Related Manuals for MANATEC LX WB-VL-65 DSP
Summary of Contents for MANATEC 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 Page No. WARRANTY – STATUTORY CLAUSE INSTALLATION 2.1. SAFETY INFORMATION 2.2. INSTALLATION REQUIREMENTS 2.2.1. LOCATION 2.2.2. POWER REQUIREMENT 2.2.3. SPACE REQUIREMENTS 2.2.4. ACCESSORIES & TOOLS REQUIREMENTS 2.3. UNPACKING 2.3.1. LCV MODELS 2.3.2. HCV MODELS 2.4. FOUNDATION 2.5. INTEGRATION 2.5.1. DISPLAY UNIT (Monitor column & Monitor) 2.5.2.
- Page 3 PARTS REPLACEMENT PROCEDURE 5.1. POWER PANEL 5.1.1. DSP BOARD 5.1.2. MOTOR CONTROL BOARD 5.1.3. SBC BOARD 5.1.4. MEMORY CARD (with Balancing program) 5.1.5. SMPS 5.1.6. MCB (HCV) 5.1.7. BUZZER 5.1.8. COOLING FAN 5.2. ROTOR LCV MODELS HCV MODELS 5.2.1. MOTOR 5.2.2.
- Page 4 WARRANTY – STATUTORY CLAUSE The equipment is provided with Warranty for one year from the date of installation or thirteen months from the date of despatch whichever is earlier, against any manufacturing defect. The Warranty is subjected to the following conditions: Ensure that proper power supply with protective Earthing is provided to the equipment through uninterruptible Power Supply (UPS).
- Page 5 INSTALLATION Installation is intended to be performed by properly trained Service personnel. Thoroughly read all Safety labels & Manual instructions before installing. Review all requirements of installation to avoid oversights resulting in revenue loss, and lost customer confidence. 2.1. SAFETY INFORMATION The safety messages presented here are reminders to the installation Engineer to exercise extreme caution during installation and training: ...
- Page 6 Proper Earthing must be provided. Also ensure that live phase is on the correct side of the socket as per the country requirement. It is strongly recommended to use a CVT (1KVA capacity for LCV models and 3KVA capacity for HCV models). Neutral to Line Volt should be 230VAC ±10% (for LCV with 230V operation) Neutral to Line Volt should be 110VAC ±10% (for LCV with 110V operation) Line to Line Volt should be 415VAC ±5% (for HCV with 400V operation)
- Page 7 2.3. UNPACKING Unpack the Main cabinet corrugated box Un-wrap the VCI sheet from Main cabinet. Remove all the four bolts from Main cabinet base to take it out from pallet. Ensure the contents as per the packing list 2.3.1. LCV MODELS Package Package Package contents...
- Page 8 2.3.2. HCV MODELS Package Package description Package contents 1. Main cabinet assembly 1 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.
- Page 9 2.4. FOUNDATION Proof of safe floor load capacity is the owner's responsibility It is strongly recommended to install Wheel balancer using Foundation bolts. Failing to comply may lead to toppling of cabinet & damage to equipment. Manufacturer will not be responsible for non-compliance Place the Cabinet at the designated location and mark the Cabinet foundation fixing holes.
- Page 10 Fix the Monitor with Monitor plate using WH-PH screw (4 Nos.) firmly and ensure the straightness. Connect one end of the Monitor power cord with Monitor and other end to the socket provided at rear (Right) side of cabinet. The location will be indicated by a sticker.
- Page 11 2.5.3. WIDTH MEASURING ROD (Applicable only for Premium model) Remove the Bracket back sheet from Bracket. Fix the Width rod assy with bracket using Allen screw & Spring washer (2 Nos.) each. Ensure the Width assy is perpendicular to cabinet. Fig.
- Page 12 DESCRIPTION OF MAIN PARTS 3.1. DSP BOARD WITH MINI UPS Digital Signal Processing board receives the raw unbalance signals from Piezo sensor, Wheel diameter & Wheel width from RLS Sensor and amplifies it through analog signal conditioners. Then the signals are processed digitally to ensure stable & accurate unbalance readings &...
- Page 13 Fig. 10 3.2.3. SBC BOARD It is a Linux OS compatible Single Board Computer that runs the front end balancing program loaded in an External memory card. This board delivers High definition Audio & Video output. Board configurations: All the signals are connected with this board using a single FRC cable. Power (5VDC) is given to this board through a Micro USB cable.
