the leftside of the wheel.

ALLOY MODESIn addition to the standard Dynamic and Static modes there are 5 Alloy modes, each of which are illustratedby LEDs on the balancer touch panel when activated. Alloy modes 1 through 5 are accessed by first togglingthe MODE key until the balancing mode desired is displayed. See the Operator's Manual for an explanation ofAlloy Mode balancing. The last used mode will again be used even when power is cycled.

ALU-S MODEALU-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 explanationof ALU-S mode balancing.

DISPLAY / CONTROL PANELThe 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 repairingthe machine.

Everytime the machine powers on, the software automatically performs a system check. The Main Processorperforms a SAPE error check. If the SAPE is good the machine enters idle state as normal. If one of themfails, for example, the distance gauge fails, machine displays “DIS” “SAP” “FAL” (System III) when themachine is powered on. If diameter gauge fails, it displays “DIA” “SAP” “FAL” (System III). If both of themfail, machine displays “2-D” “SAP” “FAL” (System III). The operator must press the “STOP” button to exitthe display and enter idle state. The machine masks the function of the failed part after SAPE check. Forexample, if the diameter gauge fails, the machine disables the measurement of diameter and measures thedistance only. Or if the distance gauge fails the machine disables the measurement of the distance gauge andmeasures the diameter only. The BFH performs the same kind of checks on each scanner. The BFH requiresthat 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”.

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GENERAL SPECIFICATIONS AND MACHINE FEATURES

MAJOR FEATURES3D (SAPE) System III, 2D (SAPE) System II SOT Low Digital, 1D (SAPE) System ILarge 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 storagepocket, 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 placementSticky at topFine and coarse weight readingsALUS mode with automatic distance gage lock and tape weight applicatorSpoke mode5 ALU modes and static balanceSplit weight Mode3 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 mountedFull size wheel guard and frame230 volt 50/60 Hz power requirements (System III) - 115 volt 60 Hz (System I, II, SOT LD)Upgradeable softwareMultiple usersSpin count: total # of all spins since manufacture, # of spins since last calibration, # of spins in servicemode, # of spins in user modeOptimization and MatchmountOunce and gram display toggleMillimeter / inch display toggleEmergency stop: When unit is spinning, if any button is pressed the shaft will stop rotating.Balancer Optimized AC induction motor with belt driveShaft lock

SPECIFICATIONSShaft 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 combinationBalance Types: Five 2-plane alloy modes, plus static, dynamic and Match Balance modes.Accuracy: 0.1 oz. (2.8g)Weight Positioning resolution: ± 0.7 degreesRim Width capacity: 3"-20" / 76 mm - 508 mmRim Diameter capacity: 8"-26" / 203 mm-660 mmMaximum Tire Diameter: 44" (1118 mm)Maximum wheel weight: 120 lbs/54Kg (System I), 133lbs/60 Kg (System II, SOT LD), 154lbs/69Kg (System III)

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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 hasbeen 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 thanthat 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 notbe tripped over or pulled.

4. Always unplug equipment from electrical outlet when not in use. Never use thecord 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 opencontainers of flammable liquids (gasoline).

6. Keep hair, loose fitting clothing, fingers and all parts of the body away frommoving parts.

7. Adequate ventilation should be provided when working on operating internalcombustion engines.

8. To reduce the risk of electric shock, do not use on wet surfaces or expose torain.

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 recommendedattachments.

12. Always securely tighten the wing nut before spinning the shaft.

13. ALWAYS WEAR SAFETY GLASSES. Everyday eyeglasses only have impactresistant 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 thelaser source.

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LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE

1. Notify all affected employees that a lockout or tagout system is going to be utilized and the reasonthereof. The authorized employee shall know the type and magnitude of energy that the machine orequipment utilized and shall understand the hazards thereof.

2. If the machine or equipment is operating, shut it down by the normal stopping procedure (depress thestop button, open toggle switch, etc.)

3. Operate the switch, valve, or other energy isolating device(s) so that the equipment is isolated from itsenergy 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 restrainedby 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 energysources, operate the push button or other normal operating controls to make certain the equipment willnot operate. CAUTION: RETURN OPERATING CONTROL(S) TO “NEUTRAL” OR “OFF” POSITIONAFTER 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.

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SERVICE GUIDELINES / HANDLING STATIC SENSITIVE PCB’S

Electrostatic discharge can destroy high impedance ICs if uncontrolled. Use the following techniquesto 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.

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 humiditycombined with wearing silks or nylons, walking on carpets, or walking with rubber soled shoes may createlarge electrostatic charges on your person, capable of blowing a hole in the substrate of an IC.

!USE STANDARD ANT-STATIC PROCEDURESWHILE PERFORMING THESE INSTRUCTIONS

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CAUTION! This product uses LASER RA-DIATION for measurements. DO NOTSTARE INTO BEAM.

Refer to these laser safetystatements whenever thissign is displayed.

Peak power 1.0 mW.Pulse duration 5 m sec.Emitted wavelength 650nm.

Class II laser product. Caution - the useof optical instruments with this productwill increase risk of eye hazard.

WARNING!!! DO NOT STARE INTO LA-SER BEAM! EYE INJURY MAY OCCURWITH PROLONGED EYE CONTACTWITH LASER. AVOID EYE CONTACTWITH THE LASER SCANNERS

WARNING!!! IN THE EVENT OF MA-CHINE MALFUNCTION, DO NOT LOOKINTO THE LASER AREA. PROLONGEDEXPOSURE TO THE LASER MAYCAUSE EYE INJURY.

PERFORM REGULAR CLEANING OF THELASER SCANNER GLASS TO ENSUREOPTIMUM OPERATION.

ALWAYS OPERATE THE WHEEL BAL-ANCER WITHIN THE RANGES STATED INTHE LABEL SHOWN BELOW.

DO NOT KNOCK OR TAMPER WITH THELASER SCANNERS

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CHAPTER 1AC/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 stopbutton, open toggle switch, etc.)

3. Use appropriate devices to isolate the equipment from the power source(s). Stored energy (such as thatin springs, elevated machine members, rotating flywheels, hydraulic systems, and air gas, steam or waterpressure, etc.) must be dissipated or restrained by methods such as repositioning, blocking, bleedingdown, 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 THETEST [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 thatof the machine.

NOTE: THE Y2k BALANCERS PERFORM A SELF-TEST ROUTINE ON START-UP. THERE IS A DELAYOF 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 WITHA DIFFERENTIAL CIRCUIT SET AT 30 MA.

2

CHAPTER 1 AC/DC POWER DISTRIBUTION

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AC THEORY OF OPERATION

Always use the “One Hand Rule” when working with AC voltages by keeping one hand in your pocket orbehind your back. Before removing wires from the Balancer, always verify that the unit is “OFF”. Turn off theMain Power Switch on the back and unplug the AC power cord from the AC outlet.

AC DISTRIBUTIONThe 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 toone side of the “ON/OFF” Rear Panel Power Switch. The hot wire continues to one side of the Line Filter. Theneutral side routes to the other side of the Line Filter. The earth ground directly connects to the BALANCERchassis, and the Line Filter. It is critical to have the proper input voltage in order for the balancer to operatecorrectly.

DRIVE MOTORThe drive motor for the unit receives AC power VIA two relays mounted directly to the Power Supply Board. Tokeep arcing at the relays to a minimum the relays are switched in synchronism. The switching times of therelays are determined individually and taken into consideration for optimum pull-in times. The motor alsoutilizes a capacitor to generate a sufficient amount of torque during acceleration and braking.

DC THEORY OF OPERATION

PROCESSOR BOARDThe operating voltage for the Main Processor is 5VDC. It receives this power from the Power Supply Boardat X1 pins 32 and 34. This 5 volts also passes through the Processor Board and supplies the Encoder PCBand both the Distance and Diameter SAPE.

ENCODER BOARDThe encoder receives 5VDC from the Processor Board. This voltage can be measured at the ProcessorBoard at X3 pin 6. The encoder is built so that there are no adjustments. The encoder disk is built onto theshaft and cannot be replaced without replacing the vibratory member. The encoder is fitted in the vibratorytube and consists of a reflective slotted sleeve which is mounted on the main shaft and the optoelectronicunit.

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 canbe measured at the Processor Board X6 pin 3. The output voltage is dependent upon the deflection of theguage 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 canbe measured at the Processor Board X7 pin 3. The output voltage is dependent upon the rotation of the guagefrom the home position.

!DANGEROUS HIGH VOLTAGES ARE

PRESENT IN THIS EQUIPMENT

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WIDTH POTENTIOMETER (SYSTEM III,IV)The width potentiometer is a 5K pot. It is supplied 5VDC from the main processor. This input voltage can bemeasured at the Processor Board X8 pin 3. The output voltage is dependent upon the rotation of the guagefrom the home position.

TRANSDUCERSThe transducers are installed in a manner that it forms a virtual transducer on each end of the shaft. Thisconfiguration gives the balancer greater accuracy along with minimal amount of erroneous readings. Bothmeasuring transducers are arranged in one plane. The tranducers produce a DC output. The DC voltage thatis generated is sent back to the processor.

DISPLAY BOARDThe Display Board receives 5VDC from the Power Supply Board. This 5 volts can be checked at the harnessof the display board X2 pin 6 or at the Power Supply Board X2 pin 6.

KEYPADThe keypad allows operator input to the Main Processor Board. The output signal passes through the PowerSupply 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 BRAKEEarly Model VPI System III onlyThe Power Supply board sends 150VDC to the Electromagnetic brake on the motor stopping the tire andwheel assembly at TDC for the outside weight location. The voltage can be measured at X13 pins 7&8 on thePower 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 PCBhas a 32mb CompactFlash card that stores all screen shots for the balancer the processor interfaces with theMain balancer processor inside the EBox via COM1. The board is powered by 5VDC via cable from the PowerPCB inside the Ebox.

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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 thevoltage reading on the display change?

NO-> Check to make sure string is attached to dis-tance gauge.Replace potentiometer.

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Check F/P 50 with the SAPE in the home position, is thevoltage 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?


Check pins 1 and 3 at connector X7 on the Processor Board.Is the voltage reading 5 VDC +/- 1 volt?


Press F/P 51 and move the SAPE gauge up, does thevoltage 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 thevoltage reading correct?


VI. Width gauge does not work. Is the width arm in the HOME position during power up?


Check pins 1 and 3 at connector X8 on the Processor Board.VPI System III, IV Is the voltage reading 5 VDC +/- 1 volt?


Press F 52 and move the SAPE to the flange, does thevoltage 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 thevoltage reading correct?


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 voltagereading 5 VDC ± 1 volt?

NO-> Replace Auto Lock switch.

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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 the100 gram weight on the inside of the Pruefrotor and spin. Doesthe balancer display 100 gr (3.5 oz) on the inside?

YES-> Move the weight to the outside plane andspin, does the outside plane display 100grams?

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 stabilizewhen the shaft is hit?

NO-> Replace the rear transducer and recalibrate

Check F/P 64 does the right display change and then stabilizewhen 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 andthe 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 assembly. Is the gap correct?

NO-> Adjust gap and retest.

Check voltage at Electro Magnetic switch is 150VDCpresent when brake pedal is pressed?

NO-> Replace Electro Magnetic switch.

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PROCESSOR PCB

X1 - From Power Supply Board.X3 - Encoder, Tranducers & Temp Sensor.

• Pin 6=5 VDCX6 - Distance SAPE

• Pin 1=Gnd

• Pin 2=Output

• Pin 3=5 VDCX7 - Diameter SAPE

• Pin 1=Gnd

• Pin 2=Output

• Pin 3=5 VDCX8 - Width SAPE

• Pin 1=Gnd

• Pin 2=Output

• Pin 3=5 VDCX9 - Serial Connection. To COM1 on

Embedded PCB (Sys IV, BFH)

KEYPAD SCHEMATIC (VPI SYSTEM III)

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KEYPAD SCHEMATIC (VPI SYSTEM I, II)

KEYPAD SCHEMATIC (SNAPON LOW DIGITAL)

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Po

wer S

up

ply B

ox

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To Processor

EMBEDDED PC (JBC SYSTEM IV)

To CRT

To Power PCB

1-11/121-1

AC / DC POWERDISTRIBUTION

02/2003 REV B.

Rod Harrison Fred Rogers

Rod Harrison Fred Rogers

Snap-on Diagnostic355 Exchange AveConway, AR 72032U.S.A.

VPI - I,II,III,IVSnapon Low Digital

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1Effective02/2003

CHAPTER 2THEORY OF OPERATION

FUNCTIONAL DESCRIPTION

The JBC VPI & SOT Wheel balancers are designed to compute static and dynamic imbalance of car, lighttruck, motorcycle and truck wheels.

Wheels are attached to the shaft using precision centering adapters and retainers. The shaft rotates onprecision bearings on the shaft support. The rotating shaft is perfectly balanced. The wheels attachednormally represent an imbalance, which creates centrifugal force and a dynamic momentum as it is spun onthe 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 theshaft support and the machine frame. These transducers contain small discs of special quartz which generatemillivolts of electric current when compressed. The current created is linearly proportional to the compressionforce.

Centrifugal force vectors are generated by imbalances in the rotating wheel. This causes a signal to begenerated by the transducers (which pick up only the vertical component of the constrained forces) in the formof a periodic sine wave.

The signal is not perfectly sinusoidal, due to noises from in the suspension system, which add to the signalgenerated 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 therim and hold. The distance to the rim and the wheel diameter are entered automatically by means of twomounted potentiometers. The rim width can be done automatically by simply pulling the width arm andtouching the outside of the rim (System III,IV only). The rim width may also be done manually by using thesupplied rim width calipers and entering the measured value. This is done by pressing and releasing the rimwidth button and toggling the UP/DOWN arrow keys on the display panel or by rotating the tire and wheelassembly until the desired number is shown.

To find wheel imbalance, the transducers signal magnitude and encoder timing are both required. A series oftiming marks on the shaft that interrupt light transmitted between two optocouplers generate a DC Squarewave each time a mark moves past an optocoupler. One additional mark offset from the encoders’ metallicstrip, interrupts a third optocoupler on the board, creating a zero-signal reset or home position. The encoderdetects 512 angular positions during each turn of the shaft, plus the home or reset position. The frequency ofthe 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 weightamount and location readings.

The CPU board gathers the information generated from the encoder and transducer via a ribbon cable. Thisboard 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.

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CHAPTER 2 THEORY OF OPERATION

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TERMINOLOGY JBC SYSTEM IVBefore using the wheel balancer it is suggested that you become familiar with the terminology and features of themachine’s components. Refer to Figures 2-1 and 2-2 for identification and location

1. Main Screen: Main information screenfor the user interface.

2. Function Key area: Six function keys F1to F6, the functionality of the keys canchange in every screen. Represents thefunction of the keys on the keyboard.

3. Status Area: Status informationfrom top to bottom, balancer model andsoftware revision, date and time, screenname, balancer status (i.e. adapter com-pensation active, loaded user), error mes-sages.

4. Start - Start Spin CycleStop - Stop the Main ShaftEscape - Moves back one pageHelp - Go to Help Screen

6. Foot Operated Shaft Lock - A foot oper-ated shaft lock is used to stabilize the shaftduring the weight placement process.

7. Shaft Adapter - A common 40 mm sizeshaft is used. The easily removable shaftcan be replaced for service or during useof certain wheel adapters.

8. Wheel Guard - The standard wheel guardis 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 israised.

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 automaticallyinput with the SAPE by touching the out-side of the wheel where the weight will belocated.

11. Display - Easy to read, user friendly dis-play featuring large LEDs and one buttonfunctions.

12. Accessory Storage - Four sturdy sidemounted pegs are supplied for storage.

13. Weight Storage Tray - Generous storagefor a variety of weight profiles and sizes aswell as built in storage pockets for the stan-dard centering cones

MainScreen

FunctionKeyArea

StatusArea


Page 2-3Effective02/2003

TERMINOLOGY JBC SYSTEM IIIBefore using the wheel balancer it is suggested thatyou become familiar with the terminology and featuresof the machine’s components. Refer to Figures 2-1and 2-2 for identification and location.

1. Inside Weight Amount and Function DisplayWindow - Shows inside or left weight amount andvarious operation messages.

2. Position Indicator LEDs - Displays the locationfor wheel weight placement.

3. Middle Display - Used to display wheel param-eters or messages.

4. Outside Weight Amount and Function DisplayWindow Shows outside or right weight amount andvarious operation messages.

5. Fine Mode Indicator - When lit indicates the bal-ancer is in the “Fine Mode”.

6. Weight Mode and Placement Display - Displaysa pictorial reference of the chosen balance mode.

7. Multi-Operator Selection - This key toggles be-tween four operators designated as A, B, C, and D.Wheel parameters are recalled upon command.NOTE: ROTATING THE SHAFT IN EITHER DIREC-TION WILL ALSO VARY DISPLAYED VALUES.

