HENNESSY INDUSTRIES Coats IBS 2000 User manual

1601 J. P. Hennessy Drive, LaVergne, TN USA 37086-3565 615/641-7533 800/688-6359 Manual Part No.: 9112388 01
HENNESSY INDUSTRIES INC. Manufacturer of AMMCO®, COATS®and BADA®Automotive Service Equipment and Tools. Revision: 12/00
Service Manual and
Troubleshooting Guide
IBS 2000
Interactive Balancing System
®

ii • Service Manual — COATS Model IBS 2000
Direct Drive

Service Manual — COATS Model IBS 2000 • iii
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Principal of Operation . . . . . . . . . . . . . . . . . . . . . . .1
Component Functions & Benefits . . . . . . . . . . . . . .2
2000 Balancer Simplified Block Diagram . . . . . . . .3
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Equipment Needed . . . . . . . . . . . . . . . . . . . . . . . . .4
Voltage & Phase Checking Procedure . . . . . . . . . . .4
Installation Instructions
Unpacking and Setup . . . . . . . . . . . . . . . . . . . . . . . .5
Hood Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Faceplate Assembly Installation . . . . . . . . . . . . . . . .5
Preliminary Inspection . . . . . . . . . . . . . . . . . . . . . . .5
Functional Checks
Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . .6
Calibration Procedures
Balancer Calibration . . . . . . . . . . . . . . . . . . . . . .6 - 7
Plane Separation (Accuracy Check) . . . . . . . . . . . . .7
Optimizing A (Distance Guage Tape Placement) . . . .7
Arm Calibration . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 8
Accuracy Problems . . . . . . . . . . . . . . . . . . . . . . . . .8
Rotation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Cycle Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Total Accuracy Verification (TVA) . . . . . . . . . . . . . . .9
Error Codes
LED Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . .9
LCD Error Codes . . . . . . . . . . . . . . . . . . . . . . . .9 - 10
Troubleshooting Flow Charts
Pre-diagnostic Check . . . . . . . . . . . . . . . . . . . . . . .11
Wheel Does Not Spin . . . . . . . . . . . . . . . . . . . . . .12
Wheel Does Not Stop . . . . . . . . . . . . . . . . . . . . . .13
No Communications . . . . . . . . . . . . . . . . . . . . . . .14
Keypad Problems . . . . . . . . . . . . . . . . . . . . . . . . . .15
No LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . .16
LCD Contrast Won’t Adjust . . . . . . . . . . . . . . . . . . .17
No LCD Back-Light . . . . . . . . . . . . . . . . . . . . . . . .18
No LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . .19
EE ERR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
A & D Arm Problems . . . . . . . . . . . . . . . . . . . . . . .20
Diagnostic Procedures
Motor and Motor Controller Checking
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Spin and Stop Diagram . . . . . . . . . . . . . . . . . . . . .21
Motor Controller Diagram . . . . . . . . . . . . . . . . . . .22
Optical Encoder Checking Procedure . . . . . . . . . . .23
Rotary Shutter Checking Procedure . . . . . . . . . . . .23
Piezo Output Test . . . . . . . . . . . . . . . . . . . . . . . . . .23
Piezo Crystal Checking Procedure . . . . . . . . . . . . .24
Balancer Display Diagnostics . . . . . . . . . . . . . . . .24
Serial Loopback Test . . . . . . . . . . . . . . . . . . . . . . . .24
Replacement Procedures for Model
IBS 2000 Balancer . . . . . . . . . . . . . . . . . . . . . . .25-30
Display Board Assembly Replacement . . . . . . . . . .25
E-Prom Replacement . . . . . . . . . . . . . . . . . . . . . . .25
LCD Board Replacement . . . . . . . . . . . . . . . . . . . .26
Start Switch Replacement . . . . . . . . . . . . . . . . . . .26
Touch Panel Replacement . . . . . . . . . . . . . . . . . . .26
Hood Magnet Replacement . . . . . . . . . . . . . . . . . .26
Hood Switch Replacement . . . . . . . . . . . . . . . . . . .26
Safety Interlock Switch Replacement . . . . . . . . . . .26
On/Off Switch Replacement . . . . . . . . . . . . . .26 - 27
Circuit Breaker Replacement . . . . . . . . . . . . . . . . .27
Power Supply Board Replacement . . . . . . . . . . . . .27
Motor Controller Board Replacement . . . . . . . . . . .27
CPU Board Replacement . . . . . . . . . . . . . . . . . . . .27
Fan Motor Assembly Replacement . . . . . . . . . . . .28
Rotary Shutter Replacement . . . . . . . . . . . . . . . . .28
Optical Encoder Assembly Replacement . . . . . . . .28
Drive Motor Assembly Replacement . . . . . . . . .28-29
Faceplate & Shaft Assembly Replacement . . . . . . .29
Piezo Assembly Replacement . . . . . . . . . . . . . . . .29
Capacitor Assembly Replacement . . . . . . . . . . . . .30
Signal Harness Replacement . . . . . . . . . . . . . . . . .30
A/D Arm Repair and Replacement . . . . . . . . . .30-31
A/D Arm Replacement . . . . . . . . . . . . . . . . . . . . . .56
A Gear Assembly Replacement . . . . . . . . . . . . . . .57
Small D Gear Assembly Replacement . . . . . . . . . .57
Large D Gear Replacement . . . . . . . . . . . . . . . . . .58
A/D Arm Subassembly Replacement . . . . . . . . . . .58
IBS 2000 Wiring Diagrams . . . . . . . . . . . . . . . .32-35

