Corghi EM8540 Operating manual

EM8540 N.A.
Cod. 4-104006 - 1.0 del 06/05
English Technical service manual

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Sperimentale Equilibratrici
- 1 -
May 2005
TECHNICAL SERVICE MANUAL EM 8540
Version with roller-driven wheel spin
CONTENTS
ELECTRICAL CONNECTION...................................................................................................................................2
SERVICE PROGRAMS ...............................................................................................................................................2
87 Working environments:............................................................................................................................................ 2
88 Sensitivity calibration (2 spins):..............................................................................................................................2
90 Automatic position search (RPA):........................................................................................................................... 3
91 Cancel/reset:..............................................................................................................................................................3
93 Display current software version.............................................................................................................................4
95 Display phase calibration coefficient......................................................................................................................4
96 Display pickup signal and phase. ............................................................................................................................ 4
97 Display search circuit board operation (encoder)...................................................................................................5
98 Display sensor operation..........................................................................................................................................5
99 Preset speed wheel spin setting: ..............................................................................................................................6
100 Electrical actuator control function:......................................................................................................................6
101 Counters:................................................................................................................................................................. 6
MBE161 MOTHERBOARD SWITCH CONFIGURATION....................................................................................6
DIAGNOSTICS PROGRAMS.....................................................................................................................................7
REMOVING THE WEIGHT-HOLDER LID .............................................................................................................7
MBE161 MOTHERBOARD UPDATES ....................................................................................................................7
REPLACING THE INSIDE SENSOR (DISTANCE AND DIAMETER) REED MICROSWITCH AND
ENCODERS................................................................................................................................................................... 7
Replacing and adjusting the reed microswitch ............................................................................................................7
Checking the operation of the diameter encoder [di] .................................................................................................. 8
Checking the operation of the distance sensor [d].......................................................................................................8
Replacing the diameter encoder....................................................................................................................................8
Replacing the distance encoder..................................................................................................................................... 9
REPLACING AND ADJUSTING THE OUTSIDE SENSOR POTENTIOMETER (WIDTH
POTENTIOMETER).....................................................................................................................................................9
Sensor errors: ...............................................................................................................................................................10
REPLACING AND ADJUSTING THE PICKUPS..................................................................................................10
REPLACING THE BRAKE PEDAL SWITCH .......................................................................................................11
REPLACING THE ENTIRE CENTRAL UNIT.......................................................................................................11
REPLACING THE QUICK LOCK CENTRAL UNIT PNEUMATIC CYLINDER GASKETS.........................11
SPIN UNIT...................................................................................................................................................................12
Replacing the electrical actuator.................................................................................................................................12
Replacing the friction roller ........................................................................................................................................12
Replacing the brake shoe.............................................................................................................................................13
Replacing the motor.....................................................................................................................................................14
TROUBLE SHOOTING.............................................................................................................................................15
TROUBLE SHOOTING.............................................................................................................................................15
ERROR MESSAGES..................................................................................................................................................19

2
ELECTRICAL CONNECTION
All EM85XX balancing machines operate on single-phase power and are supplied preset for
the specified power supply (115 V, 280V or 230 V AC). To modify this setting, the
transformer primary must be adjusted to the available mains voltage.
SERVICE PROGRAMS
The purpose of these programs is to provide the information required for quickly and
efficiently testing the various parts of the machine.
The selection procedure is as follows:
• press either of the two arrow keys, and then, within two seconds, the wheel size setting
key. This selects the first service program (number 87).
• press the arrow keys to select the next (or previous) available program, until you have
selected the program you wish to use. Each selection results in display of the code
8X...9X (X varies with the program) on the LH display and a flashing "Ent" on the RH
display to indicate the need to confirm the selection by pressing "Enter";
• press the "Enter" key to confirm.
If the presetting is not confirmed within about three seconds, the system automatically exits
the Utility environment.
The various selectable programs (each with a different X) are described below.
87 Working environments:
allows three different operators to work at the same time;
Selecting the program results in the machine displaying:
- message 1, 2 or 3 on the RH display;
- message OP (operator) on the LH display.
This service program allows selection of the operator (1, 2 or 3)
by pressing "Enter".
To confirm selection of another operator, press F.
For each working environment, the following data are stored:
- balancing mode;
- wheel size;
- the last step in the optimization procedure (OPT).
To exit from the program (and the service environment) press F.
88 Sensitivity calibration (2 spins):
Allows calibration of the sensitivity.
This must be done when the user considers that the calibration is outside the tolerance range,
or when the machine itself prompts the procedure by displaying "Err CAL".
When the program is selected the machine displays “ d F ”, hence:
- fit the calibration disc on the balancing machine;
- place the inside sensor touching the calibration disc in line with the hole with the blue outline.
- press F to confirm, and then move the inside sensor to the rest position.
- the displays will show "CAL --I".
- fit the calibration weight to the outside of the disc (position 1);
- run a first spin;
- at the end of the spin the displays will show "CAL --I";
- fit the calibration weight to the outside of the disc again, but this time at 180° to the
previous position (position 2);
- run a second spin;