8. ALU-S Activates the ALU-S mode.9. Function Button - Used to activate the various

functions. Press this button followed by pressingthe up or down arrow buttons until the desired num-ber is displayed. Press the “Enter” button to activethe function.

10. Spoke Mode - Activates the Spoke Mode.11. Rim Offset - Key is used to enter the rim offset

position using numbers from the distance gauge.Rim Diameter - Enter the rim diameter. Read thesize stated on the tire sidewall.Rim Width - Press this key to enter the rim width.Use the rim width calipers for measurement

12. Fine Weight Toggle - In normal mode “FIN OFF”round off is 0.25 oz or 5 gram, fine mode “FINON” round off is 0.05 oz. or 1 gram.

13. Cancel - Pressing this key interrupts any process.

14. Enter - This key activates whatever selection hasbeen requested, it also spins the wheel if guardframe is down.

15. Mode Selection - A series of placement locationsfor custom weight location. Useful for the wide va-riety of custom wheels on today's market.

16. Up and Down Value - Buttons are used to raise orlower displayed values for parameter entry or func-tion code activation.

17. Spoke Mode Indicator - When lit indicates thebalancer is in the “Spoke Mode”.

18. Foot Operated Shaft Lock - A foot operated shaftlock is used to stabilize the shaft during the weightplacement process.

19. Shaft Adapter - A common 40 mm size shaft isused. The easily removable shaft can be replacedfor service or during use of certain wheel adapters.

20. Wheel Guard - The standard wheel guard is asafety feature for prevention of operator injury inthe event of loose weights, debris or wheel mount-ing failure. The balancer is programed to spin uponguard closure as well as brake when the guard israised.

21. Semi-Automatic Parameter Arm - Rim distanceis automatically input with the SAPE. The SAPE isalso used in several procedures for determiningaccurate rim profiles.

22. 3DP SAPE - Rim width is automatically input withthe SAPE by touching the outside of the wheelwhere the weight will be located.

23. Display - Easy to read, user friendly display fea-turing large LEDs and one button functions.

24. Accessory Storage - Four sturdy side mountedpegs are supplied for storage.

25. Weight Storage Tray - Generous storage for a va-riety of weight profiles and sizes as well as built instorage pockets for the standard centering cones.

Figure 2-1

Figure 2-2

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TERMINOLOGY JBC SYSTEM I, II

12. ALU-S and Spoke Mode - Activates the ALU-S orSpoke Mode. Each time this button is pressed pro-gramming toggles between the two.

13. Rim Offset - This key is used to enter the rim off-set position using the numbers from the distancegauge.

14. Multi-Operator Selection - This key toggles be-tween four operators designated as A, B, C, and D.Wheel parameters are recalled upon command.

15. Display - Easy to read, user friendly display fea-turing large LEDs and one button functions.

16. Weight Storage Tray - Generous storage for avariety of weight profiles and sizes as well as builtin storage pockets for the standard centering cones.

17. Accessory Storage - Four sturdy side mountedpegs are supplied for storage of additional acces-sories.

18. Foot Operated Shaft Lock - A foot operated shaftlock is used to stabilize the shaft during the weightplacement process.

19. Shaft Adapter - A common 40 mm size shaft isused. The easily removable shaft can be replacedfor service or during use of certain wheel adapters.

20. Wheel Guard - The standard wheel guard is asafety feature for prevention of operator injury inthe event of loose weights, debris or wheel mount-ing failure. The balancer is programed to spin uponguard closure as well as brake when the guard israised.

21. Semi-Automatic Parameter Arm - Rim distanceis automatically input with the SAPE. The SAPE isalso used in several procedures for determiningaccurate rim profiles.

Figure 2-4

Figure 2-3 Display Layout

Before using the wheel balancer it is suggested thatyou become familiar with the terminology and fea-tures of the machine’s components. Refer to Figures2-3 and 2-4 for identification and location.

1. Inside Weight Amount and Function DisplayWindow - Shows inside or left weight amount andvarious operation messages.

2. Position Indicator LEDs - Displays the locationfor wheel weight placement.

3. Outside Weight Amount and Function DisplayWindow Shows outside or right weight amount andvarious operation messages.

4. Weight Mode and Placement Display - Displaysa pictorial reference of the chosen balance mode.

5. Function Button - Used to activate the variousfunctions. Press this button followed by pressingthe up or down arrow buttons until the desired num-ber is displayed. Press the “Enter” button to activethe function.

6. Enter - This key activates whatever selection hasbeen requested, it also spins the wheel if guardframe is down.

7. Up and Down Value - Buttons are used to raise orlower displayed values for parameter entry or func-tion code activation.NOTE: ROTATING THE SHAFT IN EITHER DI-RECTION WILL ALSO VARY DISPLAYED VAL-UES.

8. Cancel - Pressing this key interrupts any process.9. Mode Selection - A series of placement locations

for custom weight location. Useful for the wide va-riety of custom wheels on today's market.

10. Rim Width - Press this key to enter the rim width.Use the rim width calipers for measurement.

11. Rim Diameter - Enter the rim diameter after press-ing this key. Read the size stated on the tiresidewall.



TERMINOLOGY SNAPON LOW DIGITAL

Before using the wheel balancer it is suggested that youbecome familiar with the terminology of the machine’scomponents. Refer to Figures 2-5 and 2-6.

1. Display for inner plane imbalance2. Inner plane imbalance position indicator3. Operator / Rim width4. Outer plane imbalance position indicator5. Display for outer plane imbalance6. Display all parameters button7. Fine-Normal button8. Operator A-B-C-D toggle9. Function button - “P” codes10. Mode select button11. Balance mode indicator12. Rim width knob & manual distance entry13. Cancel/Stop button14. Manual Rim diameter15. Manaul Rim offset button16. ALU-S button17. Enter / Start button18. Wheel weight tray19. Accessories storage location20. (SAPE) gauge21. Arbor - shaft adapter22. Foot operated shaft lock23. Wheel Guard

Figure 2-5 Display Layout

12 3 4

5

17

16

15

14

13121110

6

7

9

8

Figure 2-6

18

19

20

21

22

23

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BALANCER COMPONENTS

MAIN PROCESSOR PCBThe microcontroller normally takes its instructions from the FLASH memory. A 40-pin IC socket is used totransfer the program from an EPROM to FLASH memory. Unlike EPROMs, FLASH memories do not requirewindows for UV light in order to delete data - they can be cleared and programmed electronically. Unlessotherwise 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 theencoder, transducers and SAPE potentiometers. Calibration factors are stored in this location along with theencoder PCB.

POWER SUPPLY PCBThe Power Supply Board receives 230VAC from the power cable (System II,III). The Power Supply Board ona 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 ProcessorBoard, Encoder PCB & both SAPE potentiometers.

KEYPADThe keypad is used to input data into the Display PCB. It connects directly to the display pcb via a ribboncable.

NOTE: ALL BUTTONS FUNCTION AS AN EMERGENCY STOP BUTTON WHEN THE MOTOR ISSPINNING

DISPLAY PCBThe Display PCB receives power directly from the power supply pcb. It passes 5VDC to power the tonegenerator and the LED display. It receives the information from the Main Processor Board via the powersupply pcb. This information is passed back to the Main Processor routed through the Power Supply Board.

TEMPERATURE SENSORThe system has a new force guidance structure (patent pending). The forces at the measuring transducershave been reduced, thus achieving long-term stability and high measuring accuracy. Pre-tensioning of thetransducers is achieved by two leaf springs. On the vibratory system the measuring transducers are veryclose together so that the difference in temperature has only a slight effect. The current vibratory sensor has atemperature sensor. The transducers can therefore be measured by one temperature sensor and taken intoaccount 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 MOTORThe drive unit is mounted directly to the vibratory system by means of (4) bolts. Three of the mounting holesare slotted, these are used for setting the tension on the drive belt. The drive belt is used to drive a largepulley which is mounted directly to the drive shaft of the vibratory system.

TRANSDUCERSThe transducers are installed in a manner that they form a virtual transducer on each end of the shaft. Thisgives the balancer greater accuracy along with minimal amount of erroneous readings. Both measuringtransducers are arranged in one plane. The rear transducer picks up the alternating forces of the left-handvirtual measuring plane and is supported on the machine housing. The front measuring transducer isclamped between the vibratory tube and vibratory plate and transforms the alternating forces of the right-handvirtual plane into electrical signals.



SAPE (SEMI-AUTOMATIC-PARAMETER-ENTRY)

Brand SAPE DisplayJBC System I 1D 2 WindowJBC System II 2D 2 WindowSOT LD 2D 3 WindowJBC System III 2D 3 WindowJBC System IV 2D CRT

3 Window DisplayEvery time the machine powers on, the software automatically checks the SAPE system in its initializationprocedure. The SAPE’s must be in the HOME position during start up. If the SAPE is good the machineenters 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 bothof them fail, the machine displays “2-D” “SAP” “FAL”. The operator needs to press the STOP button to exitthe display and enter idle state. The machine masks the function of the failed part after SAPE check. Forexample, if the diameter gauge fails, the machine disables the measurement of diameter and measures thedistance only. Or if the distance gauge fails the machine disables the measurement of the distance gauge andmeasures the diameter only.

2 Window DisplayIf the distance gauge fails, the machine displays “DIS” “FAL” when the machine is powered on. If diametergauge 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 operatorneeds to press the STOP button to exit the display and enter idle state. The machine masks the function ofthe 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 themeasurement 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 outand up towards the wheel the voltage(s) change. The distance from the balancer to the wheel is generatedfrom the voltage output and the diameter of the wheel is generated from the amount of voltage output whenthe arm is moved up. Adjustment are made using the F/P 50, F/P 51 and F 52 code, this procedure can befound later in this manual.

ENCODERThe encoder disk is built onto the shaft. It cannot be adjusted and can only be replaced by replacing thevibratory member. The new incremental encoder is fitted in the vibratory tube and consists of a reflectiveslotted sleeve which is mounted on the main shaft and the optoelectronic unit. To prevent dirt and lightentering, the opening in the vibratory tube must be sealed with black adhesive tape. A red visible LED andfour light detectors are fitted in the encoder part of the optoelectronic unit behind the lenses. Part of the light isreflected back from the webs of the slotted sleeve to the encoder part and focussed by the lens, such that theweb-slot pattern of the sleeve is mapped on the four light detectors. Two light detectors are connected to oneamplifier 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 guaranteereliability 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. Thesurface of the slotted sleeve must be clean and shiny, the slots must have a dull black background. Should adirt particle have settled on a web or in a slot, it can be lifted off of the slotted sleeve with self-adhesive tapeby 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 bereplaced in the field because the ball bearings of the main shaft are pressed in. The incremental encoder canbe checked with test functions F/P 36. The calibration factors are stored in this location along with the MainPCB.

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VIBRATORY SYSTEMThe vibratory member is the foundation of the balancer. It houses the encoder and transducers along with atemperature sensor for the tranducers.

ELECTROMAGNETIC BRAKEThe electromagnetic brake is used on earlier JBC System III balancers. Once the balancer reaches a lowRPM the Main Processor looks for the outside weight position. Once this location is known the Processorsends a command to the Power Supply Board to turn on the Electromagnetic brake. The Power Supply boardsends 150VDC to the Electromagnetic brake on the motor stopping the tire and wheel assembly at TDC forthe outside weight location. Once the weight is applied the operator can then press the “F” button, this sendsthe command to the Main Processor which in turns sends a command to the Power Supply Board to rotate themotor. 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 theinside 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 thewheel. 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 ofwhere the weight will be applied. Once these parameters are known after cycling the tire and wheel throughit’s spin cycle the operator can then apply the correct amount of sticky weight to the weight applicator on theend of the SAPE arm and pull the SAPE arm towards the tire and wheel assembly. D1 and TDC determineswhen to auto lock the SAPE arm to apply the sticky weight. The Power Supply Board sends 5VDC to the autolock switch engaging it to lock the SAPE arm. Once the weight is applied the outside sticky weight is appliedto the weight applicator and the operator pulls the SAPE arm towards the tire and wheel assembly. D2 andTDC determines when to auto lock the SAPE arm and apply the sticky weight. The Power Supply Boardsends 5VDC to the auto lock switch engaging it to lock the SAPE arm.

1Effective08/2004

CHAPTER 3CHECKOUT, CALIBRATION AND MAINTENANCE

GENERALThis Chapter incorporates all motorized “Y2k” balancers manufactured in Conway Arkansas. The test codesfor each digital display balancer are alike, and so are the results. This Chapter is written using the 3 windowdisplay results, if a two window display balancer is being serviced the display will be abbreviated from the 3window 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 bedisplayed 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 deviceinside 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 assemblyto 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 doesnot 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 andsmooth. Clean and retest. Check all mounting accessories cones, wingnut etc. making sure each fit onthe 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 shafttapered mounting surface. Acceptable tolerance is 0.0015" T.I.R. (Total Indicated Runout). If the surfacemeasures 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 eliminatingpotential 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. Withproper 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 sequenceevery time. A balancer must:

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CHAPTER 3 CHECKOUT, CALIBRATION AND MAINTENANCE

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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.BrakeDisplay 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 requiresinput 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 problemsshould 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 powerand ground. Check DC power for ripple or drift ( may indicate faulty regulation or failing PCB's). Ensurethere 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

ToolsMetric Sockets (4mm Thru 15mm)Metric Wrenches (6mm Thru 15mm)Assorted Hex Wrenches metric / standardInch Pound Torque WrenchFoot Pound Torque Wrench#2 Phillips Screwdriver#2 Flat Head ScrewdriverDigital Volt-ohm MeterSmall ScrewdriverHilti Rotor hammer drill (Installation Option)Pruefrotor (H6416946) or fine balancedtire/wheel assembly.3.50 ounce (100gr) wheel weightProgram EPROMLoctite #242 and #272 or #609Silicone based grease - Used for transducer ball place-mentPutty for fine wheel balancing.1, 2 and 3 ounce weights verified accurate (weigh on postalscales 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 toconfirm conformance to design specifications and certification requirements.

Mounting the Pruefrotor

Figure 3-1

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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 describedbelow.

1. Press and release the <F/P> key, the left window displays letter “F/P” and right window displays currentF/P code number.

2. Use the <UP> and <DOWN> arrow keys(JBC) or <Rotate> the right hand rotory knob (SOT), or rotatethe shaft to increase or decrease the number in the RH display until the desired F/P code is displayed.

3. In general, the F/P code will display some brief information to the operator for 1 or 2 seconds, and themachine enters the corresponding function.

SERVICE CODESThe 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 counters14 Calibration by user18 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 test55 Check AC and DC voltages59 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 SAPE83 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 settings94 Spoke mode.95 Clean and reset EEPROM 1 & 2.97 Sticky at Top.

99 SAPE 2 Accuracy test.

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F/P CODE DESCRIPTIONS OF THE BALANCER

F/P 1 TOGGLE FINE WEIGHT MODEWhen 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 onesecond (round off 0.25 oz or 5 gram).

F/P 2 RIM WIDTH INCH / MILLIMETERSelecting F/P 2 toggles the balancer between inch and millimeters for rim width. Unit will display “DtH INCH” for inches pressing F/P 2 again toggles to millimeters and the display changes to “DtH” for millime-ters.

F/P 3 GRAM / OUNCESelecting F/P 3 toggles the balancer between Grams and Ounces. Unit will display “ “ “OU” “NCE” forounce 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 COMPENSATIONSome special tires and those wheels whose center holes are not the primary reference but are lug-centricrequire an adapter. Lug-centric identifies that the tire and wheel assembly to be centered on it’s axis ofrotation must be mounted using the lug pattern instead of the center hole of the wheel. In this case, theadapter 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 andadapter together and saves it in memory and set an adapter compensation flag to tell the program to useadapter 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 andcalculation, it displays “CAL BAL” to tell the operator the machine is working on the balancingprocedure. Once the calibration is done, machine displays “ADP” “FIN” to indicate the calibrationis 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 isdifferent than ordinary balancing. In ordinary balancing the machine displays “---” “2PL” while themachine is taking data. In balancing with an adapter, the machine displays “AdP” “2PL” as it takesdata. This reminds the operator he is under adapter compensation mode. So if the operator doesnot use an adapter and the machine displays “AdP” in left the window, the operator should turn offthe adapter compensation by toggling <F> <4>, or by cycling power.

F/P 7 TOGGLE MILLIMETER AND INCH FOR DIAMETERIf a metric tire is to be balanced, the diameter can be changed to enter the tire parameters in millimetersinstead of inches. The default is set to inches. Pressing <F/P7> again toggles the balancer and forthbetween inches and millimeters. “DIA” “--I” “NCH” = inches, “DIA” “---” “---” = millimeters.