iv • Service Manual — COATS Model IBS 2000
Safety
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
READ ALL INSTRUCTIONS
1. Eye and face protection recommendations:
“Protective eye and face equipment is required to
be used where there is a reasonable probability of
injury that can be prevented by the use of such
equipment.” O.S.H.A. 1910.133(a) Protective gog-
gles, safety glasses, or a face shield must be pro-
vided by the owner and worn by the operator of
the equipment. Care should be taken to see that
all eye and face safety precautions are followed by
the operator. ALWAYS WEAR SAFETY GLASSES.
Everyday glasses only have impact resistant
lenses, they are not safety glasses.
2. Do not disable hood safety interlock system, or in
any way shortcut safety controls and operations.
3. Be sure that wheels are mounted properly, the
hub nut engages the arbor for not less than four
(4) turns, and the hub nut is firmly tightened
before spinning the wheel.
4. Read and understand this manual before operat-
ing. Abuse and misuse will shorten the functional
life.
5. Be sure the balancer is properly connected to the
power supply and electrically grounded.
6. Do not operate equipment with a damaged cord
or if the equipment has been dropped or damaged
– until it has been examined by a qualified serv-
iceman.
7. Do not let cord hang over edge of table, bench, or
counter or come in contact with hot manifolds or
moving fan blades.
8. If an extension cord is necessary, a cord with a
current rating equal to or more than that of the
equipment should be used. Cords rated for less
current than the equipment may overheat. Care
should be taken to arrange the cord so that it will
not be tripped over or pulled.
9. Keep guards and safety features in place and in
working order.
10. Wear proper clothing. Safety toe, non-slip
footwear and protective hair covering to contain
hair is recommended. Do not wear jewelry, loose
clothing, neckties, or gloves when operating the
balancer.
11. Keep work area clean and well lighted. Cluttered
and/or dark areas invite accidents.
12. Avoid dangerous environments. Do not use power
tools or electrical equipment in damp or wet loca-
tions, or expose them to rain.
13. Avoid unintentional starting. Be sure the balancer
is turned off before servicing.
14. Disconnect the balancer before servicing.
15. Use only manufacturer’s recommended acces-
sories. Improper accessories may result in per-
sonal injury or property damage.
16. Repair or replace any part that is damaged or worn
and that may cause unsafe balancer operation. Do
not operate damaged equipment until it has been
examined by a qualified service technician.
17. Never overload or stand on the balancer.
18. Do not allow untrained persons to operate
machinery.
19. To reduce the risk of fire, do not operate equip-
ment in the vicinity of open containers or flamma-
ble liquids (gasoline).
20. Adequate ventilation should be provided when
working on operating internal combustion
engines.
21. Keep hair, loose clothing, fingers, and all parts of
body away from moving parts.
22. Use equipment only as described in this manual.
23. Use only manufacturer’s recommended attach-
ments.

