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MAGNETIC PHASE GENERATOR REPLACEMENT

Models:

M400-2 (C)

No.

Description

Image

Disconnect the flat cable connector

Detach the anti-rotation spring

Remove the phase generator by undoing the

hexagonal screw turning it clockwise

SHEET 011

Содержание MS400-2

Страница 1: ...n GmbH A 5302 HENNDORF AUSTRIA Hauptstraße 67 Tel 43 6214 646612 Fax 43 6214 646622 EMail HM mail hofmann megaplan com TECHNICAL MAINTENANCE MS400 2 Version C Type 0967 MS400 2P Version D Type 1001 19 08 2013 English ...

Страница 2: ......

Страница 3: ... 2 C M400P 2 D The wheel balancer can operate at 115 V 50 60 Hz or 230 V 50 60 Hz To change the power supply voltage make the following modifications No Description Image 1 Replace the motor 2 Replace the capacitor SHEET 001 3 Replace the power board ...

Страница 4: ...LOGIC BOARD INITIALISATION Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Turn on the machine while holding down the button 2 Press to confirm 3 Initialisation done SHEET 002 ...

Страница 5: ...SELF DIAGNOSTICS Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Press 2 Press 3 Press SHEET 003 ...

Страница 6: ...he right hand display with a number between 0 and 255 Turning the wheel in the rotation direction the number displayed must increase Turning the wheel in the opposite direction the number must decrease In one full turn of the wheel the number 0 must appear once only Press 7 Statistical control parameter for internal use not important Press ...

Страница 7: ... R1 It must be equal to 200 30 with the shaft bare Press 9 Indicates the output of the piezo sensor R2 It must be equal to 200 30 with the shaft bare Press 10 Displays the DISTANCE sensor value Press 11 Displays the DIAMETER sensor value Press ...

Страница 8: ...12 Displays the WIDTH sensor value Press 13 End of self diagnostics To end self diagnostics at any time press ...

Страница 9: ...SPINDLE UNBALANCE RESET Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Press 2 Press 3 Press SHEET 004 ...

Страница 10: ...4 Press 5 Press in sequence 6 To proceed with the unbalance reset Press spin with the shaft bare 7 Spindle unbalance reset complete ...

Страница 11: ...8 To view the unbalance and timing values used to reset the spindle unbalance continue as follows Press 9 Press 10 Press 11 Press ...

Страница 12: ...d the timing value right hand display used to reset the inside unbalance are shown IN LED on Press 14 The unbalance value left hand display and the timing value right hand display used to reset the outside unbalance are shown OUT LED on Press 15 End of value reading ...

Страница 13: ...TO ENABLE AUTOMATIC GAUGES Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Press 2 Press 3 Press SHEET 005 ...

Страница 14: ...4 Press in sequence within 5 seconds from when has been pressed 5 Press 6 Press 7 select ON by pressing ...

Страница 15: ...8 Press to confirm 9 Press to cancel self diagnostics in any phase ...

Страница 16: ...DISTANCE SENSOR ADJUSTMENT Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Remove the weight tray see the relative instructions 2 Press 3 Press SHEET 006 ...

Страница 17: ...4 Press 5 Press 6 Press 7 Press ...

Страница 18: ...ress 10 The wording diS appears on the left display while a number appears on the right display which varies when the distance gauge is moved 11 Back off the screws fastening the pulley on the potentiometer shaft ...

Страница 19: ...12 Leave the gauge in rest position 13 Turn the potentiometer shaft with a screwdriver holding the pulley firm 14 until reading a number between 5 and 15 15 Tighten the screw ...

Страница 20: ...16 Refit the weight tray 17 Calibrate the automatic gauges ...

Страница 21: ...00P 2 D No Description Image 1 After DISTANCE SENSOR ADJUSTMENT press 2 The wording dIA appears on the left display a number appears on the right display which varies when the gauge is turned 3 Pull out the gauge and rest it on the adapter surface SHEET 007 ...