F/P 12 READ COUNTERSThe 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 <F/P12> is activated. The order of the counters.

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.

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F/P 14 USER CALIBRATION PROCEDUREThe JBC VPI and SOT balancers feature a user calibra-tion program which requires only a few minutes tocomplete. Perform this procedure when the balancerhas been moved, disturbed, or whenever accuracy isquestioned. Occasional field calibration will ensure yearsof reliable service.

1. Activate Calibration. Press and release the <F>key, toggle the <UP / DOWN> arrow keys (Figure 3-2a) or Press and hold the key while turning theDiameter/Function Knobuntil the display reads “F/P”“14” (Figure 3-2b).• Once F/P14 activates, the display will read

“CAL” “GAN” for one second.• The display will then read “SPN” “1”.

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 anddoing calculations. After taking data, shaft isautomatically 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 istaking data and doing calculation work. Aftertaking data, shaft is automatically stopped.

• Displays “CAL” “FIN” “ISH” when the secondstep of calibration is finished and machine saysthe calibration result is FINE.

• Displays “---” “---” when shaft stops andmachine is in the idle state.

CALIBRATION COMPLETE

NOTE: THE BALANCER WILL NOT FUNCTIONUNTIL A VALID CALIBRATION HAS BEENPERFORMED. ERROR MESSAGESWOULD BE DISPLAYED IN THE EVENTPROBLEMS OCCUR DURING THE CALI-BRATION PROCESS.

Up / DownKeys F Key

Figure 3-2a

Figure 3-3

Figure 3-4

DiameterFunction

P Key

Figure 3-2b

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F/P 18 ALU-S MODEAluminum Static: See the operation manual for a detailed explanation.

F/P 19 ALU-S ONE PLANE BALANCING MODEAluminum Static: See the operation manual for a detailed explanation.

F/P 21 KERNEL SOFTWAREWhen F/P21 is activated the machine display changes to “REV” “ISI” “ON” for 1 second. The display thenchanges to “Obj” “???” “???” for 3 seconds, this is the persistent object revision. The number means therelease date of the object. For example, if the number is Obj 20 729, it indicates year of 2002, month of Julyand date of 29th. The display then changes to “B--” “???” “???” for 3 seconds, this is the balancing kernelrevision Ex: “B” 1.21” (Balancing Kernel rev 1.21). The display then changes to “UI-” “???” “???” for 3seconds, 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 MESSAGESEnter F/P 28 the machine will display “CHC Err” for 2 seconds and then display “Err 0” for 1 second followedby the error code. Pressing the <F> again will toggle the machine to the 2nd recorded error code and soforth. The balancer can display up to 10 error codes after which the display will display “CLN ERR” allowingthe operator to clean all recorded error codes by pressing the <F> the final time and clearing all codes orpressing the <STOP> key will cancel the “Clean” operation for further diagnostics.

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 displaysencoder position in integer form (from 0 to 511) in left window and angle in floating form (from 0.00 to 359) inright window. Meanwhile, machine lights on the position bars to indicate the left weight position. So workingwith number and position LEDs, it is very easy to find the left weight’s position value and angle value. Onceuser presses <F/P> key, this function switches to fine right weight position value and angle value. Thisfunction is very useful to check the position accuracy. Press the <STOP> key to exit this function.

F/P 43 RESETTING THE COUNTERSThe counter can be reset using this code:

1. Press and release the <F> key, toggle the <UP / DOWN> arrow or Press and hold the key whileturning 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 USERThis displays or resets the total number of spins for either operator A,B,C or D depending what is chosen onthe main display.

1. Choose the operator that you would like to read or reset from the main PCB by pressing the operatormode key (A,B,C or D).

2. Press and release the <F> key, toggle the <UP / DOWN> arrow keys or Press and hold the keywhile turning the Diameter/Function Knob until “F/P” “44” is displayed and press <ENTER>. Thebalancer will display “A” “Ctr” or “B” “Ctr” or “C” “Ctr” or “D” “Ctr”.

3. The next display shows the total number of spins for the operator chosen. Press the <STOP> key whilethis number is displayed.

4. The total number of spins for that operator is now reset to zero.5. The display changes to “rSt” “A” or “rSt” “b” for 1 second.

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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 <F> key, toggle the <UP / DOWN> arrow keys or press and hold 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 <F> key, toggle the <UP / DOWN> arrow keys or press and hold the key while

turning the Diameter/Function Knob until “F/P” “51” is displayed and press enter3. 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 POTENTIOMETERThis 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> key, toggle the <UP / DOWN>” arrow keys until “F” “52” is displayed and

press enter3. Displays “A8” “dTH” and then changes to “A8” “dTH” “___” The voltage should read 4.35VDC ± 0.05

in the home position and greater than 0.15VDC when the tip of the SAPE arm is touching the backingcollar.

F/P 53 DISPLAY TESTUsed to diagnose the display panel. Once activated the display will either scroll a message or all LED’s willlight up. Pressing <STOP> displays “Goo” “_d_” “ByE” and cancels this test.

F/P 55 CHECK AC AND DC VOLTAGESPress and release the <F> key, toggle the <UP / DOWN> arrow keys or press and hold the key whileturning the Diameter/Function Knob until “F/P” “55” is displayed and press enter. Machine displays “POrVOL 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 stepup transformer generates 230VAC on these units. Press STOP button to exit this function.

F/P 59 DISPLAYS THE UNBALANCE OF THE BARE SHAFTPress and release the <F> key, toggle the <UP / DOWN> arrow keys or press and hold the key whileturning 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 <STOP> to exit this function.

F/P 60 READ SHAFT RPMThis test displays the motor RPM, a reading of 190 RPM’s +/- 10 on a VPI III and SOT Low Digital or 90RPM’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 BALANCINGMount a tire and wheel assembly. Activating this code puts the balancer in a continuous spin cycle andupdates the amount of imbalance every 5 seconds. Press <STOP> to cancel this test.

F/P 64 DISPLAYS THE TRANSDUCER OUTPUTTransducer 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 shaftrearward the read should display negative, forcing the shaft forward the reading should display a positivevoltage. Press the F/P key to toggle to the front transducer (2).

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F79 CALIBRATION OF WIDTH SAPENOTE: THIS PROCEDURE IS PART OF THE F80.

1. Press and release the <F> key, toggle the <UP /DOWN> arrow keys until “F” “79” is displayed andpress <ENTER> to activate function of F79. Onceactivated the display will change to “CAL” “SAP”“E2” for one second and the changes to “DIS”“tO” “FLA”.

2. Pull the distance gauge to the outside flange of thebacking collar, use the flat head of the calibrationweight as an index (Figure 3-5a). After a shortbeep the machine displays “bAC” “H” “POS” andchanges to “tO” “FLA” “NGE”.

NOTE: THIS STEP HAS BEEN ADDED TOBK1.21 SOFTWARE. SKIP TO STEP 3FOR EARLIER SOFTWARE.

3. Touch the tip of the width gauge to the face plateand hold it for one second or press the <F> button(Figure 3-5). The display will change to “bAC “H’‘POS” followed by a tone. Return the SAPE arm tothe home position.

4. Display will then change to “tO” “CAL” “SLG”.Screw the calibration weight onto the outside of theflange. Touch the tip of the width gauge to the tipof the calibration slug and hold it for one second orpress the <F> button (Figure 3-6). The display willchange to “SAP” “E-2” “FIN” for one secondfollowed by a tone indicating a successful calibra-tion. Unit will then go into an idle state.


Figure 3-5

Figure 3-6

Figure 3-5a

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F/P 80 SAPE GAUGE CALIBRATIONTo calibrate the SAPE gauge.

1. Make sure the SAPE arm is in the home position asshown in (Figure 3-7).

NOTE: WEIGHT TRAY MUST BE INSTALLED

2. Activate the gauge calibration program. Press andrelease the <F> key, toggle the <UP / DOWN> button orpress and hold the key while turning the Diameter/Function Knob until 80 is displayed on right displaywindow and press enter.

3. The right display will read "CAL” “3-D” “SAP" for onesecond (Do not move the arm at this point) this meansCALibration 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 willsound.

5. Display will read “bAC” “H” “POS” followed by abeep. Return the arm to the home position.

NOTE: STEP 5 IS THE LAST STEP FOR A VPISYSTEM I BALANCER.

6. Display changes to “dIA” “ -18” “POS”.

7. Gently pull the SAPE out and rest the arm of the SAPEgauge on the inner part of the bell housing as shown in(Figure 3-9). A tone will sound and the display willchange to “bAC” “H” “POS”.

8. Return the arm to the home position. The display willchange to “dIA” “42.1” “POS”.

9. Locate the Calibration Weight. Place the calibrationweight with the large end oriented on the bell collar.Extend the SAPE arm outward and rotate the extensionto just touch the end of the calibration weight as shownin (Figure 3-10). A tone will sound and the display willchange to “bAC” “H” “POS”. Return the SAPE arm tothe home position.

NOTE: THE REMAINING STEPS APPLY ONLY TOTHE VPI SYSTEM III BALANCER.

Figure 3-7

Figure 3-8

Figure 3-9

Figure 3-10

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10 The display will change to “SAP” “E-1” “FIN” for onesecond and the changes to “dis” “to” “FLA”.

11. Pull the distance gauge to the outside flange of the backingcollar, use the flat head of the calibration weight as anindex (Figure 3-11a). After a short beep the machinedisplays “bAC” “H” “POS” and changes to “tO” “FLA”“NGE”.

NOTE: THIS STEP HAS BEEN ADDED TO BK1.21SOFTWARE. SKIP TO STEP 11 FOR EARLIERSOFTWARE.

11. Touch the tip of the width gauge to the backing collar andhold it for one second or press the <F> button (Figure 3-11). The display will change to “bAC “H’ ‘POS” followed by atone. Return the SAPE arm to the home position.

12. Display will then change to “tO” “CAL” “SLG”. Screw thecalibration weight onto the outside of the flange. Touch thetip of the width gauge to the tip of the calibration slug andhold it for one second or press the “F” button (Figure 3-12). The display will change to “SAP” “E-2” “FIN” for onesecond followed by a tone indicating a successful calibra-tion. Unit will then go into an idle state.

CALIBRATION COMPLETEFigure 3-12

Figure 3-11a

Figure 3-11

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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 calibrationprocedures are the same and can easily be performed. However custom parameters must be used for thisprocedure 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 <F> key, toggle the <UP / DOWN> arrow keys or press and hold the keywhile turning the Diameter/Function Knob until “F/P” “83” is displayed and press <ENTER> to activatefunction of F/P 83.

• After entering the F/P83 function the balancer will automatically switch to default parameters (15” X6.5”).

• Press the <F/P> button to change from default parameters to user defined parameters. The display willchange to “USE” “CST” “PAR” for one second and then display “SPN” “1”. Pressing the <F/P> buttonagain will toggle the unit back to factory defaults.

NOTE: IF A TIRE AND WHEEL ASSEMBLY IS USEDPROCEED 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.

4. Press and release the <F> key, toggle the <UP / DOWN>button or press and hold the key while turning theDiameter/Function Knob until “F/P 83” is displayed. Thedisplay 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 thehood or pressing the enter key. The board displays theinformation in the following order.• Displays “CAL” “1” when the shaft reaches calibra-

tion speed. The machine is taking data and doingcalculations. After taking data, shaft is automaticallybraked to a stopped.


Figure 3-13

Figure 3-14

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7. Attach the 3.5 ounce weight (100 gr) on the inside of thePruefrotor/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 takingdata, shaft is automatically braked to a stopped.


8. Attach the 3.5 ounce weight (100 gr) on the outside of thePruefrotor/Tire & Wheel. (Figure 3-16)

NOTE: IF USING A TIRE AND WHEEL ASSEMBLY ATTACHTHE 3.5 OZ WEIGHT ON THE OUTSIDE 180 DE-GREES OPPOSITE THE INSIDE WEIGHT LOCATION.

• Spin the Pruefrotor/Tire & Wheel by lowering the hood orpressing the enter key.

• Displays “CAL” ‘3” when the shaft reaches calibrationspeed. 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 topress the <F/P> key to continue calibration, or operator canpress the <STOP> key to exit out of calibration, basiccalibration is all that is performed.

NOTE: IF THIS IS THE FIRST TIME FOR FACTORY CALI-BRATION AND THE OPERATOR PRESSES THESTOP KEY TO STOP THE REMAINDER OF CALIBRA-TION F14 WILL NOT BE AVAILABLE TO THE OPERA-TOR.

9. Press <F/P> to continue calibration.• Displays “SPN” “4”

10. Remove the Pruefrotor/Tire & Wheel from the shaft• Spin the empty shaft by lowering the hood or pressing the

enter key (Figure 3-17). The board displays the informationin the following order.

• Displays “CAL” ‘4” when the shaft reaches calibrationspeed. The machine is taking data and doing calculations.After taking data, shaft is automatically braked to a stopped.


11. Install the calibration slug on the left side of the bell housing.(Figure 3-18) Spin the shaft by lowering the hood or by pressingthe enter key.• Displays “CAL” “5” 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” “FIN” “ISH” after a successful calibration.• Displays “---” “---” when shaft stops and machine is in a

stand-by mode. Must complete F/P 84 after this function!


Figure 3-15

Figure 3-16

Figure 3-17

Figure 3-18

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F/P 84 EMPTY SHAFT CALIBRATION PROCEDURE

1. Press and release the <F> key, toggle the <UP / DOWN> button or press and hold the key whileturning 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 <ENTER> button or lower the hood.The board displays the following information.• Displays “CAL” “ 1” when the shaft reaches calibration speed. The machine is taking data and

doing calculations. After taking data, shaft is automatically braked to a stopped. Then displays“CAL” “SHF” “FIN” for one second. The machine displays the shaft resident unbalances in finemode. The fine mode LED indicator is automatically on.

• By pressing <STOP> key to exit F84 and return to idle state. The fine mode LED indicator is auto-matically turned off.

F/P 85 COPY CONTENTS OF MAIN PCB TO ENCODERWhen an Encoder PCB is replaced and on initial power up the unit will display “F/P 85”. The technicianneeds to simply press the <F/P> key to transfer the calibration factors from the Main PCB over to the newEncoder. To change the display from 85 to 86 simply press the <UP ARROW>.

F/P 86 COPY CONTENTS OF ENCODER TO MAIN PCB - BK 1.211. 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 initialpower up the unit will display “F/P 86 S-b” meaning copy the (S)haft contents to the (b)oard. Simply pressthe <F/P> key to transfer the calibration contents from the Encoder to the Main PCB.Senario 2If the “BK” software has changed, the machine will reset. After resetting the balancer will display the propermodel of software that matches the balancer if all SAPE arms are in good working order. Press the <SPIN>button to set the model correctly.Senario 3If the “BK” software has changed, the balancer will reset. If the SAPE arms are not adjusted correctly thebalancer may display the model that does not the balancer. Example: VPI System II with an out of adjust-ment or broken diameter potentiometer the unit may display JBC 1 instead of JBC 2, or it may display someSAPE failure. If the balancer does not display the correct model, the operator can simply press the <F/P>button to switch the software to display the correct model of balancer and then press the <SPIN> button toset the model. The balancer may display “Sur E” asking the operator if he/she is SURE, if the answer is yespress the <SPIN> button again to force the model.

F/P 90 MATCH BALANCEMatches the tire to the wheel. See operators manual for detailed information.

F/P 91 OPTIMIZATIONSee operators manual for details.

F/P 92 SPLIT WEIGHTSee operators manual for details.

F/P 93 CHANGE MODEL SETTINGIf the balancer is loaded with the incorrect software the technician can manually adjust the balancer for the

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correct operating system. Example: If a VPI System III is loaded with SOT Low Digital software.1. Press and release the <F> key, rotate the shaft or press and hold 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 righthand display.

2. Press the <F/P> continuously to increase 0 to 7 and press the <SPIN> button to enter the number 7.Balancer will then display 70.

3. Press the <F/P> button continously to increase 70 to 72 and press the <SPIN> button to enter thenumber 72.

4. Continue to process until the number in the display reaches “72032” (Conway Zip Code), at this timethe display will change to “YES”. Press the <SPIN> button to enter the number “72032”.

5. The machine will then display “Ent” “SEt” “brd” (3 window) or “Ent” SEt” (2 window) to indicate thesoftware model is set.

NOTE: ALL FACTORY CALIBRATION PROCEDURES ARE REQUIRED.

F/P 94 SPOKE MODESee operators manual for details.

F/P 95 CLEAN & RESET EEPROM 1 & 2Care should be taken before running this function. All information in the EEPROM will be lost includingmanufacture calibration which can not be reversed once performed. However this function can be veryuseful if data is corrupted on the EEPROM’s. Performing this function can be much quicker than re-flashingthe software.

