Cormach TOUCH MEC 1000 SONAR Installation instructions

WHEEL BALANCERS
TOUCH MEC 1000
SONAR
TECHNICAL
SUPPORT MANUAL
UK

Technical Support Manual – 03/2017 Rel. 0 Page 1
CONTENTS
1. ACCESS TO THE SERVICE “MENUS”.................................................................................................................................................2
2. ACCESSING THE TEST PROGRAMS ..................................................................................................................................................6
2.1 Shaft rotation speed test.....................................................................................................................................................7
2.2 Pick-up signals test ..............................................................................................................................................................9
2.3 Voltage – frequency converter test...................................................................................................................................12
PICK-UP SPRING PRE-LOAD ADJUSTMENT ...................................................................................................................................14
2.4 ENCODER disc test.............................................................................................................................................................15
3. ACCESSING THE CONFIGURATION “MENUS”................................................................................................................................17
3.1 Enable/Disable distance/diameter sensor ........................................................................................................................19
3.2 Enable/Disable width sensor.............................................................................................................................................21
3.3 Sensors calibration ............................................................................................................................................................23
3.3.1 Distance sensor operation test.......................................................................................................................................24
3.3.2 Diameter sensor calibration ...........................................................................................................................................26
3.3.3 SONAR DEVICE operation test........................................................................................................................................28
3.4 Enable or disable electromagnetic stopping brake ...........................................................................................................30
3.5 Enable or disable the lighting led ......................................................................................................................................31
3.6 Enable or disable the LASER ..............................................................................................................................................33
3.7 MICRO WHEEL GUARD operation test ..............................................................................................................................34
4. MACHINE CALIBRATION................................................................................................................................................................36
4.1 When to carry out machine calibration .................................................................................................................................36
4.2 Machine calibration for the CAR/SUV Wheel Types ..............................................................................................................36
4.3 Machine calibration for the MOTO wheel type .....................................................................................................................42
5. ERROR AND WARNING CODES......................................................................................................................................................46
6. ACOUSTIC SIGNALS .......................................................................................................................................................................48
7. SPECIAL VISUAL SIGNALS ..............................................................................................................................................................48
8. TROUBLESHOOTING......................................................................................................................................................................48
9. ELECTRICAL DIAGRAM ..................................................................................................................................................................50
Cormach s.r.l. reserves the right to make any change to products in order to improve them.
Cormach s.r.l. reserves the right to make any change to this manual without notice.

Technical Support Manual – 03/2017 Rel. 0 Page 2
1. ACCESS TO THE SERVICE “MENUS”
Inside the SERVICE menu, the machine has a series of CONFIGURATION programs to manage the machine settings and TESTS to help
detect any anomalies.
To access the SERVICE mode, proceed as described below:
Ph.
1
Switch the machine ON by
pressing the main switch on the
back of the wheel balancer, then
wait for the test to
verify the
software version.
2
In case of defects please report
the software version that appears
in the box inside the top left box.
3
Press on icon.

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4
At the end of the test, the
machine is in NORMAL mode.
5

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6 Press on icon to exit the SERVICE
mode and enter in NORMAL
mode.
Picture F1.1: SERVICE menu
The programs can be selected in SERVICE mode BY PRESSING ON THE MONITOR THE ICONS .

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Table 1.1: CONTROL ICONS key
Icon
Meaning
Launch number counter selection icon.
Test program menu selection icon.
Configurations menu activation icon.
Electromagnetic brake activation icon.
Illuminator activation icon.
TOUCH SCREEN monitor test and calibration icon.

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2.ACCESSING THE TEST PROGRAMS
The TEST PROGRAMS are listed in table T2.1.
Table T2.1: "TEST PROGRAMS" Menu Options
Icon
Meaning
Shaft rotation speed test selection icon.
Pick-up signal test selection icon (This also controls the parameters that affect the signal).
Shaft imbalance test enabling icon.
Bearing smoothness test enabling icon (Reserved for Cormach Technical Assistance Service).
Encoder disc reading test selection icon.
Voltage - frequency converter test selection icon.
Brake calibration program selection icon (Reserved for Cormach Technical Assistance Service).
Electromagnetic brake torque test program selection icon (Reserved for Cormach Technical
Assistance Service).