Страница 22: ...4 Back off the screw that secure the potentiometer on the pulley 5 Turn the potentiometer shaft with a screwdriver holding the pulley firm 6 until reading a number between 5 and 15 7 Tighten the screw ...

Страница 23: ...8 Refit the weight tray 9 Calibrate the automatic gauges ...

Страница 24: ...M400 2 C No Description Image 1 The wheel balancing machine is packed with the threaded terminal removed 2 Carefully clean the inside of the adapter where the terminal will be secured 3 Allen wrench provided threaded terminal SHEET 008 ...

Страница 25: ...4 Insert the threaded terminal in the adapter 5 Lock the threaded terminal by fully screwing down the hexagonal screw using the wrench provided tighten it well 6 Fitted threaded terminal ...

Страница 26: ...C M400P 2 D No Description Image 1 The wheel balancing machine is shipped with the microswitch already fitted in the correct position 2 Insert the guard pipe in the bushing 3 Hold the bushing in position while inserting the pipe SHEET 009 OK ...

Страница 27: ...4 If the bushing is free to move the microswitch may be damaged 5 Close the guard 6 Position the ring with the head of the microswitch in the slot 7 Tighten the first grub screw ...

Страница 28: ...8 Open the guard 9 Tighten the second grub screw 10 Fit the spring 11 Fitted guard ...

Страница 29: ...12 SONAR WIDTH If present connect the cable to the relative connector on the rear of the base ...

Страница 30: ...RAY REMOVAL Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Remove the 2 front caps of the weight tray 2 Remove the rear cap of the weight tray 3 Undo the 2 front screws of the weight tray SHEET 010 ...

Страница 31: ...ar screw of the weight tray 5 Push the weight tray slightly to the left and then lift it to prevent it from jamming against the pulley of the automatic gauge 6 Completely remove the weight tray 7 Weight tray removed ...

Страница 32: ...NERATOR REPLACEMENT Models M400 2 C No Description Image 1 Disconnect the flat cable connector 2 Detach the anti rotation spring 3 Remove the phase generator by undoing the hexagonal screw turning it clockwise SHEET 011 ...

Страница 33: ...4 To refit it operate in reverse order from removal ...

Страница 34: ...MENT Models M400P 2 C M400P 2 D No Description Image 1 Fit the SE spacer on the terminal complete with collar 2 Close the spindle the encoder becomes visible through the window on the plate 3 Detach the anti rotation spring SHEET 011 ...

Страница 35: ...ndoing the hexagonal screw turning anticlockwise 5 Disconnect the flat cable 6 Detach the board from the Nylon spacers 7 Remove the encoder passing the board through the rectangular hole of the plate positioned near the spacers ...

Страница 36: ...8 To refit perform the operations in reverse order ...

Страница 37: ...00P 2 D Nr Description Image 1 Remove the weight tray see the relative instructions Remove the encoder see the relative instructions 2 Mark with a felt tip pin the position of the plate on the base this will allow correctly aligning the plate when refitting it SHEET 012 ...

Страница 38: ...ndo the 2 screws A M400P 2 If the wheel balancing machine is fitted with a pneumatic spindle also undo the 3 screws B 4 Undo the 2 screws C 5 Disconnect the 2 potentiometer cables from the board A A B C C ...

Страница 39: ...6 Remove the gauge unit 7 M400P 2 CYLINDER UNIT REMOVAL Close the compressed air and disconnect the tube 8 Turn the cylinder unit 90 90 ...

Страница 40: ...9 To remove the cylinder unit the internal plate must be positioned with one of the two round sides facing up 10 Remove the cylinder unit pulling upward 11 REFITTING Fit the cylinder unit vertically ...

Страница 41: ...12 Turn the cylinder unit 90 13 Reposition the gauge unit use the mark previously made on the base 14 Screw in the 2 screws A and the 2 screws C 90 A C ...

