MANATEC LX WB-VL-65 DSP Service Manual Download

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WHEEL BALANCER

WB-VL-65 DSP LX

WB-VL-65 DSP LX Premium

WB-VL-65 DSP LX

WB-VH-200 R

SERVICE MANUAL

(Ver.1.3)

Summary of Contents for LX WB-VL-65 DSP

Page 1: ...WHEEL BALANCER WB VL 65 DSP LX WB VL 65 DSP LX Premium WB VL 65 DSP LX Premium WB VH 200 R SERVICE MANUAL Ver 1 3...

Page 2: ...INDEX ENCODER BOARD 12 3 3 4 MID CENTERING DEVICE MCD 12 3 4 MECHANICAL BRAKE 12 3 5 DISPLAY UNIT 12 3 6 KEYBOARD 13 3 7 DISTANCE DIAMETER WIDTH MEASUREMENT MECHANISM 13 3 7 1 E DISTANCE ENCODER BOARD...

Page 3: ...ls 39 5 3 1 LIMIT SWITCH 39 5 3 2 MANUAL BRAKE 39 5 4 DISPLAY UNIT 40 5 5 DISTANCE DIAMETER WIDTH MEASUREMENT MECHANISM 40 5 5 1 DISTANCE MEASURING ROD 40 5 5 2 E DISTANCE ENCODER BOARD For Wheel rim...

Page 4: ...Car washers Medical equipments etc are not connected to same power line 4 All regulations in force concerning the safety at work must be complied when choosing the installation location In particular...

Page 5: ...CB For 110V 60 50Hz operation LCV Two pole Type C 10A MCB For 415V 50 60Hz operation HCV Four pole Type C 10A MCB For 220V 60 50Hz operation HCV Four pole Type C 10A MCB For 415V 50 60Hz operation HCV...

Page 6: ...cer and should be free of heavy equipment vibrations 2 The clearances from side walls and roof should be adequate so that the Wheel guard can be opened completely and the mounting removal of wheels ca...

Page 7: ...ontents Qty 1 Main cabinet corrugated box 1 Main cabinet assembly 1 No 2 Monitor 1 No 3 Monitor column 1 No 4 Wheel guard with pipe DMR 1 No 5 Width caliper 1 No 6 Width measuring rod For Prem model 1...

Page 8: ...No 2 Monitor 1 No 3 Monitor column 1 No 4 Wheel guard 1 No 5 Wheel guard pipe 1 No 6 Width caliper 1 No 7 Top cover 1 No 8 Pneumatic lift with Ramp 1 Set 9 Accessories box Cabinet right side containi...

Page 9: ...nd holes 3 Insert the M12x125mm Lg Anchor bolt into the holes Insert the foundation pin into the Anchor bolt and hammer to lock it 4 Place the cabinet over the Foundation bolts by providing M16 Spring...

Page 10: ...ch 3 Fix the Wheel guard with pipe using Allen button head screw Spring washer Plain washer Domed cap nut 4 Nos each 4 Fix tWheel guard pipe assy with Square pipe using Domed cap nut Spring washer 2 N...

Page 11: ...ne cables 2 5 4 MCD 1 Insert the Threaded shaft into Tyre seating cone and fix the assembly with Rotor Main shaft firmly using Allen screw Spring washer 1 No each by matching the Arrow stickers pasted...

Page 12: ...tch ON OFF AC supply to the motor using Digital level signal applied from DSP board This board also acts as a power distributor Two different types of Motor control board are being used to control 1Ph...

Page 13: ...e FRC cable Power 5VDC is given to this board through a Micro USB cable Processor Broadcom BCM2837 64bit Quad Core Processor powered Single Board Computer running at 1 2GHz Graphic processor Broadcom...

Page 14: ...e for all HCV Models except single phase HCV models in which it is merged with MC Board Fig 13 3 3 ROTOR Rotor consists of Motor Piezo sensor Revolution Index encoder board MCD 3 3 1 MOTOR Low RPM AC...

Page 15: ...tering Device MCD is attached to the Rotor for centering the wheel automatically while fixing it using Wheel seating cones Fig 16 3 4 MECHANICAL BRAKE This mechanism is provided to stop wheel manually...

Page 16: ...urement The Optical encoder in this E Distance encoder board detects the distance home position of the Distance rod for arriving at the Rim distance The detected signals will be sent to the DSP board...

Page 17: ...uring spinning Error will be displayed By closing the guard error will disappear and the wheel starts spinning automatically 3 9 LASER TORCH Applicable for Premium model only Red Laser line is provide...