Service Manual — COATS Model IBS 2000 • 1
Introduction
This service manual contains the functional checks,
troubleshooting, adjustment, and part replacement
instructions for COATS®Model IBS 2000 Wheel
Balancer. Exploded views, illustrations, and an indexed
parts list facilitate parts location, ordering, and replace-
ment. All adjustments and replacements can be ren-
dered with mechanic's or electrician's tools.
Safety Notes
HIGH VOLTAGES, HIGH TORQUE MOTORS, and
HIGH SPEED ROTATING WHEELS are present in
COATS wheel balancers. Follow the SAFETY RULES
when servicing any balancer:
1. DISCONNECT BALANCER from power source
before starting any parts replacement or internal adjust-
ment.
2. LOWER GUARD HOOD before starting cycle.
3. DO NOT WEAR LOOSE CLOTHING, such as neck-
ties, while servicing the balancer.
4. LONG HAIR should be worn UP, or under a HAT.
5. WHEELS MUST BE MOUNTED PROPERLY:
• Cones must be centered in the wheel before
tightening.
• The wheel must be forced up firmly against the
faceplate.
• The hub nut must be engaged by a minimum of
four (4) full threads.
• Tighten the hub nut rotating the wheel and strik-
ing a spoke of the hub nut with the heel of the
hand.
Caution! Failure to tighten the hub nut could
result in serious injury!
Principle Of Operation
The model IBS 2000 Wheel Balancer utilizes the prin-
ciple that any rigid body rotating about an axis through
the body can be balanced using weights mounted in
two planes. In this case the rigid body is an automobile
wheel and tire assembly which is mounted precisely on
center and rotated to measure the imbalance forces in
two planes. As the wheel rotates, any imbalance in the
wheel results in radial outward forces on the wheel and
the distances from the voltages produced by the piezo
sensors.
With the forces known at the planes of the piezos the
imbalance forces at the wheel planes can be calculated
by using the distance from the force transducer planes
to the wheel correction planes. These wheel imbalance
forces are displayed for the wheel planes selected dur-
ing the setup procedure so the correction weights can
be added. A check spin is recommended to assure that
the wheel is in fact balanced. For the measurement to
be accurate:
1) the wheel must be mounted precisely on center
2) the wheel plane parameters must be entered accu-
rately
3) the distance and diameter arm and the balancer
must be calibrated carefully.
The Model IBS 2000 Balancer uses several modules
to control the balancing sequence. The COATS®Direct
Drive system includes the following primary elements:
• Direct Drive Motor and Shaft Assembly
• Motor Controller Printed Circuit Board
• CPU Printed Circuit Board Assembly
• Touch Panel
• Display Printed Circuit Board
• LCD Display
The balancing operation is started by mounting the
wheel and then selecting the planes for the desired
placement of wheel weights from the touch panel. The
wheel parameters are then entered for distance, width,
and diameters appropriate for the correction planes
selected.
The measurement is started by pushing the START
switch or lowering the hood. The display PCB responds
to the START command by sending the command to
the CPU which begins the measurement cycle. The
CPU turns the SPIN SSR ON which powers the motor
in the forward direction. As soon as the motor reaches
the measurement speed the power is removed and the
wheel coasts while the signal from the piezos is being
measured. When the measurement is completed the
CPU turns on the BRAKE SSR which reverses the
motor and brings the wheel to a stop. The WEIGHT and
POSITION readings for each plane are sent from the
CPU to the Display PCB where they are displayed. The
correction planes can be changed if desired and the dis-
plays are updated automatically.
Direct Drive

2 • Service Manual — COATS Model IBS 2000
Direct Drive
Component
Functions & Benefits
Motor Controller
Function: Controls the AC power for the spin and brake
cycles of the motor.
Benefit: Solid State Relay (SSR) replaces mechanical
contactor.
• Eliminates contact arching, RF interference.
• Eliminates mechanical problems.
• Eliminates multiple wire connections.
Also: AC power is routed through this board for the:
• On/Off Switch
• Cooling Fan
• Power Supply PCB
• Phase Converter
The SSR is electrically HOT any time the unit
is plugged into the wall!
Power Supply
Function: Supplies regulated voltage to operate the
electronics used on the PCB's.
+12 vdc (VDD)
-12 vdc (VEE)
+5 vdc (VBB)
Benefit: Separate PCB reduces board replacement
cost.
Also: Input voltage is AC line voltage routed through
the Motor Controller PCB
Display Board*
Function: Controls the lighting of all LED's.
Benefit: Separate PCB reduces board replacement
cost.
Also: Manual start switch connects to this PCB.
Power for the LCD back light and control signals come
from this PCB.
Has contrast pot adjustment.
Has +5 vcc (VCC) regulator
LCD*
Function: Displays operator interactive instructions.
Benefit: Makes the unit easier to operate and calibrate.
Single PCB replacement.
Proven technology.
Main CPU*
Function: Receives data from all input devices (piezos,
encoder, A/D pots, hoodswitch).
Processes the information and sends it to the appropri-
ate PCB.
Benefit: Separate PCB reduces board replacement
cost. Latest microprocessor design.
Also: Has +5 vdc (VCC) regulator
Phase Converter
Function: Allows three phase motor to be used on sin-
gle phase power.
Benefit: Allows the use of three phase motors in all
balancers.
Easy to convert from one phase to three phase. Uses
same capacitor as 1050 but different connectors.
Fan
Function: Keeps the motor from overheating.
Benefit: Allows us to use direct drive motors.
Also: These fans are 220v (950/1050 has 110v).
Piezos
Function: Measures the weight imbalance in a wheel.
Benefit: Proven Technology, reliable.
Also: Same as in the 1050 but different connector and
isolated.
Encoder
Function: Aids in measuring the imbalance location, in
a wheel.
Determines rotational speed and direction.
Benefit: Proven technology.
Same as a 1050 but different connector.
Motor
Function: Used for mounting and rotating the wheel.
Benefit: Direct drive, no need to balance.
No belts, less noise interference.
Replaceable faceplate and shaft assembly.
Optional 40mm faceplate and shaft assembly.
*Indicates electronic components which carry a three
year warranty.
CAUTION