Страница 42: ...15 Screw in the 3 screws B that support the cylinder unit without tightening them 16 Alignment shim part no 22FP85322 17 Fit the alignment shim into place SPESSORE PER ALLINEAMENTO 22FP85322 B ...

Страница 43: ...18 Reconnect the tube and open the compressed air 19 Open the spindle 20 Tighten the 3 screws ...

Страница 44: ...21 Close the spindle 22 Remove the shim 23 Reconnect the potentiometer cables ...

Страница 45: ...24 Refit the encoder Refit the weight tray ...

Страница 46: ... the weight tray see the relative instructions Remove the gauge unit and the cylinder unit see the relative instructions Remove the encoder see the relative instructions 2 Disconnect the motor capacitor and power supply cables and the flat cable Disconnect the piezo extension cable SHEET 013 ...

Страница 47: ...3 Undo the 4 upper retaining screws 4 Undo the 6 remaining spindle unit retaining screws 5 Gently remove the spindle unit ...

Страница 48: ...6 Spindle unit 7 Unscrew and remove the nut with relative washer pack of the dynamic piezo 8 Loosen the internal nut of the static piezo ...

Страница 49: ...9 Unscrew and remove the nut with relative washer pack of the static piezo 10 Undo the spindle plate retaining screws 11 Remove the spindle unit from the box ...

Страница 50: ...12 Replace the piezo sensors 13 Position the static piezo 14 Position the dynamic piezo ...

Страница 51: ...h the box and lock the two retaining screws 17 To lock the piezo position the following parts in sequence large flat washer 4 Belleville washers with the concave side facing the large washer small flat washer nut These must be tightened with a 400 kg cm torque wrench ...

Страница 52: ...of the dynamic piezo with a 400 kg cm torque wrench 19 Tension the tie rod of the static piezo screwing down the nut and then turn it a further 180 20 Check that the nut that joins the threaded bars is locked with a 400 kg cm torque wrench 180 ...

Страница 53: ...21 Lock the nut and relative washer pack of the static piezo with a 400 kg cm torque wrench 22 Cover both piezos with an abundant layer of silicone 23 Gently refit the spindle unit in the base ...

Страница 54: ...24 Screw in without tightening the 4 upper self threading screws 25 Screw in without tightening the 6 side self threading screws 26 Tighten the 4 upper screws with a 120 kg cm torque wrench ...

Страница 55: ...cm torque wrench 28 Reconnect the motor capacitor and power supply cables and the flat cable Reconnect the piezo extension cable 29 Refit the encoder the gauge unit the cylinder unit and the weight tray 30 Recalibrate the wheel balancing machine ...

Страница 56: ...POWER BOARD REPLACEMENT Modeo M400 2 C M400P 2 C M400P 2 D Nr Description Image 1 Remove the weight tray see relative instructions 2 Disconnect the motor cable 3 Disconnect the power cable SHEET 014 ...

Страница 57: ...4 Disconnect the potentiometer cables 5 Disconnect the flat cable 6 Disconnect the relay board cable if present ...

Страница 58: ...7 Disconnect the sonar cable 8 Disconnect the computer board power cable sonar signals 9 Disconnect the protection microswitch cable ...

Страница 59: ...10 Detach the board from the Nylon spacers 11 Fit the new power board performing the operations in reverse order ...

Страница 60: ...rim on the shaft Example 6 x 15 1 2 Take the exact measurements of the wheel mounted Caution Presetting of incorrect dimensions would mean that the machine is not correctly calibrated therefore all subsequent measurements will be incorrect until a new self calibration is performed with the correct dimensions 3 Press SHEET 015 ...

Страница 61: ...4 Press 5 Press 6 Press 7 Press ...

Страница 62: ... weight on the outside in any angular position Press 10 Shift the sample weight from the outside to the inside keeping the same angular position Press 11 Turn the wheel until the sample weight is in the 12 o clock position Press ...