1. Press and release the <F> key, toggle the <UP / DOWN> button or press and hold the key whileturning the Diameter/Function Knob until “F/P” “95” is displayed. The machine displays “CLN EEP”immediately. The user can press the <STOP> button at anytime before step 5 to abort this procedure.

2. Press F/P button, the balancer displays “ 1 1 1 “.

3. Press F/P button again, the balancer displays “ 2 2 2 “.

4. Press F/P button again, the balancer displays “ 3 3 3 “.

5. If user press F button again, balancer displays “ CLN EEP” and erases all information in the EEPROMand resets the machine.

NOTE: ALL FACTORY CALIBRATION PROCEDURES ARE REQUIRED.

F/P 97 STICKY AT TOP STOP AT TOPUsed to turn “Sticky at Top” on or off. Press <F> <97> <ENTER> display changes to “STY” “TOP” “ON”sticky at top is now on. Pressing <F> <97> <ENTER> again changes the display to read “STY” “TOP”“OFF” sticky at top is now off.

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F99 SAPE-2 ACCURACY TESTThe 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 flatedge. (Figure 3-19)

3. Press and release the <F> key, toggle the <UP / DOWN>arrow keys until “F” “99” is displayed and press <ENTER> toactivate function of F99.

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.

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 REQUIREDVALUES PERFORM AN F79 AND RETEST. Figure 3-21

Figure 3-20

Figure 3-19

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SERVICING THE BALANCER

NOTE: BEFORE OPENING THE MACHINE FOR SERVICE, DISCONNECT ELECTRICAL SUPPLY LINEAND 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 thebalancer to operate correctly. The balancer performs a systems check on initial power up. If a problem isdetected 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 & REPLACEMENTThe 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 VPIand 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 nutsholding it onto the backing plate.

• Once the keypad is removed from the backing panel it cannot be reused. The keypad can beremoved by gently peeling back at a corner. If a keypad is suspect for replacement, it is suggestedtesting a new keypad before replacement.

DisplayBacking

Membrane

!DANGEROUS HIGH VOLTAGES ARE PRESENT IN

THIS EQUIPMENT

Figure 3-22

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MAIN PROCESSOR REPLACEMENTBefore flashing the new Main PCB, check and adjust the SAPE potentiometers for the correct voltagesettings (F/P 50, F/P51, F52) see chart below. If some part of a SAPE is broken and cannot be repairedimmediately the technician can still down load the software, however some manual model settings will berequired (See Senario 3).

Checks should also be made on the part number of the processor mounted on the Processor PCB. Earlybalancers manufactured prior to December 2002 contained a part number on the processor ofEAP0201D00A. This processor can be flashed with all releases of BK software up to 1.21. Balancersmanufactured after November 2002 carries the part number EAP0201D00C. These processor will onlyaccept BK 1.21 or greater software.

SAPE voltage readings in the HOME positionF50: Distance F51: Diameter F52: Width

Model With Weight Tray No Weight TrayJBC System 1 3.9 – 4.1JBC System 2 4.2 – 4.4 2.8 – 2.9 3.2 – 3.4JBC System 3 4.2 – 4.4 2.8 – 2.9 3.2 – 3.4 4.3 – 4.4Snapon Low Digital 4.2 – 4.4 2.8 – 2.9 3.2 – 3.4Software 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 ofthe Display PCB for the Handspin or in thePower Supply Box on the motorized balancer.

3. Insert the program EEPROM in the socket onthe processor board. (Figure 3-23)

NOTE: THE NOTCH ON THE END FACE OFTHE EPROM MUST POINT TOWARDS THENOTCH ON THE SOCKET OF THE PCB.

4. Plug the power cable into the balancer and switch thebalancer to the on position. The balancer will emitthree beeps. The upload will take approximately 45seconds. After the completion of the upload thebalancer will continuously emit beeps.

CAUTION!: DO NOT REMOVE POWER FROM THEUNIT DURING THE UPLOAD PRO-CESS, PERMANENT DAMAGE TO THEMAIN PCB WILL OCCUR.

5. When the upload is complete remove power from the balancer. Remove the EPROM off of the socketusing 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.

!USE STANDARD ANT-STATIC PROCEDURESWHILE PERFORMING THESE INSTRUCTIONS

Figure 3-23

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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 aJBC 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 tochange 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 andremove the weight tray. Avoid breaking or damaging wire harnesses. Harnesses may be held in placewith various retainer clips.

NOTE: WHEN INSTALLING THE WEIGHT TRAY, BE CAREFUL NOT TO CRUSH WIRES.

POWER SUPPLY BOXAll Balancers

• Disconnect the power from the rear of themachine.

• 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 payingspecial attention to the wiring harness thatare connected.

• Un-plug each of the harnesses from thepower supply box marking each harness toensure correct installation.

Figure 3-24

Figure 3-25

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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 losethe ball bearings on each end of the tranducers.These allow the transducer to center easily on thevibratory member.

• If the transducer is being replaced using a markermark the front and rear transducer harnesses. Cutthe two wires at the transducer. The positive lead ofthe harness is marked with a black band. (Whenusing a harness and transducer assembly, this stepis unnecessary.)

INSTALLATION OF TRANSDUCER• The front and rear transducer must be installed

correctly in order for the balancer to function cor-rectly. (Figure 3-27) The rear transducer uses thelast 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 blackband.

• Insert the clip into the transducer firmly snapping itinto place. Once the wire is installed it cannot beremoved without destroying the transducer.

• Apply a small amount of grease to each end of thetransducer. Place the ball bearings in place on thetransducer. Place the transducer assembly in thevibratory system.

• Finger tighten the set screw to position the trans-ducer. The wire connection should be on the bottom.A properly installed transducer will be able to rotatefreely but must have no side to side motion.

• Snug the jam nut that holds the setscrew. This nutshould be tightened solidly, but need not be ex-tremely tight. Recheck the transducer to ensure thatno lateral movement exists after tightening the jamnut. Adjust as necessary.

• Hold the pre-load plate in position up to the jam nutand finger tighten the set screws to just holdthe plate in place without movement. Tighten theupper screw ½ turn, then tighten the lower screw onefull turn, then tighten the upper screw an additional ½turn.

• Reassemble the complete balancer and perform acomplete factory calibration to ensure proper opera-tion.

NOTE: MOVING THE TRANSDUCER AFTER CALI-BRATION WILL CHANGE THE ACCURACYAND REQUIRE FACTORY CALIBRATION

Figure 3-27

Rear Transducer

Front Transducer

Encoder

Set Screw

Set Screw

Figure 3-26

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ENCODER REMOVALAll Balancers• Disconnect power.• Remove weight tray.• Disconnect the 10 Pin ribbon cable from the en-

coder PCB.• Remove the phillip screw holding the encoder PCB

to the shaft tube. (Figure 3-28)

NOTE: BE CAREFUL NOT TO LET FOREIGN DEBRISFALL INSIDE THE TUBE.

VIBRATORY MEMBER REMOVALAll 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 thevibratory. Pay special attention of spacer place-ment. (Figure 3-30)

• Lift up on the vibratory member and remove.

VIBRATORY INSTALLATIONAll 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.• 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 INSTALLTHIS COMPONENT FROM THE OLD VIBRA-TORY SYSTEM TO THE NEW VIBRATORY.USE OF A PRUEFROTOR MUST BE USED TOMAINTAIN ISO 9000 STANDARDS.

10 Pin connector

Screw

Spacers

Figure 3-28

Figure 3-30

Figure 3-29

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Effective08/2004

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 <F/P> <51>.• Pull out the SAPE arm and rest it on the vibratory tube (Fig-

ure 3-32), using a flatblade screwdriver turn the potentiometerto a voltage reading of 4.00VDC +/- .10.

• Run <F/P/C> <80> for SAPE calibration.

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.• Reverse procedure for installation.

Figure 3-31

Figure 3-32

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DISTANCE SAPE / POTENTIOMETER VPI III, IV• Disconnect the power from the rear of the machine.• Remove the weight tray.• 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 theframe. (Figure 3-33)

DISTANCE SAPE / POTENTIOMETER INSTALLATIONVPI III, IV

• Install 10K potentiometer onto bracket and tighten 13mmnut.

• Install SAPE Wheel onto potentiometer shaft and handtighten 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 <F> <50> System IV <C80>.• Hold the SAPE wheel firmly, using a flatblade screwdriver turn the

potentiometer to a voltage reading of 4..30 ± .05.• Run <F/C> <80> for SAPE calibration.

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• 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 suretheir is no binding.

• With the SAPE arm in the HOME position pro-gram <F/P> <50>.

• Hold the SAPE wheel firmly, using a flatbladescrewdriver turn the potentiometer to avoltage reading of 4.00 ± .05VDC (VPI SYSTEM I)4.30 ± .05 (VPI SYSTEM II, SOT Low Digital).

• Run <F/P> <80> for SAPE calibration.

Return SpringPotentiometer

Auto-Lock Mechanism

Fully extended At Rest

Figure 3-34

Figure 3-35

Figure 3-33

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Effective08/2004

WIDTH SAPE / POTENTIOMETER INSTALLATIONJBC 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 onthe 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

<F> <52> System IV <C82>.• Losen the 10mm nut and hold the gear. (Figure 3-36)

Using a flatblade screwdriver turn the potentiometer to avoltage reading of 4.35 ± .05VDC or greater than 0.15when the tip of the SAPE is touching the backing collar.

• Run <F79 for SAPE calibration, System IV <C82>.

ELECTRIC BRAKE PEDAL ADJUSTMENTEarly model JBC VPI System III balancers

• Remove the two screws securing the brake pedalassembly.

• 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

switch on the brake pedal assembly until the circuit isopen. (Figure 3-37)

• Check to make sure that the circuit closes when thebrake pedal is depressed.

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

clutch plate to 0.2mm by moving the motor pulley.(Figure 3-38)

• Apply power to the balancer and retest braking capabil-ity by pressing on the brake pedal.

Adjustment Screw

ActivatorMicroswith

Figure 3-37

0.2MM

ElectromagneticSwitch

CluctchPlate

Figure 3-36

Figure 3-38

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Effective08/2004

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 locatedat the top of the cable as indicated on.(Figure 3-39)

• Using a flatblade screwdriver turn the cablecounterclockwise to apply tension to thebrake or clockwise to loosen the brake.

• The cable is properly adjusted when the tireand wheel assembly has a little resistance.

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 ofthe springs and washers.

• Remove the two 5mm bolts holding thepedal to the frame. (Figure 3-40)

• Separate the pedal from the pedal bracket.• Pull the cable through the protective flex

tubing.• Reverse pocedures for installation.

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.

!DANGEROUS HIGH VOLTAGES ARE

PRESENT IN THIS EQUIPMENT

Figure 3-39

Figure 3-40

Figure 3-41

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Effective08/2004

HOOD SWITCH / CAM / SPRING(VPI SYSTEM III, IV)


• Remove the weight tray.• Disconnect the Hood Switch from the Power

Supply Board and remove the wiring from theconnector.

• Remove the two (2) screws holding the switchto the mounting bracket. (Figure 3-42)

• Remove the set screw holding the cam to thehood shaft and slide the cam off of the shaft.

NOTE: THE HOOD SPRING IS UNDER PRES-SURE. TO RELEASE PRESSURERAISE THE HOOD TO THE OPENPOSITION.

• Remove the screw from the shaft that at-taches the hood spring.

• Reverse procedures for installation.

HOOD SWITCH / CAM / SPRING(VPI SYSTEM II & SOT Low Digital)




• Remove the two (2) screws holding the switchto the mounting bracket. (Figure 3-43)

• Remove the set screw holding the cam to thehood shaft and slide the cam off of the shaft.

NOTE: THE HOOD SPRING IS UNDER PRES-SURE. TO RELEASE PRESSURERAISE THE HOOD TO THE OPENPOSITION.

• Remove the screw from the shaft that at-taches the hood spring.

• Reverse pocedures for installation.

HOOD SWITCH / CAM / SPRING(VPI SYSTEM I)




• Remove the cover plate from the wheel guardbox.

• Remove the two (2) screws holding the switchto the wheel guard box. (Figure 3-44)

• Install the new switch and route the wiringharness through the access hole.

• Install the wiring into the connector.• Reverse procedure for installation.

Figure 3-42

Figure 3-43

Figure 3-44

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Blank Page

1Effective02/2003

CHAPTER 4JBC SYSTEM IV

GENERAL

The JBC System IV CRT balancer is manufactured under the Y2k balancer system. The balancer is similarto the JBC VPI System III. The cabinet and electronics used for the System IV balancer is identical to that ofthe 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 serialconnection 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 thebalancer 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 accomplishedafter the machine has been turned on. If a test is not successful: a series of audible signals is given, or anerror code is read out. A three-tone signal is given once, if the machine is operative. In case there is afunctional error it must be acknowledged by pressing the STOP or ESC key and there is no three-tonesignal.

Listed below are the steps that the balancer performs along with possible “E Codes” “C Codes” or “H Codesthat 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). Thiscan 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 signalledby the error code is not remedied (using service codes C85 or C86), the machine will remain in servicecode 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 thenext step only if the trouble is remedied.

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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 Fwhich 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 lineC. Incremental encoder (Current of optoelectronic LED)D. Transducer signal availableE. Auto Stop System (Voltage for relay)

A. Hardware test - Power supply voltageC10800C10801C10804Service 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 lineC10810C10811Service 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 LEDC10705C10706C10707C10708Service Codes: C75, AdC1 to check LEDIf the current / voltage is below or above a limit the error code is displayed.

D. Hardware test - Transducer signalsC10410C10420C10430Service 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

C10380C10381C10382C10383Service 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 isdisplayed.

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 abortedusing the STOP or ESC key.

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CHAPTER 4 SYSTEM IV

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7. Check home position of left SAPE E3

Service Codes : C80 (& C81) to calibrate SAPEC92 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 SAPEC92 to check distance and diameter of actual calibration

During the second attempt the inner SAPE gauge arm was again not replaced to home position. Innerand 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 pressSTOP 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. OuterSAPE 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 inthe sequence as given below:

C80 – Calibration of inner SAPE gauge armC81 – Measurement of flange to zero plane distanceC82 – Calibration of outer gauge armC83 – Basic calibration of vibratory systemC84 – Measurement of residual main shaft unbalanceC88 – Adjustment of 12 h positionC90 – Saving calibration data

After a successful boot up the following screen should appear. (Figure 4-1)

Figure 4-1

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Effective01/2005

DISPLAY DESCRIPTION

The Display of the VPI System IV balancer is divided into three parts. Each of these parts display differentinformation 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), errormessages.

MainScreen

FunctionKeyArea

StatusArea

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 FunctionStop = Stop the Main ShaftEscape = No FunctionHelp = Go to Help Screen

F1 = Go to Function Screen / Enter Service ModeUser Calibration / Text EditorF2 = Adapter compensation function or if adaptercompensation is active; switch off. The unbalanceof an adapter can be temporarily compensatedwith this function. If the adapter compensation isactive it is indicated by the adapter compensationicon in the status area. (Operator Manual)F3 = No FunctionF4 = Go to Balancing Function (Operator Manual)F5 = No FunctionF6 = Optimization menu (Operator Manual)

Figure 4-2

Figure 4-3

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FUNCTION SCREEN

Start = No FunctionStop = Stop the Main ShaftEscape = Back to Introduction ScreenHelp = Go to Help Screen

F1 = User CalibrationF2 = Go to text editorF3 = No FunctionF4 = No FunctionF5 = Used to toggle selected FunctionF6 = Used to change selected Function

While pressing and holding in the “F6” key rotatethe shaft. The green indicator arrows in the “MainScreen” area will either move up or down depend-ing on the direction of the shaft rotation. Once theindicating arrow reaches the function to bechanged release the “F6” key. Press and hold the“F5” key to toggle the function. The indicator arrowat the bottom of the “Main Screen” area indicatesadditional information. The two “--” marks at thetop of the Main Screen area indicates that there isno information above the selected function.