Service Manual — COATS Model IBS 2000 • 3
2000 Balancer
Simplified Block Diagram
Piezo
Fan
Phase Converter or Jumper
AC Power
On/Off
Interlock
Switch (NO)
Closed with
hood down
Encoder Motor
Main CPU
A
Motor
Controller
Power
Supply
Display
Board
LCD Board
Hood Switch (NO)
Closed with hood down
Manual Start
+12
- 12
+ 5
Interlock switch only on models
produced after 12-22-97.
Note:
Note:
The normal position is when the
magnet is next to the switch.
NC = Normally Closed
NO = Normally Open
D
Direct Drive

4 • Service Manual — COATS Model IBS 2000
Direct Drive
Servicing
Service should be performed only by a factory trained
COATS®Service Technician. The troubleshooting and
service procedures in this manual are arranged to allow
rapid and thorough service. The steps are:
• Preliminary Inspection
• Functional Checks
• Repair Of Failure
• Replacement Or Adjustment
• Functional Checks
Identification of replacement parts required can be
accomplished by using the pictorial breakdown and index
in this manual. It is important that the FUNCTIONAL
CHECKS be performed IN SEQUENCE and the PROB-
LEM ISOLATED. If an adjustment is made, the entire
FUNCTIONAL CHECK must be performed SUCCESS-
FULLY before the balancer can be considered available
for service.
Equipment Needed
1. AC / DC - Volt / Ohm meter (DVM).
2. Test Wheel - Domestic 14" x 6" steel wheel with a
center hole suitable for mounting with a back cone. A
new 195/70/14 tire properly mounted and inflated, bal-
anced to within 0.02 ounces should be part of this wheel
assembly. The lateral run out of this wheel should be less
than 1/8". Modeling clay and 4 oz. test weight.
3. Flat and Phillips screw drivers, and dead blow hammer.
4. Tester for phone cables and jacks. (Modapt adaptor,
Contact East Part #118-785, call 1-800-225-5334 to order.)
5. Thread locking anaerobic (Loctite 242 or equivalent).
Retaining compound (Loctite 601 or equivalent).
6. Torque Wrench & a 5/16 X 6" hex socket for the
torque wrench.
7. Small Allen wrenches, pot adjusting tools, & a 3/8"
nut driver.
8. Chip extractor tool, Ammco part # 29977.
9. A dial indicator (runout gauge) , Ammco part # 2850,
or 29752.
10. Sockets: 3/8, 7/16, 3/4, 1/2, 9/16 inch, a speed han-
dle, or ratchet.
11. A drill and 1/8" drill bits, pop rivet gun, and 1/8" rivets.
12. A 7/16" - 3/8" box end wrench, and cutters for banding.
Voltage & Phase Checking Procedure
1. Unplug the Balancer from the power source.
2. Perform all voltage checks shown in the appropriate
diagram and chart at the power receptacle. If one or all
voltage measurements is faulty be sure to check the sta-
tus of the circuit breakers that supply the Balancer.
3. Check from one of the power terminals to the
ground terminal to verify a ground is present. The voltage
measurement should be approximately one half of the
available voltage (i.e. 220V should read 110V).
Note: If any faults are found in the above pro-
cedure, it is the responsibility of the owner.
COATS®authorized service personnel are not
responsible for wiring within the building.
4. Plug the balancer into a power source.
5. Use an Ohmmeter to check the resistance between
the frame of the balancer and the building ground. The
resistance should be less than 1 ohm. If the resistance
measurement is greater that one (1) ohm, check the
power cord plug and frame connection for proper contact.
RED
WHITE
GREEN
GROUND XYZ
BLACK
GREEN
BLACKRED
GROUND A B
THREE PHASE VOLTAGE REQUIREMENTS / INFORMATION
208V/220V/230V 380V 460V
X - Y 195-250 370-420 420-480
X - Z 195-250 370-420 420-480
Y - Z 195-250 370-420 420-480
Plug
Installed Hubbell 2421 Hubbell 2431
Required Hubbell 2420 or Hubbell 2430 or
Mating Outlet Equivalent Equivalent
SINGLE PHASE VOLTAGE
REQUIREMENTS/ INFORMATION
208V/220V/230V
A - B 195 - 250
Plug Hubbell
Installed 5466-C
Required Hubbell 5462 or
Mating Outlet Equivalent