Technical Support Manual – 03/2017 Rel. 0 Page 7
2.1

Shaft rotation speed test
This menu option is used to run the shaft rotation speed test. This test allows you to control the number of shaft RPMs during the
launch. A number indicating the speed of the shaft will be viewed on the right display.
To access the RPM TEST program, proceed as described below:
Ph.
1 Press on icon.
2 Press on icon.

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3
Lower the wheel guard: the
machine will run a launch.
4
NOTE: the speed of rotation also depends on the frequency of the main supply. The
nominal speed of rotation stated in table T11.2 refers to a frequency of 50 Hz. If the
frequency, in that country, is 60 Hz, the speed of rotation will be 20% greater (if motor
and pulley are the same).
If the speed of rotation is much lower than stated, ensure that the main supply voltage
does not drop excessively during rotation. If the main supply voltage is correct, check
the belt tension. If the belt tension is correct, check the motor and the PWRB board.
At the end of the launch, the
screen will display the speed of
rotation in RPM (revolutions per
minute). It is possible to repeat
rotation every time it is necessary.
The nominal speed of rotation
must be between 135 ÷ 145
RPM as stated in table T8.2.

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5
Press on icon to exit the RPM TEST
program.
2.2

Pick-up signals test
This menu option is used to run the pick-up signals test. This program allows you to check the pick-up signal. To run the test, you
will need to mount a preferably balanced steel wheel (complete with rim and tyre) measuring approximately 15” in
diameter and 6” in width (or as similar as possible), on the machine. A 50-gram weight must be applied on the external
side of the wheel.
If the wheel size is different from the measurements provided above, the detected pick-up signals will differ from those stated in
table T8.2. The pick-up signals depend heavily on wheel diameter and width (the greater the diameter, the higher the signal, just as
the greater the width the higher the signal).
To access the PICK-UP SIGNAL TEST program, proceed as described below:
Ph.
1 Mount a preferably balanced steel wheel (complete with rim and tyre) measuring approximately 15” in diameter and
6” in width (or as similar as possible), on the machine.
2
A 50-gram weight must be applied on the external side of the wheel.
3
Press on icon.

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4 Press on icon.
5
Example
Example
Lower the wheel guard: the
machine will run a launch and
display shaft RPM. The machine
will spin continuously and the
pick-
up signals at the three
attenuation processes
(Attenuation 1, Attenuation 2,
Attenuation 4) will be displayed in
sequence. Each attenuation value
reading must be between 70 ÷
120 (See table T8.2).
This sequence repeats until the
wheel stops spinning when the
wheel guard is raised.
If the value of both or one of the
two pick-
ups is 0, check the
connection and change the pick-
up, or both, if necessary.

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6
Example
Press on icon to exit the SIGNAL
TEST program.
The values of the displayed signals are expressed in an internal number format and not in any international unit of measure.
The attenuation circuit controls the pick-up signals to avoid saturating the input stage of the CPU-LCD board which offers poor results.
If both pick-up signals differ significantly from the values provided in table T8.2 but are similar to each other, check whether:
•The adjustment springs are pre-loaded correctly;
•Both pick-ups are the original ones;
•The CPU-LCD is operating correctly (it is possible to run this check through the VFC TEST described below).
If both pick-up signals differ significantly from the values provided in table T8.2 and differ from each other, check whether:
•The pick-up A and pick-up B cables have been connected to the wrong connectors;
•The pick-up adjustment springs are pre-loaded correctly;
•The CPU-LCD is operating correctly (it is possible to run this check through the VFC TEST described below).
If only one pick-up signal differs significantly from the values provided in table T11.2, check whether:
•The pick-up A and pick-up B cables have been connected to the wrong connectors;
•The pick-up adjustment springs are pre-loaded correctly;
•Both pick-ups are the original ones;
•The CPU-LCD is operating correctly (it is possible to run this check through the VFC TEST described below).

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2.3

Voltage – frequency converter test
This menu option is used to run the voltage - frequency converter test (or VFC) on the CPU-LCD board. The converter voltage –
frequency test shows two numbers on the displays that represent the electronic control board conversion values.
To access the VOLTAGE - FREQUENCY CONVERTER TEST program, proceed as described below:
Ph.
1 Press on icon.
2 Press on icon.