Страница 63: ...12 End of calibration ...

Страница 64: ...ENCODER COUNT TEST Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Press 2 Press 3 Press SHEET 016 ...

Страница 65: ...position is shown on the right hand display with a number between 0 and 255 Turning the wheel in the rotation direction the number displayed must increase Turning the wheel in the opposite direction the number must decrease In one full turn of the wheel the number 0 must appear once only Press to exit self diagnostics ...

Страница 66: ... OUT 60 OUT POS at low at 6 o clock IN 60 OUT 0 IN POS at low at 6 o clock Permitted tolerance on 60g 5 Residual tolerance max 5g ADAPTER TEST With the wheel perfectly balanced tilt 180 and measure the unbalance values MAX ERR 6 gr It is advisable to use a new wheel of good quality for this test The error due to tilting should be less than 6g Replace the centring cones if necessary SHEET 017 ...

Страница 67: ...MACHINE OSCILLATION TEST Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Press 2 Press 3 Press SHEET 018 ...

Страница 68: ... 10 spins with automatic calculation and display of the maximum oscillation If you wish to run more than 10 automatic spins press and to select the desired number in the range 5 999 7 Oscillation max permitted 2 g i e 4 grams on the indicator To return to the measuring frame press ...

Страница 69: ...DISTANCE GAUGE CALIBRATION Model M400 2 C M400P 2 C M400P 2 D No Description Image 1 Mount the calibration tool on the shaft 2 Press 3 Press SHEET 019 ...

Страница 70: ...4 Press 5 Press 6 Press 7 Press ...

Страница 71: ...8 Press 9 Leave the distance gauge in rest position and press 10 Move the gauge up against the calibration tool in line with the adapter surface and press 11 Return the gauge to rest position ...

Страница 72: ...12 Calibration done ...

Страница 73: ...DIAMETER GAUGE CALIBRATION Model M400 2 C M400P 2 C M400P 2 D No Description Image 1 Mount the calibration tool on the shaft 2 Press 3 Press SHEET 020 ...

Страница 74: ...4 Press 5 Press 6 Press 7 Press ...

Страница 75: ...8 Move the gauge to the 80mm measuring position bottom notch and press 9 Move the gauge to the 150mm measuring position top notch and press 10 Return the gauge to rest position 11 Calibration done ...

Страница 76: ...WIDTH SONAR CALIBRATION Model M400 2 C M400P 2 C M400P 2 D No Description Image 1 Press 2 Press 3 Press SHEET 021 ...

Страница 77: ...4 Press 5 Press 6 With the gauge in rest position measure the distance from the 0 of the distance gauge to the 0 of the width sonar 7 Enter the distance measured by pressing and ...

Страница 78: ...If after calibration the control detects a measuring error of more than repeat the calibration changing the distance value tolerance 20 mm with respect to the value measured with a rule until obtaining a correct width value ...

Страница 79: ...C M400P 2 C M400P 2 D No Description Image 1 Remove the weight shelf see relative instructions Remove the gauge unit see relative instructions Remove the encoder see relative instructions 2 Detach the spring 3 Detach the pedal rod SHEET 022 ...

Страница 80: ...4 Pull the brake rod out from the top 5 Unscrew the fastening nut 6 Remove the brake 7 Mechanical brake removed ...

Страница 81: ... 2 C M400P 2 C M400P 2 D No Description Image 1 Mount the calibration tool on the shaft 2 Move the gauge up against the calibration tool in line with the adapter surface and press 3 After acquiring the dimensions hold down SHEET 023 ...

Страница 82: ...4 Check that the distance measured is 212 3 ...

Страница 83: ...BELT TENSION CHECK Model M400 2 C M400P 2 C M400P 2 D No Description Image 1 Machine without weight tray see Weight tray removal 2 Hold the wheel locked and press SHEET 024 ...