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 settingsAfter 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

Figure 4-4

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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 defaultAll unbalance values below the threshold are set to zero if suppression of minor unbalances is enabled. Ifthe right, left and static unbalance values are set to zero the OK segment is on. If the ALU mode is notnormal 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 themeasurement 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

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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 tocomplete. Perform this procedure when thebalancer has been moved, disturbed, or wheneveraccuracy 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)

2. Press and release the “Calibration” key(F1).

(Figure 4-6)

Figure 4-5

Figure 4-6

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3. With nothing mounted on the shaft lower the wheelguard and press the “SPIN” key. The balancershould spin and come to a complete stop. (Figure4-7)

4. After the balancer comes to a stop raise the wheelguard and screw the calibration slug into left sideof the flange plate. Lower the wheel guard andpress the “SPIN” key. The balancer should spinand come to a complete stop. Once the shaftstops the display should display “OK” and thespeaker sounds the Snap-on “TüDüLü”. (Figure 4-8)

Calibration Complete

Figure 4-7

Figure 4-8

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ENTERING SERVICE MODE

1. From the Introduction Screen press the “FUNC-TION” key (F1) to enter in to the Function Menu.(Figure 4-9)

2. By pressing the F6 key 3 times successively the“SERVICE” key (F4) will become active. (Figure 4-10)

3. By pressing the F4 key the service program willbecome active. (Figure 4-11)

Figure 4-9

Figure 4-10

Figure 4-11

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C CODES

By pressing and holding the “C-CODE” key (F1) androtating the main shaft the user can select the desiredC-Code. Once the desired C-Code isdisplayed in the C-Code identifier windowthe technician needs to simply release the“C-Code” key (F1). After each C-Codechange it is recommended that thetechnician save the change by use of the “C90” code.There are many C-Codes available however there arevery few that are required to diagnosis and repair theSystem IV balancer. Many codes are written forengineering purposes and are not valid for field use.

C Description28 Display and clear error codes43 Reset counters47 Select machine model55 Indication the line voltage56 Indication of the circuit state of the wheel guard switch57 Indication of temperature59 Indication of the residual unbalance compensated for using code C8460 Motor: Indication of RPM of main shaft74 Indication of position counter and basic incremental encoder test75 Display values from AD converter76 Indication of the voltages used by the 2 step motor control80 Calibration of the inner SAPE gauge arm and the AutoStopSystem81 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 shaft85 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 data92 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 CODESThe last 10 different malfunction codes are written into the error memory so that they can be called up andreported by the operator of the wheel balancer e.g. for remote diagnosis of malfunctions. The most recentmalfunction code is written into memory location 1 and the previous error codes are shifted to the higher memorylocations. 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, “—” isdisplayed. 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).

Figure 4-12

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C43 RESET COUNTERSThis C-Code is used to reset all balancer counters. The following counters are reset. This code will not clearany 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 calibration0: No reset of counters1: Reset of counters

C47 SELECT MACHINE MODELThis balancer is sold world wide under different brands and model numbers. The only model available in thedomestic market in the USA. is the “Sys IV” balancer. If changes are made by accident all factory calibrationprocedures will need to be performed. It is advised that no changes be made to the software settings.

C55 INCOMING LINE VOLTAGEMeasured line voltage going into the electronic box. The correct voltage is 230VAC ± 10%. If the balancer ishas a step-up transformer installed so that the unit can be plugged into 115VAC the incoming voltage is whatis measured after the transformer.

C56 CIRCUIT STATE OF THE WHEEL GUARDThis test function can be used to determine the angle at which the wheel guard switch trips. With the wheelguard 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 SENSORMeasures the vibratory temperature, unit measures in centigrade (°C)

C60 MOTOR RPMOnce this code is called up “---” is read out in the right display. As soon as measured data is available, thecurrent speed is read out. The correct value is 190 ± 10.

C74 POSITION COUNTER AND BASIC INCREMENTAL ENCODER TESTOnce 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 registerthen 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 locationreading is “- - -”. After synchronization the angular position is display as a value in a range between 0 and511.

-00 after switching power on (main shaft not moved at all), or after pressing the Special function key-07 after 2 turns backward A- and B channel signals are OK, but there is no synchronisation in back-

ward direction.-0b after 2 turns forward A and B channel signals are OK, but there is no synchronisation in forward

direction.-1b after 2 turns forward backward 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 nextpage

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-27 after 2 turns backward A and B channel signals are OK, synchronisation in backward direction isOK as well

-2F after 2 turns in each direction A and B channel signals are OK, but synchronisation was made inbackward 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

CommentsIf 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 CONVERTERAD input Channel DescriptionAdC 0 0.0 REF-AD Reference voltage of external AD converterAdC 1 1.0 fLED-CW LED current controlAdC 2 2.0 fSON-TMP Temperature ultrasonic unitAdC 3 3.0 fBAL-TMP Temperature of transducer/vibratory systemAdC 4 4.0 fANA3 Motor currentAdC 5 5.0 fANA2 Power interface board multiplexer channel YAdC 6 6.0 fANA1 Power interface board multiplexer channel XAdC 7 7.0 fPOT freeAdC 8 8.0 fPOt-WHO Width potentiometerAdC 9 9.0 fPOT-OFS Distance/extraction potentiometerAdC 10 10.0 fPOT-DIA Diameter/angle potentiometerAdC 11 11.0 RF1V23 Internal reference voltage of analogue unit potentiometerAdC 12 12.0 VCC-W ½ voltage of +5V supplyAdC 13 13.0 fLINE-V Mains voltage controlAdC 14 14.0 AIR Input of voltage amplifier in front unbalance channelAdC 15 15.0 AIL Input of voltage amplifier in rear unbalance channelAdC 16 5.0 VCSSw* 0.793 * supply voltage to external switchesAdC 17 6.0 freeAdC 18 5.1 VBrCur* Coil current of solenoid brakeAdC 19 6.1 freeAdC 20 5.2 VDisp* Supply voltage of display boardAdC 21 6.2 VAssStat* Voltage on capacitor of AutoStopSystemAdC 22 5.3 VRimSens* Identification of rim materialAdC23 6.3 VRelCur* Coil current of relayAdE 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 SYSTEMNOTE: THIS FUNCTION MUST BE PERFORMED IF C-CODE 47, 85 & 86 IS INITIATED OR IF

SOFTWARE IS INSTALLED OR UPGRADED.

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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 thevoltage reading in the left hand display window, the correct value is 4.00VDC ± .10. See DiameterSAPE 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

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4. Fully extend the distance gauge and press the “ENTER” key (F6) to store the value and proceed to thenext step. (Figure 4-14)

5. Place the large pancake portion of the calibration slug down on the bell housing and pull the distance armout and rest it on the pancake portion of the calibration slug. Press the “ENTER” key (F6) to store thevalue and proceed to the next step. (Figure 4-15)

Figure 4-14

Figure 4-15

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6. Raise the gauge arm, and touch the tip of the calibration slug. Press the “ENTER” key (F6) to store thevalue and proceed to the next step. (Figure 4-16)

7. Step 5 has no function. Press the “ENTER” key (F6) to proceed to the next step. (Figure 4-17)

Figure 4-16

Figure 4-17

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8. Pull the distance gauge out slowly at least 3 times until the “Auto Lock” clamps and locks the distancegauge, after which return it to the home position. Repeat this process 3 consecutive times, the softwarewill then advance to step 7. Watch the “Status Area” if the arm is pulled out to quickly or to slowly thebalancer will flash an “H26” or “H28” code. (Figure 4-19)

9. Pull out the gauge arm 7 times with increased constant speeduntil it clamps. After each clamping hold thegauge arm for at least 1 second in the clamped position before repeating the procedure. When the gaugearm has been pulled out and clamped 7 times, the reading will automatically advance to C ---. (Figure 4-20)

CALIBRATION COMPLETE STORE FACTORS USING C90

Figure 4-19

Figure 4-20

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C81 MEASURING ADAPTOR FLANGE AND ZERO PLANE1. 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)

C82 WIDTH GAUGE ARM ADJUSTMENT / CALIBRATION1. 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 ifadjustments are required. (Figure 4-22)

Figure 4-21

Figure 4-22

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2. Touch the tip of the width gauge to the outer face of the backing collar, the value should be greater than0.15. Press the “ENTER” key (F6) to store this value. (Figure 4-23)

3. Screw the calibration weight into the threaded hole on the outside of the backing collar. Touch and hold thetip of the width gauge to the tip of the calibration weight. Press the “ENTER” key (F6) to store this value.(Figure 4-24)

CALIBRATION COMPLETE STORE FACTORS USING C90

Figure 4-23

Figure 4-24

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C83 CALIBRATION OF UNBALANCE MEASUREMENTThis test can be done either using a Pruefrotor or Tire and Wheel assembly. If a tire and wheel assembly, isused 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 shaftand enter in the parameters of the Pruefrotorusing the balance screen. (Figure 4-25)

2. Enter the “Service” routine and select C83.Press the “START” button to begin the mea-suring run. (Figure 4-26)

3. If a Pruefrotor is used, screw the 100 gramweight on the left side of the Pruefrotor if thevalue displayed is not “100” in step 2 pressand hold the “ENTER VALUE” key (F4) androtate the shaft until the custom weight isdisplayed. Press the “ENTER” key (F6) toenter the value of the test weight and toproceed to step 3. Press the “START” buttonto begin the measuring run. (Figure 4-27)

Figure 4-25

Figure 4-27

Figure 4-26

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4. Remove the 100 gram calibration weight andinsert it into the right hand plane of thePruefrotor. Press the “START” key to beginthe measuring run. (Figure 4-28)

5. Step Number 5 has not been programmed.Press the “ENTER” key (F6) to advance to thenext step. (Figure 4-29)

6. The ambient transducer temperature isdisplayed for 1 second. (Figure 4-30)

Figure 4-30

Figure 4-29

Figure 4-28

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7. Remove the 100 gram weight, lower the hood andpress the “START” button to begin a measuringrun. (Figure 4-31)

8. Insert the calibration weight that is supplied withthe balancer on the left side of the backingplate. Press the “START” button to begin ameasuring run. (Figure 4-32)

9. Store the new factors using C90.

10. Must complete C84 after this function


C84 EMPTY SHAFT COMPENSATION

1. Remove all accessory items from the MainShaft. (Figure 4-33)

2. Lower the hood and press the “START” buttonto begin the measuring run.



Figure 4-31

Figure 4-32

Figure 4-33

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C88 ANGULAR UNBALANCE POSITION

1. Mount the Pruefrotor on the balancer shaftand enter in the parameters of the Pruefrotorusing the balance screen. Press the “START”button to begin the measurement run. (Fig-ure 4-34)

2. Attach the 100 gram weight to outside of thePruefrotor and press the “START” button.(Figure 4-35)

3. After the shaft comes to a complete stoprotate the shaft to locate the 100 gram weightat “BOTTOM DEAD CENTER” position. Pressthe “ENTER” key (F6) to save the data.(Figure 4-36)



Figure 4-34

Figure 4-35

Figure 4-36

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C90 SAVING ADJUSTMENT DATAAll calibration data must be saved into memorybefore powering down the unit. Any data that is notsaved 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

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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 thatprogram is loading.

5. A continuous sequence of beeps and flashes indicatesthat program loading is complete.


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

1Effective10/2007

INTRODUCTION

The BFH/Optima Series system is a wheel balancing machine equipped with three optical scanners. Twoscanners capture images of the wheel rim profiles (inner and outer), so that the co-ordinates ofoptimum positions for application of the balancing weights can be calculated automatically andwithout 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 toproceed 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 principleof LASER triangulation. This device comprises a LASER source, a lens and a linear optical image sensor (aCCD – charge coupled device). The beam of coherent light emitted by the LASER source hits the object whosedistance is to be measured. The beam of light is diffused (scattered) in a plurality of light rays from the surfaceof the object and the rays are concentrated by the lens in a spot on the sensitive surface of the linear opticalimage sensor. The position of the spot on the sensor is determined by a digital analysis of the electrical signalproduced by the sensor.

The distance between the object and the LASER source may be calculated. In practice, a calibration procedureis performed and a polynomial interpolation of a suitable degree is used. Specifically, the BFH/Optima systemimplements 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 andCCD 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 thesecond is on. Complete sensor readouts are kept in the computer’s memory. The difference of theacquired 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.

CHAPTER 5BFH SERIES

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ProfilingIn the BFH/Optima Series system, the distance measuring devices (range finders) are rotated in a plurality ofknown positions by a stepper motor, so that they constitute optical scanners. The scanners, detecting thedistances from a known position of a plurality of points on the object to be explored (the wheel rim) allows thespatial 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 acertain sense optimum, for the application of balancing counterweights. The co-ordinates of these positions arecalculated automatically and without contact.

The complete weight position detection process is as follows:

1. Scan rim contour to determine typical rim parameters2. Compare current rim pattern with a set of stored rim patterns3. Select the best match stored rim pattern4. Pick pre-established weight locations associated with the best match pre-established rim pattern5. Calculate weight amount and display6. Allow the user to modify suggested weight location by moving the laser pointer7. “Learn” from experience

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Rim Runout Measurement - Rim- Tire Matching / OptimizationIt 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 tire2. Uneven distribution of weights on the rim3. Geometrical deformation of the tire4. Geometrical deformation of the rim5. 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 therim at a predetermined point. The rim is rotated about the wheel balancer shaft and a plurality ofdistance measurements are taken at known rim angles of rotation. The operation is repeated for atleast one other known distance measuring device position. On the basis of the data gathered in thisway, a calculation process defines the eccentricity (Radial Runout) and angle (Lateral Runout) of therim axis relative to the axis of rotation. This data can be used to provide the user an indication of the quality ofthe rim examined. It is also used to provide the user with indications on how to position the tire relative to therim in order minimize the effects of such deformations.

In fact, the system allows the measurement of geometrical data relative to tire deformations, deviation of thetire axis from its axis of rotation. The distance measuring device is moved by rotation and translation to aknown position so that the LASER beam hits the surface of the tire at a predetermined point. The wheel isrotated about the wheel balancer axis and a plurality of distance measurements are taken at known wheelangles 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 bymeans 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 tominimize the concurrent effects of such deformations in accordance with appropriate criteria. Typically, thetire is rotated with respect to the rim opposing the peak (maximum) of thetire radial runout with the minimum of the rim radial runout, thus minimizing the radial runout of the assembledwheel.

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BFH/OPTIMA SERIES MAJOR COMPONENTSThis 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 BOARDThe Camera Processor board is the liason between the three Scanner / CCD assemblies and the MainProcessor PCB inside the Ebox.

J6/7/8/9Pin # Direction Name Description1 Digital Out Q3 Stepper Motor Phase B2,5 Power Out Un Common Power Supply3 Digital Out Q4 Stepper Motor Phase D4 Digital Out Q2 Stepper Motor Phase C6 Digital Out Q1 Stepper Motor Phase A

J10Pin # Direction Name Description1 Power Out +5Vdc Digital Power Supply (5V)2 Digital In Zpos3 Motor 3 Zero Position3,4 dGnd Digital Ground

J11Pin # Direction Name Description1 Digital In PH-A Encoder Phase A2,4 dGnd Digital Ground3 Digital In PH-B Encoder Phase B

J12Pin # Direction Name Description1,2,4,6 Power In External 5V power supply3,5,13,14 External Ground7,8,9,10 NC Not Connected11 Digital In IIC-SCif External IIC Serial Clock12 Digital I/O IIC-SDif External IIC Serial Data

J13Pin # Direction Name Description1,2,3 Power In External Motor Power Supply4,5,6 External Motor Ground

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J14,15,16Pin # Direction Name Description1,18,20 Digital Ground2 Analog In OSx OS CCD signal3 Analog In DOSx DOS CCD signal4,12 Power Out +5Vd 5V Digital Power Supply5 Digital Out FRMstx Frame Start Signal6 Out LPx Laser Pointer Switch7 Digital Out RSTx Reset signal8,10 Power Out +3.3Vd 3.3V Digital power supply9 Digital In AUXoutx Auxialiary Digital out11 Digital In CONVstx Conversion start signal13 Digital I/O SDA IIC serial data14,16 Digital Out E0/1 IIC EEPROM address configuration15 Digital Out SCL IIC serial clock17 Digital In Zposx Scanner home position signal19 Digital Out LASERx Laser modulation signal

ELECTRONIC BOXThe 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 Clampswitch”. The box is backwards compatible but the older Ebox will not work in the BFH/Optima balancer.

J9Rear

ScannerMotorDrive

J8Rear

ScannerMotor

J7OutsideScanner

Motor

J6Inside

ScannerMotor

J16RearCCD

J15Outside

CCD

J13MotorPower

J10Rear

EncoderZero

J12PCB

Power

J11PowerClamp

EncoderJ14

InsideCCD

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SCANNER / LASER / CCDThe 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 serviceablecomponents on these assemblies with the exception of the manufactures mechanical adjustments. DONOT ATTEMPT TO MAKE ADJUSTMENTS OTHER THAN THE ZERO REFERENCE STATED LATER INTHIS MANUAL. Each scanner assembly has a zero stop that has minor adjustment. The rearscanner assembly and the outside scanner assembly are identical and can be swapped. However, theinside scanner assembly has a different mounting bracket and cannot be interchanged with the othertwo assemblies. For troubleshooting purposes the units can be swapped at board level. Should anyof these assemblies require replacement the balancer will flag an E360 error code and force a scanner calibra-tion.