Page 18: ...are not zero Pre calibration check 1 Ensure the foundation is proper 2 Ensure the Cabinet is free from shake 3 Check the Belt tension and RPM The RPM should be 175 20 5 4 1 1 LCV MODELS Pre calibrati...

Page 19: ...alance should be 50gm min For Single point use a fairly balanced wheel with Rim dia 12 16 Unbalance should be 30gm min Use keys to move to next parameters Two point calibration Low Point High point is...

Page 20: ...ensure wheel mounted is with minimum unbalance To know the millivolts of Raw calibration after completing Tyre zero press key to go to RAW CALIBRATION run the wheel to view millivolts of SA SB display...

Page 21: ...n weight signal is too high Press Key to proceed or any other key to exit error message appears check whether the correct calibration weight is added on the appropriate plane or weight is not added in...

Page 22: ...shown below Once selected following sub options will be provided in WEIGHT CALIBRATION screen as shown below Fig 31 Select the Car or Truck mode to proceed with the Weight calibration SPINDLE ZERO By...

Page 23: ...ues will be displayed in millivolts in respective window goes to OUTER CALIBRATION screen To know the millivolts of Raw calibration after completing Tyre zero press key to go to RAW CALIBRATION run th...

Page 24: ...th message prompts for few seconds and system will go back to WEIGHT CALIBRATION screen During Outer or Inner calibration if Calibration weight signal is too high Press Key to proceed or any other key...

Page 25: ...1V If the displayed voltage is not within specification loosen the lever fixing Allen screw and Grub screw to move the DMR slightly and then rotate the Lever fixing rod till required voltage is set T...

Page 26: ...od in zero position ie Stopper Position and ensure the displayed Width voltage Outer Dia voltage is 1 00V 0 1V 2 50V 0 1V respectively If the displayed Outer dia voltage is not within specification mo...

Page 27: ...Width rod at the top edge of MCD and hold it for few seconds till Audio indication and then move the Width rod to Home position The system will go to WIDTH CALIBRATION screen Select WHEEL CALIBRATION...

Page 28: ...ues as shown below Fig 47 Press key to save the Width calibration values Then move the Width measuring rod to its home position Mount a Wheel ensure the Rim Distance Width measured in RIM PARAMETERS s...

Page 29: ...count is displayed as 0 Fig 49 2 Press key to return to OPTIONS 4 6 SELF TEST 1 Once Self test is selected press twice to execute the Self test Status of respective functions will be displayed as sho...

Page 30: ...cycle test is selected press twice to run Wheel Ensure the Duty cycle of 40 60 RPM of Rotor LCV 175 5 15RPM HCV 200 5 15RPM are displayed in the window Fig 53 2 Duty cycle should not be 00 at any con...

Page 31: ...ackup 4 12 CUSTOMER INFORMATION 1 Once Customer data is selected follow the On screen instructions to feed the Customer information file as per the requested format via USB Pend drive with FAT32 file...

Page 32: ...d minimum unbalance value according to the Rim diameter as given below Rim diameter Weight cutoff range For LCV 5 to 25gm For HCV 20 to 40gm 1 Once Weight cutoff is selected default cutoff value will...

Page 33: ...3Pin SR Width 3Pin SR Encoder 10Pin FRC Wheel guard 2Pin SR SBC board 26Pin FRC Buzzer 2Pin SR Fan 2Pin SR Membrane 6Pin SR connectors from DSP board Fig 61 2 Remove the fasteners and replace the def...

Page 34: ...ne and restore the connectors refer Wiring diagram Chapter 7 2 Ensure the 40Pin FRC is connected correctly with reference to Pin1 4 Load the Micro SDHC card 5 Re fix the Cooling fan assy over the SBC...

Page 35: ...errors 5 1 6 5 1 6 MCB HCV HCV models 3Phase HCV models 1Phase Fig 65 1 Switch off MCB and disconnect the main power cord for LCV model In case of HCV model switch off the Mains MCB also 2 Remove the...

Page 36: ...BC board by observing the air flow direction and restore the connector 3 Switch on the Balancer and ensure fan is running and exhaust function 5 2 ROTOR LCV MODELS 1 Remove the Allen screw from the Th...

Page 37: ...g the Sensor nut ensure the SA SB screw rods are centered in the slotted hole in Cabinet Fig 72 7 Fix the Driven pulley with Main shaft and then put the Belt between Driven Motor pulleys Fig 73 8 Fix...