Страница 84: ...3 If the belt tension is correct the motor pulley must not turn ...

Страница 85: ...LT TENSION ADJUSTMENT Model M400 2 C M400P 2 C M400P 2 D Tools required Pin wrench UNI ISO 2982 2983 Nr Description Image 1 Remove the weight tray 2 Release the power plate cables from the clips SHEET 025 ...

Страница 86: ...3 Loosen the 3 power plate retaining screws 4 Place the power plate on the bottom of the base 5 Accessing the motor ...

Страница 87: ...6 Loosen the two fastening nuts on the left hand side of the motor 7 Use the pin wrench illustrated 8 Position the pin wrench on the socket wrench and then adjust the belt tension ...

Страница 88: ...ts 10 If possible check the belt tension with suitable instruments 1 1 In service conditions the belt tension is between 380 and 400 Hz When installing a new belt overtension it up to 450 Hz to recover the natural belt elongation that occurs in the first 48 hours ...

Страница 89: ...escription Image 1 Use a megohmmeter with a full scale of min 3000 MΩ 2 Test the insulation between the dynamic sensor poles between the blue and the yellow wires MIN 2000 MÙ 3 Test the insulation between the yellow wire and the machine body MIN 2000 MÙ SHEET 026 ...

Страница 90: ... 2000 MÙ 5 Test the insulation between the static sensor poles between the white and the yellow wires MIN 2000 MÙ 6 Test the insulation between the yellow wire and the machine body MIN 2000 MÙ 7 Test the insulation between the white wire and the machine body MIN 2000 MÙ ...

Страница 91: ...8 Discharge the piezo sensors before connecting them to the electronic circuit ...

Страница 92: ...emove the weight tray see relative instructions Remove the encoder see relative instructions Remove the SE terminal see relative instructions 2 Remove the gauge unit and the cylinder unit see relative instructions 3 Remove the 2 grub screws that fasten the external ring nut SHEET 027 ...

Страница 93: ...wrench to act on the external ring nut 5 Hold the rod locked with a flat jaw wrench 6 Remove the ring nut You will need to use force when removing the ring nut as the rod threading will have been scratched by the fastening grub screws ...

Страница 94: ...7 Remove the air springs and plate 8 Using a needle file file off the burr on the rod threading in the ring nut locking area 9 Fit the air springs ...

Страница 95: ...10 Fit the plate 11 Fit the ring nut holding the rod locked with the flat jaw wrench 12 Lock the ring nut by screwing it down with the adjustable toothed jaw wrench ...

Страница 96: ...ng grub screws 14 Refit the gauge unit and the cylinder unit see relative instructions 15 Refit the SE terminal see relative instructions Refit the encoder see relative instructions Refit the weight shelf see relative instructions ...

Страница 97: ...VDD UNIT REFASTENING Model M400 2 C M400P 2 C M400P 2 D SHEET 028 ...

Страница 98: ...Model M400P 2 C M400P 2 D No Description Image 1 Continue with Weight tray removal Magnetic encoder replacements Gauge unit and cylinder removal 2 Gauge units and cylinder removed 3 Remove the motor fastening nuts SHEET 029 ...

Страница 99: ...4 Remove the motor 5 Remove the belt 6 Replace the belt ...

Страница 100: ...7 Fit the motor without locking the nuts 8 Identify the hole on the wall for belt tension 9 Insert the screwdriver and tension the belt also see the specific instructions ...

Страница 101: ...ll act on the motor tie rods using a jaw wrench 11 Lock the motor 12 Insufficient tautness may cause rapid belt wear The specific instructions for the belt tensioning and slipping check procedures are given in the maintenance manuals ...

Страница 102: ...POWER LAYOUT DIAGRAM Model M400 2 C M400P 2 C SHEET 030 ...

Страница 103: ...POWER LAYOUT DIAGRAM Model M400P 2 D SHEET 030 ...

Страница 104: ......

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