3
- at the end of the wheel spin, if the calibration has run successfully the message "END
CAL" will be displayed; otherwise, the message "Er3 CAL" will appear for a short time;
- press F to exit the calibration function.
NOTES
- On completion of the calibration procedure, remove the calibration weight and remove
the automatic calibration disc from the balancing machine;
- the user can interrupt the program at any moment by pressing F;
- if the machine displays "ER3 GE2", this indicates an error in performing the calibration
procedure; repeat the calibration;
- message "d 212" displays if the inside sensor has failed; to continue with calibration,
place the inside sensor against the blue hole on the calibration disc and enter the distance
value read on the sensor ruler in manual mode.
- the calibration procedure described above is valid for any type of wheel!
90 Automatic position search (RPA):
Selecting the program results in the machine displaying:
- message RPA on the LH display;
- message ON or OFF on the RH display.
When this program is selected it is possible to enable automatic weight position search by
pressing Enter.
Select:
- OFF to disable automatic position search;
- ON to enable automatic position search;
To exit from the program (and the service environment) press F.
91 Cancel/reset:
- display of the first gram of unbalance;
- rounding to the nearest inch of the diameter and width measured with the automatic
sensors.
Selecting the program results in the machine displaying:
- message "1 oF" on the RH display;
- message "on .5" on the LH display.
In normal operation, even when unbalance display in "gr x 1" is selected, the first gram of
unbalance is not displayed. In this condition, when program "91" is selected the machine
displays "1 oF" on the RH display. Pressing Enter enables display of the first gram and
amplification of the machine's sensitivity (the RH display reads "1 on"). When Enter is
pressed again, the system switches from one mode to the other in alternation.
At switch-on the machine presets to display the diameter and width measured with the
automatic sensors rounded to the nearest inch. In this condition, when program "91" is
selected the machine displays "on .5" on the LH display. Pressing Enter enables displaying
the diameter and width measured with the automatic sensors with a precision of a tenth of an
inch (the LH display reads "oF .5"). Press Enter again to switch between the two modes.
Important
Press Enter to change the display setting when the central element of the position centered indicator
is on. Press either of the two arrow keys to transfer control from one display to the other.
To exit from the program (and the service environment) press F.

4
The program is used for:
- maximum precision display of the unbalance values so as to be able to balance the wheel
perfectly and run further checks on it;
- maximum precision display (tenth of an inch) of the correspondence between the diameter
and width values measured with the automatic sensors and the nominal wheel dimensions.
93 Display current software version
Selecting the program results in the machine displaying:
- message "rEL" (release) on the LH display;
- numeric message "XX.Y" on the RH display, which is the version of the program
currently running on the machine.
- Pressing Enter displays: the date of the software version (day, month, year), the balancing
machine model and the country of destination.
To exit from the program (and the service environment) press F.
The program is used for:
checking the version of the CPU software and updating it, if necessary.
95 Display phase calibration coefficient
Selecting the program results in the machine displaying:
• "F" on the LH display
• the phase calibration coefficient on the RH display;
The data is expressed in encoder marks (integer part) and eighths of a mark (decimal part)
(each mark corresponds to approximately 1.4 degrees).
Press Enter to display the result of the disk calibration procedure.
To exit from the program (and the service environment) press F.
The program is used for:
- checking the values of the phase calibration coefficient are in the allowed range, from -
2.0 to +2.0.
- checking that the disk calibration values are between 97 and 103 grams;
96 Display pickup signal and phase.
Selecting the program results in the machine displaying:
- message "96" on the LH display;
- message "GO" flashing on the RH display.
Before selecting the program, proceed as follows:
- fit the simulator disc to the balancing machine;
- apply a sample weight to the outside of the rim;
- run a spin cycle.
The machine acquires the unbalance signals and then displays in sequence:
- the phase difference F between the pickup signals relative to the ideal value of 180° (RH
display). The data is expressed in encoder marks (integer part) and eighths of a mark
(decimal part) (each mark corresponds to approximately 1.4 degrees);
- values proportional to the levels of the signals from the inside and outside pickups.
- the signal amplifier calibration value;
- the spin speed;
- rejected periods.