- Page 14 3.2.4. SMPS The 15W SMPS generates Single output 5V/3A, output. It is a wide operating voltage SMPS ranging from 85V to 264VAC / 50Hz - 60Hz input. The DC 5V output is then converted to +12V, -5V by DC to DC Converter section in E- DSP board.
- Page 15 3.3.3. REVOLUTION INDEX ENCODER BOARD This board is fixed with Rotor plate to detect the revolution pulse and Index for each rotation using IR LEDs and Photo detector positioned exactly opposite to each other at a fixed distance. The detected pulse & index signals are transmitted to DSP board via E- Distance encoder board.
- Page 16 3.6. KEYBOARD This soft touch Membrane pad is an user friendly input device with Icon based keys for universal understanding. The Keypad is available in the Top cover. Fig. 18 3.7. DISTANCE / DIAMETER / WIDTH MEASUREMENT MECHANISM The mechanism is equipped with an E-Distance encoder & RLS sensors for measurement of Wheel Distance &...
- Page 17 3.8. WHEEL GUARD Wheel guard is provided to prevent the balancing weights flying out from its rim or stone / foreign particles sticking to the tyre in any direction except towards the floor. Also a safety Interlock switch is provided to ensure that the Wheel guard is closed during spinning of wheel.
- Page 18 OPTIONS This feature is protected with service password and should be used only by authorised Service personnel Program related options can be accessed by using the Navigation keys to select button in the WELCOME screen followed by pressing key. System will prompt to enter the Password. keys as password.
- Page 19 SPINDLE ZERO By default, LOW POINT will be highlighted. Press key to proceed with Low point calibration. Fig. 25 Remove Wheel, Wheel seating cone & QCLN from shaft if already mounted. Press key twice to run the Empty shaft. SA & SB Sensor values will be displayed (in millivolts) in the respective window (limit: 30mV) including RPM and the system will go to RIM PARAMETERS screen.
- Page 20 TYRE ZERO Enter the Wheel parameters as explained in Chapter 7.4.1 of Operating manual and then press key to go the TYRE ZERO screen. Fig. 27 Press key twice to run the wheel. SA & SB Sensor values will be displayed (in millivolts) in respective window and goes to OUTER CALIBRATION screen.
- Page 21 Remove the Calibration weight from the Outer plane & fix it on the Inner plane of the wheel directly opposite as shown below: Fig. 29 Press key twice to perform Inner calibration. The added weight will be displayed in the Inner plane window and the Outer plan window will be zero. Fig.
- Page 22 4.1.2. HCV MODELS Both LCV calibration & HCV calibration should be performed separately. “Car cal. data not available” / “Truck cal. data not available” message will be displayed in WHEEL RUN screen if Calibration data is not available Pre calibration (Applicable for Factory & Authorized Engineer) Following sub options will be provided in WEIGHT CALIBRATION screen as shown below.
- Page 23 For Truck use a fairly balanced wheel with Rim dia of 20”-24”. Unbalance should be 50gm min. For Car use a fairly balanced wheel with Rim dia of 12”-16”. Unbalance should be 30gm min. keys to move to next parameters. If empty shaft unbalance is more, “Spindle unbalance is beyond limits for calibration”...
- Page 24 DO NOT disturb the Wheel position until Outer calibration is performed Press key twice to perform Outer calibration. The added weight will be displayed in the Outer plane window and the Inner plane window will be zero. The system will proceed to perform Inner calibration. Remove the Calibration weight from the Outer plane &...
- Page 25 4.2. DIAMETER CALIBRATION (Applicable only for Premium/+ model) Width & Diameter calibration could not be done if “Auto width" & "Auto dia" option is disabled in SETTINGS as explained in Chapter 8 of Operating manual Use navigation keys to select DIA CALIBRATION & press key.
- Page 26 Move the Distance/Diameter measuring rod & touch the inner plane profile of the Rim properly and hold it for 3 seconds until Audio indication and then move the Distance/Diameter measuring rod to its home position. Fig. 41 key to save the Diameter calibration values. “Dia calibration saved and Press completed”...
- Page 27 Press key to save the Zero position. Return the Width rod to Home position. System will go back to WIDH CALIBRATION screen. Select MCD CALIBRATION menu and press key. Following screen will be displayed: Fig. 43 Touch the 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.