POWER SUPPLY PCBThe Power Supply PCB receives 230VAC power from the Electronic box. This voltage can be measured using aDigital Volt Meter at J1 pins 1 and 2 on the Power Supply PCB. The AC power passes through on-board bridgerectifiers converting the power to 9VDC which is used to power all of the (4) Scanner Motors. This 9VDC can bemeasured at J2 pins 1,2 and 3. Pins 4,5 and 6 are ground connections. This voltage must be adjusted after theinstallation of the Power Supply PCB. Follow the procedure below to measure and adjust the output voltage tothe 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 VoltMeter 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.

Pin 1

Pin 6

Adjustment Pot

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POWER CLAMP ASSEMBLYThe BFH/Optima series balancer is equipped with a power clamp that eliminates the need for a standard orquick clamp nut. The Power Clamp is activated by lifting up on the foot pedal mounted on the balancer. Thevibratory 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 willnot open or close if the shaft is spinning. The large pulley drives the power clamping jaws while the magneticbrake is engaged and is holding the shaft. Should the clamping jaws be engaged during the event of a powerfailure 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.

Manual Stops

Access Hole

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SELF TEST DURING START UP

The BFH/Optima performs a start-up routine when power is applied. A series of self diagnostic tests isconducted after the machine has been turned on. If a test is not successful: a series of audible signals isgiven, or an error code is displayed. A three-tone signal is given once, the machine is operative. In casethere 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 Codesthat 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). Thiscan 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)


The microcontroller was not able to detect a keyboard. Check cabling between microcontroller andkeyboard.

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 signalledby the error code is not remedied (using service codes C85 or C86), the machine will remain in servicecode 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 (usingservice codes C47), the machine will remain in service code mode.

5. Check keyboard (E 89)


One of the keys F1 to F6, HELP, ESC, START supplies a key code. The machine will proceed with thenext 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. PressSTOP or ESC key to check the pedal switch once again and to delete the error code reading. If thetrouble 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 datais missing.

Calibration procedure C122 is required to calibrate the actual position of the laser scanners with respectto the balancer reference plane.

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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 notable 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 unplugged, damaged or missing.

9. Check BFH/Optima Hardware (E 362)


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)


Left side scanner self test failed or CCD not calibrated or zero mark not detected.


11. Check BFH/Optima Outer Scanner (E 364)


Right side scanner self test failed or CCD not calibrated or zero mark not detected.


12. Check BFH/Optima Rear Scanner (E 365) (Excluding 800)


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 toF 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 lineC. Incremental encoder (Current of optoelectronic LED)D. Transducer signal availableE. Auto Stop System (Voltage for relay on Motor Control Board)

A. Hardware test - common errorsC10F02 - Test returned with an error. No valid test results availableC10F07- Test function reported an unkown errorC10F18- Test timed out. No valid test results available

B. Hardware test - Power supply voltageC10800C10801C10804Service Codes: C55 to check line voltage.If the line voltage is below or above a limit the error code is displayed. (See “C55”)

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C. Hardware test - 5V lineC10810C10811Service 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 LEDC10705C10706C10707C10708Service Codes: C75, AdC1 to check LEDIf the current / voltage is below or above a limit the error code is displayed.

E. Hardware test - Transducer signalsC10410C10420C10430Service 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 systemC10380C10381C10382C10383Service 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 modelA 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 abortedusing 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.

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DISPLAY DESCRIPTION

The Display of the BFH/Optima Series balancer is divided into three parts. Each of these parts displaydifferent 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.

BALANCER SETUP

On the initial installation the balancer should besetup for the customer preferences i.e. ounce/gram, day/month/year, time, etc. Press the“Function” key (F1)

Start = No FunctionStop = Stop the Main ShaftEscape = No FunctionHelp = Go to Help Screen

F1 = Go to Function Screen / Enter Service ModeUser Calibration / Text EditorF2 = Adapter compensation function or if adaptercompensation 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. (OperatorManual)F3 = No FunctionF4 = Go to Balancing Function (Operator Manual)F5 = No FunctionF6 = Optima menu (Operator Manual)

MainScreen

FunctionKeyArea

StatusArea

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FUNCTION SCREENStart = No FunctionStop = Stop the Main ShaftEscape = Back to Introduction ScreenHelp = Go to Help Screen

F1 = User CalibrationF2 = Go to text editorF3 = No FunctionF4 = No FunctionF5 = Used to toggle selected FunctionF6 = Used to change selected Function

While pressing and holding in the <F6> key rotatethe shaft. The green indicator arrows in the “MainScreen” area will either move up or down depend-ing on the direction of the shaft rotation. Once theindicating arrow reaches the function to bechanged release the “F6” key. Press and hold the<F5> key to toggle the function. The indicatorarrow at the bottom of the “Main Screen” areaindicates additional information. The two “--”marks at the top of the Main Screen area indi-cates that there is no information above theselected function.

FUNCTION DESCRIPTION

Balancer operating mode.Saving the operating mode setting in the non volatile memory. The saved setting are now active after the nextpower 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 settingsAfter 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

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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 defaultAll unbalance values below the threshold are set to zero if suppression of minor unbalances is enabled. If theright, left and static unbalance values are set to zero the OK segment is on. If the ALU mode is not normal theunbalance 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 themeasurement 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

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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 modeScreensaver 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 thebalancer has been moved, disturbed, or whenever accuracy is questioned. Occasional field calibration willensure years of reliable service.

1. Press and release the <Function> key (F1)from the “Intro Screen”.

2. Press and release the <Calibration> key (F1).

3. With nothing mounted on the shaft lower the

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wheel guard and press the <SPIN> key. The bal-ancer should spin and come to a complete stop.

4. After the balancer comes to a stop raise the wheelguard and screw the calibration slug into left side ofthe flange plate. Lower the wheel guard and pressthe <SPIN> key. The balancer should spin andcome to a complete stop. Once the shaft stops thedisplay should display “OK” and the speaker soundsthe Snap-on “TüDüLü”.

Calibration Complete

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ENTERING SERVICE MODE

1. From the Introduction Screen press the <FUNCTION>key (F1) to enter in to the Function Menu.

2. By pressing the <F6> key 3 times successively the“SERVICE” key (F4) will become active.

NOTE: BEFORE PERFORMING ANY “C-CODES”ON THE BFH/OPTIMA BALANCER THETECHNICIAN MUST FORCE THE BAL-ANCER INTO THE MANUAL MODE. SEE“BALANCER OPERATING MODE” UNDER“FUNCTION DESCRIPTION EARLIER INTHIS CHAPTER.

3. By pressing the <F4> key the service program willbecome active.

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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 simplyrelease the “C-Code” key (F1). After each C-Code change it is recommended that the technician save thechange by use of the “C90” code. Many codes are written for engineering purposes and are not valid for fielduse.

C Description28 Display and clear error codes43 Reset counters47 Select machine model55 Indication of the line voltage56 Indication of the circuit state of the wheel guard switch and both foot pedal switches57 Indication of temperature59 Indication of the residual unbalance compensated for using code C8460 Motor: Indication of the RPM of main shaft74 Indication of the position counter and basic incremental encoder test75 Display values from AD converter76 Indication of the voltages used by the 2 step motor control80 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 shaft85 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 data98 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 pointer122 Calibration of the Scanner / Laser / CCD assemblies (Inner, Outer and Rear).

123 Manufacturing diagnostic and mechanical adjustment test.

C28 DISPLAY AND CLEAR ERROR CODESThe last 10 different malfunction codes are written into the error memory so that they can be called up andreported by the operator of the wheel balancer e.g. for remote diagnosis of malfunctions. The most recentmalfunction code is written into memory location 1 and the previous error codes are shifted to the highermemory 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 step2. Use the option selection to choose “1” and acknowledge with the “Enter” key (F4).

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C43 RESET COUNTERSThis C-Code is used to reset all balancer counters. The following counters are reset. This code will not clearany 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 calibration0: No reset of counters1: Reset of countersC47 SELECT MACHINE MODELThis balancer is sold world wide under different brands and model numbers. To validate any softwareupgrades. Enter C47, press the <F4> key followed by pressing the <F6> key, the balancer will reboot after afew seconds.

C55 INCOMING LINE VOLTAGEMeasured line voltage going into the electronic box. The correct voltage is 230VAC ± 10%.

C56 CIRCUIT STATE OF THE WHEEL GUARDThis test function can be used to determine the angle at which the wheel guard switch trips. With the wheelguard 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 downon 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 SENSORMeasures the vibratory temperature, measurement displayed in Celcius.

C60 MOTOR RPMOnce this code is called up “---” is displayed in the right display. As soon as measured data is available, thecurrent speed is displayed. The correct value is 190 ± 10 RPM.

C74 POSITION COUNTER AND BASIC INCREMENTAL SHAFT ENCODER TESTOnce 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 registerthen 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 locationreading is “- - -”. After synchronization the angular position is display as a value in a range between 0 and511.

-00 after switching power on (main shaft not moved at all), or after pressing the Special function key-07 after 2 turns backward A- and B channel signals are OK, but there is no synchronisation in back-

ward direction.-0b after 2 turns forward A and B channel signals are OK, but there is no synchronisation in forward

direction.-1b after 2 turns forward/ backward 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 A and B channel signals are OK, synchronisation in backward direction is

OK as well

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-2F after 2 turns in each direction A and B channel signals are OK, but synchronisation was made inbackward 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

CommentsIf 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 DescriptionAdC 0 0.0 REF-AD Reference voltage of external AD converterAdC 1 1.0 fLED-CW LED current controlAdC 2 2.0 fSON-TMP Temperature ultrasonic unitAdC 3 3.0 fBAL-TMP Temperature of transducer/vibratory systemAdC 4 4.0 fANA3 Motor currentAdC 5 5.0 fANA2 Power interface board multiplexer channel YAdC 6 6.0 fANA1 Power interface board multiplexer channel XAdC 7 7.0 fPOT freeAdC 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 potentiometerAdC 12 12.0 VCC-W ½ voltage of +5V supplyAdC 13 13.0 fLINE-V Mains voltage controlAdC 14 14.0 AIR Input of voltage amplifier in front unbalance channelAdC 15 15.0 AIL Input of voltage amplifier in rear unbalance channelAdC 16 5.0 VCSSw* 0.793 * supply voltage to external switchesAdC 17 6.0 freeAdC 18 5.1 VBrCur* Coil current of solenoid brake (not used)AdC 19 6.1 freeAdC 20 5.2 VDisp* Supply voltage of display boardAdC 21 6.2 VAssStat* Voltage on capacitor of AutoStopSystemAdC 22 5.3 VRimSens* Identification of rim material (not used)AdC23 6.3 VRelCur* Coil current of relayAdE 1 AE1 External AD converter (rear transducer)AdE 2 AE2 External AD converter (front transducer)* via multiplexer on the power interface

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C83 CALIBRATION OF UNBALANCE MEASUREMENTThis test must be done using a Pruefrotor.

NOTE: THIS TEST REQUIRES THE USE OF A PRUEFROTOR. ALL TESTS MUST BE DONE WITHTHE BALANCER IN THE MANUAL MODE. AFTER ALL TEST ARE DONE THE BALANCERMUST BE SWITCHED BACK INTO THE PREFERRED OPERATING MODE. ALSO CHECK THEVCC VOLTAGE “C110” AND ADJUST IF NECESSARY BEFORE ANY CALIBRATION IS DONE.

3. After the spin cycle completes, screw the 100 gramweight on the left side of the Pruefrotor and press the<ENTER> key (F6) to enter the value of the test weightand to advance to step 3. Press the <START> buttonto begin the measuring run.

1. Mount the Pruefrotor on the balancer shaft and enter inthe parameters of the Pruefrotor using the balancescreen.

2. Enter the “Service” routine and select C83. Press the<START> button to begin the measuring run.

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4. Remove the 100 gram calibration weight and insert it intothe right hand plane of the Pruefrotor. Press the<START> key to begin the measuring run.

6. The ambient transducer temperature is displayed for 1second.

5. Step Number 5 has not been programmed. Press the<ENTER> key (F6) to advance to the next step.

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7. Remove the Pruefrotor. Install the small and medium coneon the shaft. Remove the pressure cup from clamping nutand clamp both cones on the shaft. Lower the hood andpress the <START> button to begin a measuring run.

8. Insert the calibration weight that is supplied with the bal-ancer on the left side of the backing plate. Press the<START> button to begin a measuring run.


NOTE: MUST COMPLETE C84 AFTER THIS FUNCTION

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C84 EMPTY SHAFT COMPENSATIONNOTE: THIS PROCEDURE REQUIRES THE USE OF A SPECIAL CALIBRATION RING

(EAM0033D53A). DO NOT ATTEMPT THIS PROCEDURE WITHOUT IT. THE BALANCERMUST BE IN THE MANUAL MODE FOR THIS PROCEDURE.

1. Mount the Small Cone, Medium Cone and the clampingsleeve on the shaft.

2. Lower the hood and press the <START> button tobegin the measuring run.

3. After the spin cycle completes remove the clampingsleeve and install the 4mm calibration ring(EAM0033D53A) between the Medium Cone and theclamping sleeve. Press the <Spin> button for thebalancer to complete a spin cycle. After the balancercomes to a stop the empty shaft calibration is complete.

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C88 WHEEL WEIGHT POSITIONING

1. Mount the Pruefrotor on the balancer shaft and enter in theparameters of the Pruefrotor using the balance screen. Pressthe <START> button to begin the measurement run.

2. Attach the 100 gram weight to outside of the Pruefrotor andpress the <START> button.

3. After the shaft comes to a complete stop rotate the shaft tolocate the 100 gram weight at “BOTTOM DEAD CENTER”position. Press the <ENTER> key (F6) to save the data.

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C90 SAVING CALIBRATION DATAAll calibration data must be saved into memorybefore powering down the unit. Any data that is notsaved 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.

2. Press the <ENTER KEY> to save all previouscalibration data to permanent memory.

CALIBRATION DATA SAVED

C98 POWER CLAMP ENCODEROnce the code is called up the reading should display “---”. After the incremental encoder has identified zeroreference, the angular location is displayed in a range between 0 and 63. Use of this C code and meaningare 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.

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C110 VCC VOLTAGEThe operating voltage of the processor is +5.23 VDC ± .25 volts. If the voltage is out of range the balancermay experience a reset problem or it may display 81118b indicating that the voltage is to high or 81018bindicating that the voltage is below the acceptable range. A small adjustment on the balancer power supplycan 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 problemwith 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.

3. Power up the unit.

4. Enter the service menu and press <C110>.

5. Using a tweaker tool, adjust the voltage between +5.20 and +5.26 VDC.

Adjust

men

tPot

!HIGH VOLTAGE PRESENT

6. Verify the voltage reading at the embedded PC connection to ensure that it is acceptable.

C120 ENABLE / DISABLE LASER POINTER0 = Disable laser pointer1 = Enable laser pointerThis feature will turn the laser on/off during the ALU-S mode. It is recommended that the laser should beenabled.

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C122 SCANNER / LASER / CCD CALIBRATIONBefore 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 scanneradjustments be made using the C123 procedure before calibrating the scanner assemblies.

NOTE: THE BALANCER MUST BE IN THEMANUAL MODE AND ALLPRUEFROTOR PARAMETERS ENTEREDBEFORE CONTINUING THIS PROCE-DURE . AT LEAST TWO REVOLUTIONSOF THE SHAFT SHOULD BE MADE SOTHAT THE SHAFT ENCODER CANLOCATE HOME REFERENCE. THISCAN BE DONE BY QUICKLY ROTATINGTHE SHAFT UNTIL THE ENCODERREADS.

1. Mount the Pruefrotor as shown in the figure onthe right, making sure the the orientation of thePruefrotor is turned correctly. Failure to do sowill fail the calibration procedure.

2. Using a small magnetic torpedo level, turn theshaft until the Pruefrotor is in the verticle posi-tion.

3. Press the <Enter> key (F6). After doing so thedisplay will change and display a random num-ber. This number is not important however makenote of the number for the next step. For ourexample we have used 133.2.

4. Slowly rotate the shaft clockwise 20° (153.2). Thedisplay will quickly show “LOCK” and the magneticbrake of the balancer will engage. The innerscanner will scan the inside profile of thePruefrotor DO NOT MOVE THE SHAFT UNTILINSTRUCTED. After the scanner completes theprofile a beep will sound.

NOTE: LOWER THE HOOD FOR THE FOL-LOWING STEPS.

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5. Slowly rotate the shaft clockwise 70° (223.2). Onceagain the “LOCK” will display and the magneticbrake will engage.

The outside scanner will begin to take an outside profileof the Pruefrotor The laser light will move from thebalancer shaft out to the end of the Pruefrotor (See thered arrow to the right). After the profile has been takena beep will sound.

At this point it is possible to proceed two different waysproviding you have a “T” calibration tool, UI 2.9 (or higher)AWP 0.71 (or higher). If the balancer has the software andtool to accomodate the “T” fixture proceed to step 6b.