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3
Example
The voltage - frequency converter
test program displays two
numbers that represent internal
conversion values used in the
electronic control board, and
must be between 40.0 ÷ 45.0
(See table T8.2).
If the value of both or one of the
two pick-
ups is 0, check the
connection and change the pick-
up, or both, if necessary.
4
Example
Press on icon to exit the VOLTAGE
-
FREQUENCY CONVERTER TEST
program.
Il Value A refers to pick-up A VFC, while value B refers to pick-up B VFC. The displayed values must be stable (if no one touches or
bumps into the machine) and must be between the tolerance range stated in table T8.2. If the machine is touched or bumped into,
both VFC channels will vary and re-stabilise when the mechanical interference stops.

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PICK-UP SPRING PRE-LOAD ADJUSTMENT
For correct operation the pick-up must be pre-loaded with a spring. To do so, the spring must be compressed by a screw, according
to the following:
1. ALL PROCEDURES (INCLUDING MINOR) MUST BE CARRIED OUT BY QUALIFIED STAFF;
2. BEFORE PERFORMING ANY PROCEDURE, DISCONNECT THE ELECTRICAL POWER SUPPLY;
3. Tighten the hex screw, by hand, as far as it will go;
4. Repeat step 1 for the other pick-up;
5. Make sure that the springs and hex keys are perpendicular to the pick-up support unit. If necessary, loosen the screw, turn
the spring (or switch it around the other way) and repeat steps 1 and 2 until the set-up is perpendicular;
6. Tighten the screws on the two pick-ups by turning them three full times. It is good practice to spin the two pick-up springs
by a full turn, alternating one at a time. See picture F2.1;
7. Calibrate the machine.
IMPORTANT: Every time a pick-up tightens or loosens, it is compulsory to calibrate the machine.
Picture F2.1: Pick-up spring pre-load adjustment
3 turns

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2.4

ENCODER disc test
This menu option is used to run the ENCODER disc test. To access the ENCODER TEST program, proceed as described below:
Ph.
1 Press on icon.
2 Press on icon.

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3
Example
Example
Turn the shaft and make sure all of
the values between 0 ÷ 255 are
read (from 000 to 255 turning
clockwise, and from 255 to 000
turning anti clockwise). When the
reset "notch" on the encoder disc
is in position H12, the displayed
value must be 000 (or it must be
reset to 000 if the value is
different).
If the count is incorrect, clean the
encoder disc; check and/or adjust
the mechanical DEB board
fastening system. If there are no
mechanical problems, then check
the cable and change the encoder
board if necessary.
4
Press on icon to exit the ENCODER
TEST program.

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3.ACCESSING THE CONFIGURATION “MENUS”
The machines must be configured so that the electronic control board (CPU-LCD) receives communication from the installed devices.
The configuration must be carried out from the CONFIGURATION MENU, on the parameters that are available in SERVICE mode.
The CONFIGURATION MENU also makes it possible to run a number of operations (such as resetting the SPIN counter) reserved for
technical staff. To access the CONFIGURATION MENU program, proceed as described below:
Ph.
1 Press on icon.
2 Press on icon to exit the
CONFIGURATIONS MENU.

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Table: T3.1 CONFIGURATION Menu Options
Icon
Meaning
Settable threshold selection icon for CAR wheels (CAR).
Settable threshold selection icon for SUV wheels (SUV).
Settable threshold selection icon for MOTORBIKE wheels (MOTO).
Grams/ounces unit of measure selection icon.
Inches/mm unit of measure wheel dimensions selection icon.
Iron/Zinc balancing weight material selection icon.
Sensor calibration program activation icon.
Distance/Diameter sensor activation icon.
SONAR activation icon for wheel width automatic measurement.
WHEEL GUARD MICRO operation test icon.
SONAR calibration program activation icon.
Electromagnetic brake activation icon.
Illuminator activation icon.
Laser mode activation icon (RESERVED FOR “CORMACH s.r.l.” STAFF).
Work language selection icon.