5
Notes
•
The values displayed are independent of the set dimensions.
•
With the wheel stationary, the measured data can be displayed alternately by pressing
Enter.
• It is possible to run additional spin cycles while still in the program.
• To exit from the program (and the service environment) press F.
The program is used for:
checking that the displayed values are within the correct range:
- phase difference F from -2.0 to +2.0
- inside pickup signal I from 200 to 280
- outside pickup signal E from 110 to 170
- signal amplifier calibration from 55.8 to 57.8
- n. rejected periods from 0 to 6
97 Display search circuit board operation (encoder).
Selecting the program results in the machine displaying:
- message "Pos" on the LH display;
- a numerical value from 0 to 255, depending on the shaft angle, on the RH display.
If the program is evoked immediately after the machine is switched on, the display reads "Pos
rot" to indicate the need for turning the shaft until the encoder zero reference passes in front
of the search circuit board: when this is done the message cancels from the display.
It is also possible to run a spin cycle (the displays read "97 GO") during which the pulses
measured by the search circuit board are totaled. On termination of the spin cycle the LH
display shows the expected count (384) and RH display flashes the actual total. These values
are displayed for 5 seconds after which the current angular position of the shaft is again
displayed.
To exit from the program (and the service environment) press F.
The program is used for:
checking the operation of the search circuit board. When the shaft is turned in either direction
the count should run continuously from 0 to 255, and at the end of a spin cycle the two
displayed values should coincide.
98 Display sensor operation
Selecting the program results in the machine displaying:
- message "di" on the LH display;
- the value in marks of the signal from the diameter sensor on the RH display.
As the sensor is retracted, the value is continuously updated.
Press the keypad wheel data setting button, and the following display:
- message "d" on the LH display;
- the value in marks of the signal from the distance sensor on the RH display.
The value changes as the sensor is moved in/out.
Press the keypad wheel data setting button, and the following display:
- message "Lr" on the LH display;
- the converted voltage from the width potentiometer.
This value also changes as the outside sensor is moved in/out.
To exit from the program (and the service environment) press F.

6
The program is used for:
checking the operation of the sensors used for automatic data input. When the sensors are
moved, the displayed values should vary continuously within the following ranges:
diameter sensor from 0 to 1000 (+/-10) from standby to full stroke (see
“replacing the diameter sensor”);
distance potentiometer from 0 to 490 (+/-10) from standby to full stroke;
width potentiometer from 5 to 245 (+/-10) from standby to full stroke.
99 Preset speed wheel spin setting:
Selecting this program displays the set default speed value (rpm). The arrow keys can be used
to modify the speed setting at which the data will be acquired in subsequent wheel spins
performed in the context of this program.
To exit from the program (and the service environment) press F.
The program is used for:
checking that the unbalance values are calculated precisely for all allowed spin speeds.
100 Electrical actuator control function:
Selecting the program results in the machine displaying:
- message "Pos" on the LH display;
- a numerical value which shows the position (in marks) of the electrical actuator, on the
RH display.
The program enables:
• moving the actuator to the spin or brake position with the START/STOP buttons
respectively.
• moving the actuator gradually with the arrow keys. This function is particularly important
when servicing or replacing the actuator;
• moving the actuator to mid-stroke with ENTER;
To exit from the program (and the service environment) press F.
The program is used for:
- Checking the operation of the electrical actuator and its control logic.
- Servicing the spin/brake unit.
- The no load current values (in marks) read by the electrical actuator also appear, both in
spin and brake modes.
101 Counters:
Selecting the program results in the machine displaying the following counters:
• [LAN TOT] n. of spin cycles run;
• [LAN CAL] n. of spin cycles run since the most recent sensitivity calibration,
• [N° PIS] n. of electrical actuator cycles.
Press Enter to select the counter you wish to display.
MBE161 MOTHERBOARD SWITCH CONFIGURATION
The circuit boards on the balancing machine are equipped with hardware and software to
enable their use on a variety of models. They are already configured to operate correctly and
do not require configuration.