6. Slowly rotate the shaft clockwise 5° (228.2). Once thecorrect position is reached the “LOCK” will bedisplayed and the magnetic brake will engage andlock 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 ofthe bell housing and the runout profile of the Pruefrotor.

7. The balancer will emit a tone after completing thecalibration procedures and an “END” will be displayedfor step 5. Perform a C90 to store the new calibrationfactors.

6b. Unclamp the Pruefrotor and clamp the “T” fixture on theshaft with the reference hole (yellow arrow) away fromthe balancer. Using a torpedo level, vertically level the“T” fixture. Press <F6> to confirm.

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 willengage and travel across the back. When the scan iscomplete the brake WILL NOT release. Firmly grab the“T” fixture and press <F6>, the brake will release.Perform a C90 to store the new calibration factors.

NOTE: IF AN “ERROR” OCCURS DURING CALIBRA-TION REPEAT EACH STEP CAREFULLY.SHOULD AN ERROR OCCUR A SECONDTIME MAKE SURE EACH SCANNER ISADJUSTED CORRECTLY USING C123.

CALIBRATION COMPLETEC123 DIAGNOSTIC FUNCTIONSWhen troubleshooting the BFH/Optima series balancer it isrecommended that the technician use the diagnostic informa-

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tion that is available on screen in both the C122 and C123 functions. Information from each scanner / laserassembly is reported on screen and is color coded for easy diagnostics. When the balancer is initially poweredup the unit will run a self diagnostic test of all internal components. Each of these test are outlined in theservice manual (TEEWB519A). After running the internal diagnostic test the software initiates a self test of all 3scanner and laser assemblies along with the AWP board. If there are any failures to report the technician candetermine the failed component using C123. Some failures reported are easily repaired with minor adjustmentsand 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 areidentified as:

Inside Camera Outside Camera Rear Camera Rear SlideCarCCD0 (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 <FUNCTION>key (F1) to enter in to the Function Menu.

2. By pressing the <F6> key 3 times successively the“SERVICE” key (F4) will become active.

NOTE: BEFORE PERFORMING ANY “C-CODES” ONTHE BFH/OPTIMA BALANCER THE TECHNI-CIAN MUST FORCE THE BALANCER INTOTHE MANUAL MODE.

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3. By pressing the <F4> key the service program willbecome active.

4. Press and hold the <C-CODE> key (F1) and rotate themain shaft the to select C122 or C123. Release the<F1> key once the desired C-code is displayed.

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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



Las0Ena(45) Las0Pw(37) Las0Pwm(41) Mot0Pw(20) Mot0Chk(16) Mot0Ena(24) Ch4:X.XX



Busy(44) MsEnc(40) MotorPw(32) Mot3Pw(23) Mot3Chk(19) MoteEna(27) Ch7:X.XX

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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 Notes0 MainPw Analog/logic power supply1 CCD0 Inner CCD signals2 CCD1 Outer CCD signals3 CCD2 Rear CCD signals24 MainEEP Main board EEPROM memory valid5 EEP0Chk Inner EEPROM memory valid6 EEP1Chk Outer EEPROM memory valid7 EEP2Chk Rear EEPROM memory valid 28 MainCal Cameras calibration (E360,C122)9 EEP0Cal Inner scanner factory calibration10 EEP1Cal Outer scanner factory calibration11 EEP2Cal Rear scanner factory calibration 212 Z0Fail Inner motor home mark detection13 Z1Fail Outer motor home mark detection14 Z2Fail Rear motor home mark detection 215 Z3Fail Rear shift motor home mark detection 216 Mot0Chk Inner motor missing steps17 Mot1Chk Outer motor missing steps18 Mot2Chk Rear motor missing steps 219 Mot3Chk Rear shift motor missing steps 220 Mot0Pw Inner motor current sink / power check 121 Mot1Pw Outer motor current sink / power check 122 Mot2Pw Rear motor current sink / power check 1 - 223 Mot3Pw Rear shift motor current sink / power check 1 - 232 MotorPw External motor power supply 133 EEP0Ack Inner EEPROM memory ACK34 EEP1Ack Outer EEPROM memory ACK35 EEP2Ack Rear EEPROM memory ACK 236 MainAdc Camera board A/D converter check37 Las0Pw Inner laser current sink / power check 138 Las1Pw Outer laser current sink / power check 139 Las2Pw Rear laser current sink / power check 1 - 240 MsEnc Shaft encoder zero mark detection 341 Las0Pwm Inner laser modulation 142 Las1Pwm Outer laser modulation 143 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 andcamera assembly)3. Valid after runout measurement only.

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STATUS FLAGS (SHOWN IN BLUE)Status Bits, 0 (disable) is displayed in GRAY, 1 (enable) is BLUE.

Bit Displayed Meaning24 Mot0Ena Inner motor power enable25 Mot1Ena Outer motor power enable26 Mot2Ena Rear motor power enable27 Mot3Ena Rear shift motor power enable28 Z0Mark Inner motor home mark29 Z1Mark Outer motor home mark30 Z2Mark Rear motor home mark31 Z3Mark Rear shift motor home mark44 Busy Firmware ready/busy status45 Las0Ena Inner laser power enable46 Las1Ena Outer laser power enable47 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 range0 5.00 V power supply 4.80 V ÷ 5.60 V1 -5.00 V analog power supply -5.60 V ÷ -4.80 V2 3.30 V logic power supply 3.00 V ÷ 3.60 V3 9.00 V external motor power supply 8.00 V ÷ 12.00 V4 AUX 0 external input 0 V ÷ 4.096 V5 AUX 1 external input 0 V ÷ 4.096 V6 Laser current sink 0 V ÷ 4.096 V7 Motor current sink 0 V ÷ 4.096 V

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C123 MECHANICAL SCANNER / LASER / CCD ADJUSTMENTIf the BFH/Optima balancer fails any part of the C122 camera calibration it may be necessary to adjust oneor more of the cameras. If any of the Scanner assemblies require replacement it will also be necessary tocheck the mechanical adjustment before calibration.

1. Access the service menu and program thebalancer to run C123.

2. Step 1 accesses and avtivates the inside laserand “motor 0”. Press the <Enter> key (F6) tostart the inside scanner. Deactivate the scan-ner motor by pressing the <Enter> key (F6).

3. Looking down at the anchor tab just under themain shaft a laser light will be illuminated. Thefigure to the right shows the direction of travel.The scanner must stop somewhere between thetwo black illustrated lines. See “Inside Scan-ner Adjustment” for procedure.

4. Press the <Enter Values> key (F4) and turnthe shaft to proceed to the outside scanner.

5. Step 2 accesses and runs the outside scannertest “motor 1”. The Pruefrotor must bemounted on the shaft to verify the accuracy ofthis test.

NOTE: THE HOOD OF THE BALANCERMUST CLOSE TO THE CORRECTHEIGHT BEFORE ANY ADJUST-MENTS ARE MADE. SEE “HOODADJUSTMENT” FOR THIS PROCE-DURE.

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7. Press the <Enter> key (F6) to start the outsidescanner motor and laser. The laser must scanfrom the outside edge of the power clamphorizontally across the Pruefrotor towards theback of the balancer. See Outside ScannerAdjustment for procedure. Press the <Enter>key to stop the scanner motor and to proceedto the next step.

8. Press the <Enter Value> key (F4) and turn theshaft to access the rear scanner “motor 2”.Rotate the Pruefrotor forward 5° from a levelposition.

9. Press the <Enter> key (F6). The rear scannerassembly will leave the home position andstop towards the middle. The scanner motorwill begin to move between two fixed points.The laser line should fall somewhere withinthe cutout hole on the Pruefrotor.

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 adjustmentscrew

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10. Press the <Enter> key to stop the scannermotor and to proceed to step 4. Press and holdthe <Enter Value> key (F4) and turn the shaftto access the rear scanner horizontal drive“motor 2”.

11. Remove the Pruefrotor from the shaft. Pressthe <Enter> key (F6). The rear scanner willbegin to scan from left to right. From the rearof the unit see where the laser line is runningalong the shaft. The rear drive laser shouldrun parallel with the shaft and in the center. Ifthe laser does not run parallel with the shaftthe rear scanner assembly may not bemounted parallel with the cabinet or thevibratory system may not be level with thecabinet. Press the <Enter> key (F6) to stopthe motor drive. Press the <Esc> key on thekeyboard to exit this test.

CCD / LASER / SCANNER INSTALLATION

Should any of the scanner assemblies require replacement it will be necessary to make some mechanicaladjustment before calibrating the unit (C83, 84, 88 and 122) and returning it to service. These adjustmentsshould run parallel with the C123. The ribbon cable that feeds the CCD must have some slack at thescanner assembly. This can be tested by manually pressing on the scanner assemblies. A small amountof play is necessary and they should return to thehome postion.

INNER SCANNER INSTALLATION

1. Power down the unit.

2. Remove the 4 phillip screws that secure theshield.

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3. It may be necessary to manually swing thescanner assembly downward to access thebolts that secure the assembly to the vibratory.

4. Remove the two Socket Head Cap Screw thatsecure the assembly to the vibratory. DONOT DROP THE SCANNER ASSEMBLY.

5. Disconnect all cables and reverse thisprocedures for installation.

OUTER SCANNER INSTALLATION

1. Power down the unit.

2. Remove the 4 phillip screws that securethe shield.

3. Firmly hold the scanner assembly and removethe 2 Socket Head Cap Screw (1 and 2) thatsecure the scanner assembly to the hoodframe.

4. Disconnect all cable assemblies and reversethe 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 ADJUSTMETBefore making any adjustments to the outside scan-ner it is recommended that the hood be checked forthe proper height in the closed position. Failure to doso could cause the outside scanner to fail during aC122 calibration.

5. Measure the distance from the ground to thecenter of the shaft and record this distance.Measure distance between the ground and thecenter of the adjustment screw labeled (3) in thefigure above. If the measurements are differentthe hood must be adjusted to match the twomeasurements.

6. Loosen the Hex screw on the back side of thehood block. Loosen the jam nut (yellow). Usinga wrench turn the adjustment screw (red) untilwhile monitoring the height between the groundand the screw mentioned in step 5.

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OUTER SCANNER INSTALLATION CONTINUED

The HOME reference and the orientation of the projected laser can only be adjusted using the mountingscrews listed below. NOTE: DO NOT TAMPER WITH THE SCANNER ASSEMBLY. THE SCANNERASSEMBLY COMES CALIBRATED FROM THE FACTORY.

7. Mount a Pruefrotor on the balancer shaft and secure. Program the balancer for step 2 of C123. Verifythat the laser light moves horizontally from left to right. The illustrations below show the direction thatthe laser line moves using the adjustments screws. Each direction of movement can and will effect theother adjustments. In most cases the number (1 & 2) adjustment screw is the only needed movementafter 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 toadjust all adjustment screws. Before doing so it is recommended to level the scanner in two locationsbefore any adjustments are made. Doing so will bring the scanner very close to specs and only a smallamount of adjustment will be necessary. Level the scanner in the two locations indicated.

3

1 - 2

4 - 5

9. Using the adjustment points below will adjust the projected scanner light in the following orientation.

4

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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 scannerassembly and disconnect all wires.

5. Special attention must be spent when installing therear scanner assembly. The scanner bracket andthe mounting bracket must be aligned parallel witheach other.

6. Install the protection glass onto the scanner boxassembly.

7. Program step 4 of C123.

8. Look at the reflection of the laser back on thescanner. The reflection should come close tobeing on top of the original light source.

NOTE: AFTER ANY CHANGES AND ORADJUSTMENTS TO EACH OF THE 3SCANNERS THE BALANCER MUST BECALIBRATED. FAILURE TO CALIBRATETHE BALANCER WILL YIELD ERRORS.

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REAR SCANNER DRIVE BELTThe belt that drives the rear scanner inside the housing is a one piece cog belt. Over time the belt may become hard and brittle and require replacement. The belt will come as a single belt that needs to simply becut. The rear scanner assembly moves across the back of the balancer using a drive motor mentionedearlier. The drive motor has a cog gear mounted that drives the scanner assembly.

1. Loosen the two Phillips sheet metal screws and removethe 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 andinstall the one end of the belt with the cog side facingdown.

4. Feed the belt through the drive assembly. It may benecessary to loosen the motor to feed the belt through.Once the belt is installed lift up on the drive motor, thiswill tighten the belt and not allow it to slip off the geardrive.

5. Tighten each end that secures the belt. DO NOTOVER TIGHTEN THE SCREWS SECURING THEBELT, THIS MAY CUT THROUGH THE BELT.

6. Snip the remaining excess and retest the rear drive.

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FIELD PROGRAMMING THE CAMERA PROCESSOR PCBThe BFH/Optima has two processors that can be programmed. The main processor which is inside of theElectronic box and the Camera Controller PCB. Each processor is programmed using the EEprom socketon the Main Processor PCB. Programming the main Processor is mentioned earlier in this manual. Thecamera processor PCB is flashed in the same manner.


2. Place EEPROM in micro-controller socket with flat endat bottom of socket close to large blue connector. Thenotched end is 3 spaces short of other end of socket.

3. Turn on balancer.

4. The following is a sequence of events that will takeplace; three light audible beeps accompanied by 3green light flashes on the Camera PCB followed by 1red flash followed by 3 more green flashes followed bya constant flicker of the red LED. (Location CircledBelow).

5. A continuous sequence of tones will sound from thekeyboard 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.

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REMOVING THE BELL HOUSINGIt 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 2bolts securing the bell housing to the mainshaft.

3. Turn the main shaft and the bell housingopposite direction to line the Hex Head CapScrew with the keyhole.

4. Using a rubber mallet tap the face of the bellhousing to break taper of the shaft.

5. Pull the bell housing out away from thebalancer.

6. Hold the main shaft and turn the bell housingclockwise, un-screwing and separating thetwo shafts.

7. When installing a new bell housing or re-installing the old bell housing make sure thatboth tapered portions are clean and free fromany dirt particles. Failure to do so may causedamage to both pieces and separation may beimpossible.

8. Always make sure that the bell housing is fullyscrewed onto the main shaft before aligningthe key holes. This can be accomplished bypulling the bell housing away from the bal-ancer and making sure that the bell housing isfully screwed onto the main shaft.

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IMPORTANT BALANCER INFORMATIONBefore 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 Function 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 datemay.

Balancer Kernel - Revision Number and Date

Display - Revision Number and Date

Optima - AWP, Version Number

QUALIFYING THE BALANCERThe BFH/Optima is a very precision piece of equipment. In order for each scanner to accurately measuretire 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 theseprocedures should be checked on every service call. These steps will validate each component, should afailure of a component occur the balancer will not pass one of these test and it will be necessary to completea 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. (Seeadjustment)

5. 9 volt camera power supply - The output voltage of the camera power supply is 9.25 VDC ± .25 (Seeadjustment)

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.

Snap-on Diagnostic309 Exchange AveConway, AR 72032U.S.A.

EEWB519A

Rod Harrison

Rod Harrison

07/2006 REV D.

AC / DC POWER DISTRIBUTION

1-1 5-47/48

David Cullum

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CHAPTER 6BFH800C

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 theoriginal 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 newservice 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 followingsetup 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 inthe balancer that will result in comebacks.

The BFH800b incorporates a potentiometer that monitors the state of the hood guard. The potentiometersmeasures the speed of the wheel guard as it closes so that it can accurately profile the outside of the wheel. Ifthe potentiometer should get out of adjustment the balancer would display an error icon to the user indicatingthat the sonar was not able to accurately profile the wheel when the guard was closed thus forcing the user tomanually 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 StatusSonar Information

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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 thewheel guard. The measurement should be between 32.375 and 32.625. Adjust the hood guard bolt asshown 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 screwsonce the correct adjustment is obtained.

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4. Using the C123 dianostic screen refer to the potentiometer voltage on Channel 4. The value must bebetween .5V - 1.8V. If the values are not correct gently separate the gear mounted on the potentiometerwith the large gear and turn the potentiometer until the correct value is reached. Gently release thepotentiometer bracket and make sure that the teeth on both gears meet correctly.

Ch 4: Set at 1.32V

Wheel Guard Closed

Ch 4: Set at 3.43V

Wheel Guard Open

5. Raise the wheel guard to it’s most open position. Channel 4 value should be at least 2V above what it wasin the closed state. It may be necessary to adjust the hood guard bolt shown in Figure 4 to achieve therequired voltage.

Figure 4

6. Press <F6> to check the inner scanner for proper travel and operation

7. Return to the Function screen and set the balancer to the manual mode.

8. Enter Pruefrotor measurements.

9. Spin the balancer once to wake up the encoder.

10. Perform C83 - C84 - C88

Gear Separation

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Lower the hood forthe following step.