- Page 28 Move the Distance/Diameter measuring rod & touch the inner plane profile of the Rim properly and hold it for few seconds until Audio indication and then move the Distance/Diameter measuring rod to its home position. System will go to next screen. Fig.
- Page 29 4.5. DISTANCE ROD TEST Once Distance measuring test is selected, move the Distance measuring rod from Home position to maximum length and ensure the count increments from 0 to 90 (±1 count) in steps of 1 in the window. Now return the rod to home position &...
- Page 30 4.8. LASER & TORCH SETTING (Applicable for Premuim+ model) After entering into the OPTIONS, select the Laser Torch button. Following screen will be displayed: Fig. 52 keys to select the required option and then press key to turn on of turn off the feature.
- Page 31 4.11. BACKUP FACTORY DATA Once Backup Factory Data is selected, the system will backup the Factory calibration data automatically: Fig. 55 DO NOT press any key during the backup process. Once the process is completed, system will go back to OPTIONS screen. Important Note: Ensure calibration is correct before doing Backup 4.12.
- Page 32 4.14. RESTORE FACTORY CALIBRATION Once Restore Factory Calibration is selected, the system will restore the Calibration data automatically: Fig. 58 DO NOT press any key during the backup process. Once the process is completed, system will go back to OPTIONS screen. 4.15.
- Page 33 PARTS REPLACEMENT PROCEDURE Switch off Balancer and disconnect the Mains power cord. Remove the top cover from main cabinet 5.1. POWER PANEL Remove the all connections from Power panel assembly and detach it from Main cabinet by removing the fasteners. LCV models HCV model (image to be changed)
- Page 34 Switch ON the Balancer and conduct Self Test program as explained in Chapter 4.6 without any errors. LCV model HCV 3Phase model HCV 1Phase model Fig. 62 5.1.3. SBC BOARD Remove the Cooling fan assembly mounted over the SBC board. Disconnect the Power I/P (Micro USB), Video O/P (HDMI), DSP board (40Pin FRC) connectors &...
- Page 35 5.1.5. SMPS Disconnect the AC I/P & DC O/P wires. Remove the fasteners and replace the defective SMPS with New one and restore the wiring by observing the correct I/P & O/P indications in SMPS, except the O/P power to DSP Interface board (refer Wiring diagram - Chapter 7.2).
- Page 36 5.1.8. COOLING FAN Remove Fan connector (2Pin SR) from DSP board. Remove the Fan assembly mounted over the SBC board. Fig. 66 Remove the defective Fan from the Fan plate and replace it with new one. Then mount the new fan assembly over the SBC board by observing the air flow direction and restore the connector.
- Page 37 Remove the Rotor fixing bolt and detach the Rotor assembly from cabinet. Fig. 70 Fixing the new Rotor assembly with Cabinet & fasten it firmly. Fig. 71 Fixing the SB Screw rod with the Rotor & tighten it firmly with nut. Before fastening the Sensor nut, ensure the SA &...
- Page 38 HCV MODELS Remove the Closing guards at the Rotor side as shown below: Fig. 75 Remove the Threaded shaft, Motor belt and remove the Revolution index encoder board connections (10Pin FRC). Fig. 76 Loosen the Sensor SA & SB fixing nuts & detach SB screw rod from Rotor stem: Fig.
- Page 39 Fix the new Rotor assembly with Cabinet & fasten it firmly. Also ensure the 0° of Rotor assembly while tightening the fasteners. Fix the SB screw rod with Rotor stem by maintaining its same length. Tighten the SB screw rod nut. Ensure the SA & SB screw rods are centered in the slotted hole in Cabinet: SA + Sensor SA...
- Page 40 5.2.1. MOTOR Disconnect the Motor cable from Motor control board and remove the Belt from motor pulley. LCV model HCV model Fig. 81 Remove the Belt from Motor pulley. Detach Motor from main cabinet by removing the Allen screws. Fig. 82 LCV model HCV model Fig.
- Page 41 Take out the Revolution Index encoder board from Rotor. Fix the new board with Rotor by matching the slot in the Round segment encoder. Do not touch the Encoder. Connect 10Pin FRC cable with Revolution index encoder board. Switch ON the Balancer. Run Wheel Tracking test (Ref. Chapter 4.4) & Duty cycle test (Ref.
- Page 42 Fig. 85 5.3. MECHANICAL BRAKE (NA for SR Rev.R50/above & HCV models) 5.3.1. LIMIT SWITCH Remove the Limit switch clamp and disconnect the cables from Motor control board. Fig. 86 Remove the Limit switch from clamp and fix new Limit switch with correct direction.