7
A
DIAGNOSTICS PROGRAMS
These programs serve primarily for repairing the circuit boards and should be used with
reference to the boards' circuit diagrams. We recommend using them exclusively for this
purpose; the service programs described above are generally sufficient for service staff to
identify malfunctions.
In case of need, the documentation for the diagnostics programs can be requested from
Corghi.
REMOVING THE WEIGHT-HOLDER LID
Remove in sequence:
- mini-anvil;
- diameter and distance sensor arm;
- sensor arm support disk (A in the
figure);
- four bolts securing the weight-holder
lid;
- remove the weight-holder lid taking
care not to stress the sensor rod.
Refit the parts in reverse order, making
sure to check that:
- the sensor lever touches only the support disk in standby, without touching the weight-
holder lid;
- the support disk (A in the figure) does not touch the weight-holder lid.
MBE161 MOTHERBOARD UPDATES
A portable programmer "PRG161" is required to update the control unit (MBU) of the
MBE161 motherboard. The firmware is stored in a special memory card (MEMSTICK),
which inserts into a slot in the PRG161.
For the use of the programmer and hence also for programming the MBE161 motherboard,
refer to the PRG161 programmer user manual.
REPLACING THE INSIDE SENSOR (DISTANCE AND DIAMETER) REED
MICROSWITCH AND ENCODERS
To ensure correct wheel size measurements, the inside sensor must be mounted in such a way
that its aluminum mount is perfectly supported by the block (to which are mounted the
central unit's leaf springs) and the inside pickup leaf spring.
The reed sensor which sets the standby position must also be correctly adjusted.
Function 98 displays the encoder signals.
Replacing and adjusting the reed microswitch
In case of replacement or disassembly of
the microswitch, its trip distance must be
adjusted.
The setting is correct when:
- when the sensor arm is moved 2.5
mm away from the standby position,
the microswitch is open;

8
- if this condition obtains, when the machine is switched on it displays "ERR10";
-
when the sensor arm is moved 2 mm away from the standby position, the microswitch is
closed; at this point the "ERR10" message is cancelled.
-
To adjust the position of the sensor, move it on its axis with the two nuts securing it to the
mount.
Checking the operation of the diameter encoder [di]
To check the operation of the diameter sensor, proceed as follows:
- move the inside sensor to the standby
position (the arm is snug against the
support disk);
- rotate and extend the arm until it rests
against the turntable shaft in the
position shown in the figure; check that
1000 +/- 10 marks have been read.
If the sensor does not read correctly,
check in sequence:
1) the flat cable;
2) the mounting of the sensor in its
housing;
3) the adjustment of the reed microswitch;
4) that reed sensor cable is connected correctly;
If the above checks do not reveal any defects, replace the encoder.
Checking the operation of the distance sensor [d]
Check that the total stroke is 490 +/- 10 marks;
If the sensor does not read correctly, check in sequence:
1) the flat cable;
2) the mounting of the sensor in its housing;
3) the adjustment of the reed microswitch;
4) that reed sensor cable is connected correctly;
If the above checks do not reveal any defects, replace the encoder.
Replacing the diameter encoder
- Remove the diameter encoder complete with gear.
- Remove the gear and fit it to the new encoder; tighten down the mounting nut.
- Fit the new encoder plus gear to the sensor mount gear in such a way that the play
between the two gears is minimal at all positions.
- Reconnect the cable to the diameter sensor (RP2).
Warning: to reduce diameter reading
errors due to mechanical play, the
spring (A in the figure) must be
correctly preloaded. To check the
preload, immobilize the diameter
sensor arm and move the large gear
wheel (B in the figure) by hand in both
directions. If the spring is correctly
installed, when the wheel is released it