C122 CAMERA AND SONAR CALIBRATION

Before the Scanner and Sonar can accurately obtain the data needed to balance the wheel and tire assemblythey must be calibrated. The calibration information is stored on the CCD / Scanner PCB. This information isstored using C90 after completing the calibration.

NOTE: THE BALANCER MUST BE IN THE MANUAL MODE AND ALL PRUEFROTOR PARAMETERSENTERED BEFORE CONTINUING THIS PROCEDURE . AT LEAST TWO REVOLUTIONS OFTHE SHAFT SHOULD BE MADE SO THAT THE SHAFT ENCODER CAN LOCATE HOMEREFERENCE. THIS CAN BE DONE BY QUICKLY ROTATING THE SHAFT UNTIL THE EN-CODER READS.

1. Mount the Pruefrotor as shown in the figure on theright, making sure the the orientation of the Pruefrotoris turned correctly. Failure to do so will fail the calibra-tion procedure.

2. Using a small magnetic torpedo level, turn the shaftuntil the Pruefrotor is in the verticle position.

3. Press the <Enter> key (F6). After doing so thedisplay will change and display a random number.This number is not important however make note of thenumber for the next step. For our example we haveused 133.2.

4. Slowly rotate the shaft clockwise 20° (153.2). Thedisplay will quickly show “LOCK” and the magneticbrake of the balancer will engage. The inner scannerwill scan the inside profile of the Pruefrotor DO NOTMOVE THE SHAFT UNTIL INSTRUCTED. After thescanner completes the profile a beep will sound.

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5. Remove the Pruefrotor from the shaft and install the Sonar Calibration tool (EAA0344G09A). Slowly rotatethe calibration fixture (Figure A below) clockwise until a reading between 284 - 304mm appears on thesonar diagnostic flag. Press the <F6> key to enter this value. Rotate the shaft 180° (Figure B), thereading should be approximately 50mm less than the previous reading. A tape measure can be used toverify the distance from the sonar to the face of the calibration fixture.

6. The balancer will emit a tone after completing the calibration procedures and an “END” will be displayed forstep 5. Perform a C90 to store the new calibration factors.

Sonar Reading

Wheel Guard Closed

Between 284 - 304 Between 234 - 254Figure A Figure B

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12VDCOutput

12 Volt DC Power Supply

120 VACInput

BFH800B SPECIFIC COMPONENTS

SonarPotentiometer

InnerScannerMotor

12VoltInput

EncoderInput

KeyboardInput

AWP Processor

InnerScanner

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SonarAssemblySonar

Cable

Sonar and CableAssembly

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APPENDIX ACODES

KERNEL CODESA 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 Description21 Time Service22 I2C bus device driver23 Serial device driver24 Sound device driver25 External AD converter26 Internal AD converter27 Temperature measurement28 Piezo transducer29 Incremental encoder Main shaft2A Incremental encoder belt disc2B Relay management2C Hand-spin brake2D Electromagnetic brake2E main supply line2F motor30 Supervisor31 Watchdog timer

41 Auto stop system42 Data conditioning43 Rim data management44 Sape device45 Display device46 Keyboard device47 Brake device48 Motor device49 Drive (Motor & Brake)4A Power clamp4B Incremental potentiometer4c Rim light

61 Balancing algorithm62 Balancing calibration63 Behind the spokes placement64 <not used>65 Optimisation66 Measurement control

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81 Command language (Commands coming from the UI)82 Calculator83 Message Server (Message service from BK to UI)84 Message Server (User messages from BK to UI)85 Sleep command86 Balancing Kernel : Test statemachine (eg selftest during startup)

A1 Event systemA2 User managementA3 State machineA4 complex data typeA5 Persistent objectsA6 Pipe deviceA7 Power on time counter (-> time stamp for error recording)A8 Counter for total spins / in service-, in user mode

C1 Self testC2 User interfaceC3 User interface

Priority ID Description

0 Critical error (will be recorded in user mode)1 Warning message2 For information only3 All of above, but will not be recorded in the error record (persistent objects p30 to p39)

Error ID Limits DescriptionF01 Not completeF02 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 memoryF04 Out of range Mod 27, Temperature: Out of RangeF05 Buffer fullF06 Channel not foundF07 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 existsF09 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 fileF0B Drive full

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APPENDIX A CODES

Effective10/2007

Error ID Limits DescriptionF0C Bad nameF0D 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-Eserial line. Check external and internal cabling.

F0E Format failedF0F Bad parameter

Mod 41, ASS : Invalid time specified

Mod 44, SAPE : Bad parameter during calling time serviceMod 81, cmd : Parameter of a kernel command is bad. Such an error can

occur as a result from a hardware malfunction.

F10 Bad mediumF11 Error in expression

Mod C3, User Interface : Communication Error between balancing kernel anduser interface (BK -> UI). This error can be cleared bypressing STOP or Escape.

This error can caused by a bad connection of the RS232-E serial line. Checkexternal and internal cabling.

F12 OverflowMod 41, ASS : Too many time clientsMod 44, SAPE : Overflow (e.g. invalid time period)

F13 Not implementedF14 Read onlyF15 Bad lineF16 Bad data typeF17 Not running (still not initialised)

This error can occur after a measuring run, if the incrementalencoder 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 TimeoutMod 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 converterThis error can caused by a malfunction of the incrementalencoder. Check C74 and C54.A malfunction of the micro-controller board Check C75 ifADE1 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 apower clamp machine?)- Requested action not allowed

50 UT_CMPLX_ERROR_MatrixSingular60 ERR_VOLTAGE_ZERO61 ERR_VOLTAGE_BELOW_LIMIT63 ERR_VOLTAGE_ABOVE_LIMIT64 ERR_VOLTAGE_really_HIGH100 Keyboard : No time client available

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APPENDIX A CODES

Effective10/2007

Error ID Limits Description101 ERROR_KEYB_NO_HARDWARE_AVAILABLE102 ERROR_KEYB_ORDER_BUSY120 Display (Digital) : No Hardware available130 Bad parameter for the frequency of beep command131 Bad parameter for the volume of beep command132 Bad parameter for the sound file of beep command133 Bad parameter for the repetition of a beep134 Sound file corrupted

140 RS232-E : Wrong parameter for ioctl call.141 RS232-E : Input buffer overrun occurred142 RS232-E : Transmission error143 FIFO_KORRUPT144 FIFO_WRONG_ACTION145 FIFO_EMPTY_READ146 FIFO_FULL_WRITE147 FIFO_STRING_ENDE148 PIPE_NO_COMPLETE_MESSAGE_AVAILABLE149 SER_WRONG_ACTION14A SER_NO_HARDWARE14B SER_ERR_RESET_FIFO14C SER_ERRORCODE_EXISTS

160 ERROR_PO_INIT_READORDER_FAILED161 ERROR_PO_INCORRECT_DATA_OR_HEADER_SIZE162 ERROR_PO_EEPROM_IS_FULL163 ERROR_PO_I2C_WRITE_ORDER164 ERROR_PO_NO_TIMECLIENT_AVAILABLE165 ERROR_PO_ORDER_IS_BUSY166 ERROR_PO_ORDER_IS_FULL167 ERROR_PO_PRODUCTION_READ_WRONG_TYPE168 ERROR_PO_EEP1_EEP2_ARE_DIFFERENT169 ERROR_PO_CRC_EEP1_ERROR16A ERROR_PO_CRC_EEP2_ERROR16B ERROR_PO_ORDER_HAS_FAILED16C ERROR_PO_NOT_AVAILABLE16D ERROR_PO_CRC_EEP1_EEP2_ERROR

180 ERROR_I2C_QUEUE_FULL181 I2C_ERROR_ORDER_NOT_FOUND182 I2C_ERROR_ORDER_TOO_BIG183 I2C_ERROR_ORDER_BUSY184 I2C-Bus : No order in I2C queue185 I2C-Bus : No active order in I2C queue186 I2C_ERROR_TOO_MANY_SOP187 I2C_bad_SDA188 I2C_bad_SCL189 I2C_busy18A I2C_no_Acknowledge18B No Acknowledge from device18C I2C_ERROR_NO_ACK_FROM_START18D I2C_ERROR_NO_ACK_FROM_STOP18E I2C_ERROR_NO_ACK_FROM_SEND118F I2C_ERROR_NO_ACK_FROM_SEND2190 2C_ERROR_NO_ACK_FROM_RECEIVE

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APPENDIX A CODES

Effective10/2007

Error ID Limits Description191 ERROR_I2C_SYNCHRONOUS_ORDER_TIMEOUT192 ERROR_I2C_ASYNCHRONOUS_ORDER_TIMEOUT193 ERROR_I2C_ORDER_HAS_FAILED

201 ERROR_DS_USER_BREAK202 Drive system : Timeout during speed up

- hand-spin only! speed does not settle after start command203 ERROR_DS_SPEED_NOT_REACHED204 Drive system : Speed slows down during measuring

- speed falls below limit while measuring205 Drive system : Wheel speeds up in reverse turn

- Hand-spin only! main shaft rotating backwards on start command206 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 setto high speed)

210 Drive system : Clamping device got stuck in clamped position211 Drive system : Clamping device got stuck in unclamped position212 Drive system : Displacement limit exceeded during (un)clamping213 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 locked216 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 motor350 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) 361361 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

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APPENDIX A CODES

Effective10/2007

Error ID Limits Description410 Transducer 1, No signal411 Transducer 1, transimpedance to low412 Transducer 1, RC time constant out of range415 Transducer 1, transimpedance amplifier; idle voltage out of range416 Transducer 1, DC amplifier; idle voltage out of range418 Transducer 1, amplifier saturation419 Transducer 1, Transfer function out of range

420 Transducer 2, No signal421 Transducer 2, transimpedance to low422 Transducer 2, RC time constant out of range425 Transducer 2, transimpedance amplifier; idle voltage out of range426 Transducer 2, DC amplifier; idle voltage out of range428 Transducer 2, amplifier saturation429 Transducer 2, Transfer function out of range

430 Transducer 1&2, No signal431 Transducer 1&2, transimpedance to low432 Transducer 1&2, RC time constant out of range435 Transducer 1&2, transimpedance amplifier; idle voltage out of range436 Transducer 1&2, DC amplifier; idle voltage out of range438 Transducer 1&2, amplifier saturation439 Transducer 1&2, Transfer function out of range

500 BL_BAL_ERROR_NoConverge501 BL_BAL_ERROR_ResultInvalid502 BL_BAL_ERROR_TooMuchLoops510 BL_BAL_ERROR_NoCalUser511 BL_BAL_ERROR_FailCalUser512 BL_BAL_ERROR_SideCalUser

560 c1 value too low, if a user calibration tool assumed561 c2 value too low, if a user calibration tool assumed565 c1 value too low, if a 100g weight and calibration rotor assumed566 c2 value too low, if a 100g weight and calibration rotor assumed570 c1 value too high, if a calibration rotor only assumed571 c2 value too high, if a calibration rotor only assumed580 -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 sinks602 Internal error : Cannot register event sink603 Internal error : Invalid event level

701 ERROR_IEMS_INV_PARAM702 Incremental encoder not initialised. Software is not able to detect the reference

mark.703 Incremental encoder : Counter - reference mark mismatch705 2.50 V Opto electronic, No voltage on shunt resistor706 4.30 V Opto electronic, VCC on shunt resistor707 16 mA Opto electronic, Current through LED below limit708 20 mA Opto electronic, Current through LED above limit

NOTE: C1 = FRONT TRANSDUCERC2 = REAR TRANSDUCER

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APPENDIX A CODES

Effective10/2007

Error ID Limits Description710 Hand-spin with electromagnetic released brake

- main shaft rotates backwards

800 170 V Line voltage below limit801 265 V Line voltage above limit804 275 V Line voltage much too high810 5.10 V VCC below limit811 5.35 V VCC above limit820 5.00 V Keyboard/display voltage below limit821 5.35 V Keyboard/display voltage above limit830 4.50 V External voltage (pedal) below limit, see keyboard module831 External voltage (pedal) above limit, see keyboard module

900 Power fail detected950 OPTIMA hardware main board fault detected951 OPTIMA hardware inner scanner fault detected952 OPTIMA hardware outer scanner fault detected953 OPTIMA hardware rear scanner fault detected9FF ERROR_SELFTESTe01 ASA: Status of an activated order has changed due to network manager or shop

management software activities.

H CODES SYSTEM IVH# Internal code(s) DescriptionH0 Wheel running conditions cannot be improved by optimisationH1 Further optimisation not recommended but feasibleH2 Weight minimisation is recommended, optimisation can achieve no further

improvementH20 The correction plane cannot be re-located using the gauge armH21 Indexing position does not match correction planeH22 0x492215 Unclamping of power clamp device is disabledH26 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 readjustmentH82 Self test disturbed during executionH90 0x492203 - Acceleration during start or stop too slow

- Measuring speed not reachedH91 0x492204 Speed variations during measuring run

E CODES SYSTEM IV

E# Internal code(s) DescriptionE1 Rim dimensions entered incorrectlyE2 Wheel guard is not closedE3 Gauge arm not in home positionE4 Outer gauge arm not in home positionE5 Range of electrical unbalance compensation exceeded (residual adapter

unbalance)E6 Calibration weight not attached to flange

E7 No balancing mode for this wheel typeE8 Valve position was not enteredE9 Optimisation was carried out incorrectly

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APPENDIX A CODES

Effective10/2007

E10 Wheel guard is not open, wheel may not be clamped / unclampedE12 Pedal is operated, measuring run not possible

E13 The clearance of the solenoid brake is too wide.E14 The power clamping device is not clampedE15 Corrective terms for readjustment are out of rangeE16 Calibration weight attached erroneously to flangeE17 Wheel slipped on adapter

E28 Wrong direction of rotation (hand spin)E29 Speed too high (hand spin ?)E30 Run-out measurement failedE31 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 measurementE85 Power clamp service interval expiredE88 The rotating speed of the main shaft exceeds the safety limitE89 Key contact or pedal switch closedE92 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 managementsoftware activities.

E141 Check sum of EEPROM 1 is wrongE144 Check sums of both EEPROMs are wrongE145 Contents of the EEPROMs are different

E300 The micro-controller was not able to detect a keyboard.Check cabling between micro-controller andkeyboard.

E341 Check sum of EEPROM 2 is wrong

E360 OPTIMA hardware wheel profiler position calibration requiredE361 OPTIMA wheel profiler is not present or is not responding during self testE362 OPTIMA main camera board power on self test failureE363 OPTIMA left side scanner self test fail or CCD not calibrated or zero mark not detectedE364 OPTIMA right side scanner self test fail or CCD not calibrated or zero mark not detectedE365 OPTIMA rear scanner self test fail or CCD not calibrated or zero mark not detectedE366 OPTIMA main camera board memory self test failureE367 OPTIMA motor power supply missing or out of rangeE368 OPTIMA main camera board A/D converter failureE369 OPTIMA main shaft encoder zero mark detection failure or missing cable

E370 OPTIMA inner CCD signals failureE371 OPTIMA inner scanner memory not respondingE372 OPTIMA inner scanner memory not validE373 OPTIMA inner scanner not calibratedE374 OPTIMA inner motor current sink or power supply failureE375 OPTIMA inner scanner zero mark not detectedE376 OPTIMA inner motor missing stepsE377 OPTIMA inner laser current sink or power supply failureE378 OPTIMA inner laser modulation failure

E Description

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APPENDIX A CODES

Effective10/2007

E380 OPTIMA outer CCD signals failureE381 OPTIMA outer scanner memory not respondingE382 OPTIMA outer scanner memory not validE383 OPTIMA outer scanner not calibratedE384 OPTIMA outer motor current sink or power supply failureE385 OPTIMA outer scanner zero mark not detectedE386 OPTIMA outer motor missing stepsE387 OPTIMA outer laser current sink or power supply failureE388 OPTIMA outer laser modulation failure

E390 OPTIMA rear CCD signals failureE391 OPTIMA rear scanner memory not respondingE392 OPTIMA rear scanner memory not validE393 OPTIMA rear scanner not calibratedE394 OPTIMA rear motor current sink or power supply failureE395 OPTIMA rear scanner zero mark not detectedE396 OPTIMA rear motor missing stepsE397 OPTIMA rear laser current sink or power supply failureE398 OPTIMA rear laser modulation failure

E400 OPTIMA pull index user calibration failureE404 OPTIMA rear shift motor current sink or power supply failureE405 OPTIMA rear shift scanner zero mark not detectedE406 OPTIMA rear shift motor missing steps

E812 The drive pulley was not readjusted by 180º relative to the main shaft

E900 No model selectedE901 Machine not calibratedE990 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.

E Description

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APPENDIX A CODES

Effective10/2007

John Bean, Blackhawk, Hofmann, Kansas Jack - JBC VPI ......Once the balancer reaches balancing speed...

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