- Page 43 5.4. DISPLAY UNIT Remove the Monitor power cord and HDMI cable from the Monitor. Fig. 88 Detach the Monitor from Monitor column plate. Replace the Monitor with new one and fix it. Restore the Monitor power cord & HDMI cable connections Power up the Balancer and ensure the Monitor functions.
- Page 44 LCV Basic model HCV model 45mm 60mm Cabinet Cabinet outer outer outer outer face face face face LCV Premium/+ model Fig. 91 Connect 10pin FRC cable with E-Distance encoder board. Switch ON the Balancer & run Distance measuring test as explained in Chapter 4.5 to ensure the Distance measuring rod counts.
- Page 45 IN WIDTH MEASURING ROD Remove the Safety cover from Width block and disconnect the Width cable from RLS Sensor board and also remove the connector from Outer Dia RLS Board: Fig. 94 Remove & replace the defective board, ( either Width or the Outer dia) with new RLS Sensor board .
- Page 46 5.8. LASER BEAM Open the Laser/ Torch cover by removing the screws. Take out the Laser from housing and then by removing the grub screws. Remove the Laser cable by disconnecting the Torch connector CN8 (3Pin SR) from I/F Board. Take out the cable through the hole in cabinet. Replace the Laser.
- Page 47 RECOMMENDED SPARE PARTS (For 2 years operation) Qty/Sys WB-VL-65 WB-VL-65 WB-VH-200 WB-VL-65 WB-VL-65 WB-VH-200 DSP LX DSP LX DSP LX DSP LX Code Spare description Premium / + Premium / + 230V 50Hz 230V 50Hz 440V 50Hz 110V 60Hz 110V 60Hz 220V 60Hz Z2193 Z2194...
- Page 48 DIAGRAMS 7.1. BLOCK DIAGRAM 7.1.1. LCV MODELS Fig. 99 Ref.: WB-VL-SM Ver.1 3.doc...
- Page 49 7.1.2. HCV MODEL THREE PHASE OPERATION Fig. 100 Ref.: WB-VL-SM Ver.1 3.doc...
- Page 50 SINGLE PHASE OPERATION Fig. 101 Ref.: WB-VL-SM Ver.1 3.doc...
- Page 51 7.2. WIRING DIAGRAM 7.2.1. LCV MODELS Fig. 102 (1 of 3) Ref.: WB-VL-SM Ver.1 3.doc...
- Page 52 Fig. 102 (2 of 3) Ref.: WB-VL-SM Ver.1 3.doc...
- Page 53 Fig. 102 (3 of 3) Ref.: WB-VL-SM Ver.1 3.doc...
- Page 54 7.2.2. HCV MODEL THREE PHASE OPERATION Fig. 103 (1 of 3) Ref.: WB-VL-SM Ver.1 3.doc...
- Page 55 Fig. 103 (2 of 3) Ref.: WB-VL-SM Ver.1 3.doc...
- Page 56 SINGLE PHASE OPERATION Fig. 103 (3 of 3) Ref.: WB-VL-SM Ver.1 3.doc...
- Page 57 TROUBLE SHOOTING The common troubles and error messages which can be attended by the users are listed in the table given below. For Troubles and Error messages other than that are listed in the table contact the Service Engineer for Trouble shooting. The Service Engineer may ask for information to help in diagnosing the service concern.
- Page 58 Error Causes Remedies Empty shaft millivolts Check for any shake in cabinet foundation. Check the Rotor assembly for it proper fitness. Spindle may not be in specified Remove the QCLN/Cone/Wheel while running unbalance is range. Empty shaft may have beyond limits for empty shaft.
- Page 59 EQUIPMENT Error Causes Remedies Run the Key test (Ref. Keypad getting struck or not Loose contact in Keypad Chapt.4.10) and trouble shoot. working Check & ensure the Keypad connection. Some of the keys are not ...
- Page 60 Error Causes Remedies Improper foundation or supply line. Ensure proper foundation. disturbed. Check and correct Loose Loose connection in Laser connection from DSP board to connector Laser generator connection. Laser line not working Fault in Laser line generator ...
- Page 61 Manufactured by All rights reserved. Any reproductions of this document, partial or complete, are not allowed without prior consent of Manufacturer 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 changes at any time without further notice to any of its products to improve reliability, functions, design or whatever can be thought suitable...