Page 38: ...connections 10Pin FRC Fig 76 3 Loosen the Sensor SA SB fixing nuts detach SB screw rod from Rotor stem Fig 77 4 Remove the Rotor fixing Allen screw and detach Rotor assembly from cabinet Fig 78 5 Rem...

Page 39: ...Ring at 2nd division from bottom in the Deflection scale and make sure the Small O Ring is at bottom most position in the Force scale 2 Place a 5mmT reference flat tangentially to the Drive belt betw...

Page 40: ...g the Motor screws ensure the alignment of Motor with Driven pulley Fix the belt with Motor pulley and adjust the Belt tension correctly 5 Connect the Motor cable with Motor control board 6 Switch on...

Page 41: ...6 Loosen the lock nuts of SA and SB sensors 7 Loosen out the sensor stud nuts and take out the studs 8 Take out the sensors 9 Replace new sensor side of sensor should be facing the cabinet 10 Vertical...

Page 42: ...ing the Limit switch is in activated position 4 Apply the Brake pedal manually release it to check the functions 5 Switch ON the Balancer ensure that the motor is running without any problem 5 3 2 MAN...

Page 43: ...d Align the assembly properly to have a free movement and then tighten the two screws 5 Re fIx the DMR lever 6 Go to Distance test option and check the function Fig 89 5 5 2 E DISTANCE ENCODER BOARD F...

Page 44: ...S board refix it with screws in loosen condition watching the magnet is facing to centre of IC After adjusting to centre tighten the two screws 4 Same three steps applicable for replacing the board in...

Page 45: ...o Rim parameters window to check the displayed Rim width matches with the Width measured manually 5 6 5 6 5 6 WHEEL GUARD 5 6 1 LIMIT SWITCH 1 Disconnect the Limit switch cable from DSP interface boar...

Page 46: ...the Laser function 7 Align the Laser line parallel to main shaft by marking a line on floor with reference to main shaft centre line Use the pendulum with rope refer image to Mark three dot points at...

Page 47: ...1 X2664 Sensor DH VH DSP 1 1 X2757 RLS DMR board 1 1 Parts E2638 EMI Filter with Surge Supressor 1 1 E2710 SBC board Linux compatible 1 1 1 1 1 1 E2640 Memory card Micro SDHC 1 1 1 1 1 1 B4312 On Off...

Page 48: ...Ref WB VL SM Ver 1 3 doc 45 7 DIAGRAMS 7 1 BLOCK DIAGRAM 7 1 1 LCV MODELS Fig 99...

Page 49: ...Ref WB VL SM Ver 1 3 doc 46 7 1 2 HCV MODEL THREE PHASE OPERATION Fig 100...

Page 50: ...Ref WB VL SM Ver 1 3 doc 47 SINGLE PHASE OPERATION Fig 101...

Page 51: ...Ref WB VL SM Ver 1 3 doc 48 7 2 WIRING DIAGRAM 7 2 1 LCV MODELS Fig 102 1 of 3...

Page 52: ...Ref WB VL SM Ver 1 3 doc 49 Fig 102 2 of 3...

Page 53: ...Ref WB VL SM Ver 1 3 doc 50 Fig 102 3 of 3...

Page 54: ...Ref WB VL SM Ver 1 3 doc 51 7 2 2 HCV MODEL THREE PHASE OPERATION Fig 103 1 of 3...

Page 55: ...Ref WB VL SM Ver 1 3 doc 52 Fig 103 2 of 3...

Page 56: ...Ref WB VL SM Ver 1 3 doc 53 SINGLE PHASE OPERATION Fig 103 3 of 3...

Page 57: ...IRLED Photo transistor slots in board holder Run the Tracking test Ref Chapt 4 4 check Revolution pulse from the encoder match the Round segment encoder slot with Rev encoder board to get the correct...

Page 58: ...se is provided for HCV 12 Shaft movement detected during START Stop shaft movement and try again Shaft is rotating in clockwise direction Stop the shaft rotation and run the Wheel 13 Tyre unbalance is...

Page 59: ...e AC Fuse Replace the SMPS Replace the SBC board 7 Electric shock in the system System Earth may not be proper Make arrangements for proper Earthing 8 Brake pedal goes too much down The inner rod adju...

Page 60: ...12 Torch light not working Loose connection in LED light connector Fault in LED light Fault in DSP Mother board Check and correct Loose connection from DSP board to LED light connection Replace the L...

Page 61: ...acturer All information illustrations and specifications contained in this Manual are based on the latest information available at the time of publication Manufacturer reserves the right to make chang...

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MANATEC LX WB-VL-65 DSP, Service Manual

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