Service Manual — COATS Model IBS 2000 • 5
Installation Instructions
Unpacking and Setup
1. Remove the staples from around the bottom of the
carton, and carefully remove the box.
2. Unstrap and remove the hood, accessory box and all
packing.
3. Inspect the unit and all accessories for damage.
Note: Report any damaged or missing parts to
the Hennessy Order Entry Department imme-
diately. CALL 1-800-688-6359.
4. Remove the three (3) hold down brackets from the
machine & pallet. Do not discard. Retain for the customer,
he may wish to use them to bolt his unit to the floor.
5. Remove the balancer from the pallet.
Caution! This unit is very heavy and will
require assistance for lifting and moving. DO
NOT DROP! DO NOT LIFT BY THE MOTOR
SHAFT!
Note: If there is a bolt on the back of the hood
support bracket, near the bottom right side of
the accessory column, REMOVE IT. It will inter-
fere with the hood installation.
6. Remove the Allen head bolt at the bottom of the pod
tube, and retain for later use.
7. Loosen the four (4) bolts on the tube brackets, and
slide the tube into position with the locating ring.
8. Install the Allen head bolt.
Caution! Be careful not to damage the wire
harness.
9. “Snug” the bolts on the tube brackets, but do not
overtighten. The Pod should swing with some resistance,
but not loosely.
10. Push the harness into the pod tube, and install the
plastic cover.
11. Check the power plug with the phase of the
machine on the serial tag. Make sure the plug matches
the customers outlet.
Hood Installation
1. Install the hood magnets (two sets, for hood switch
and interlock switch to the holes on the hood cam. The
nylon washer goes between the magnets and the cam.
Do not over tighten, or the magnets will break.
2. Slide one of the nylon bushings onto the hood bar,
flange to the cam.
3. Lift the hood up and slide the bar into the machine,
you may need assistance. Let it rest on the hood stop.
4. Slide the other nylon bushing into position from the
inside, slide on the washer and the retaining ring.
5. Attach the hood spring. The straight end goes at the
bottom of the machine the hook end into the hood.
Note:The hood must be in the raised position,
to install the spring. For Safety, you should
have someone support it.
Faceplate Assembly Installation
1. Remove the hub nut and cones from the threaded
shaft. Store on the accessory pegs.
2. Clean the contacting surfaces of both the motor shaft
and faceplate assembly with a soft cloth. Note the wit-
ness marks on both, these should be aligned before
installing.
3. Slide the 6 inch socket head bolt (included in the parts
bag) and the (5/16 X 6") Allen wrench extension into the
faceplate assembly. Hand tighten.
4. Attach the torque wrench. Hold the faceplate with
one hand to keep from turning. Tighten to 20 ft/lb.
Caution! DO NOT OVER TIGHTEN. Over tight-
ening will result in damage to the motor shaft.
5. Dial indicate the faceplate and shaft assembly there
should be not more than .002-inch on the faceplate and
not more than .001 runout on the shaft. If so refer to
Faceplate Assembly Replacement procedures.
Preliminary Inspection
1. The floor should be a solid, flat surface that does not
allow the balancer legs to set into a recess in the floor or
sink into the floor itself.
2. The balancer should sit on all three (3) legs. Make
sure the legs have not filled with dirt, wheel weights, or
any foreign matter that may prevent a leg from making
contact with the floor.
3. Inspect all cones, hub nut, pressure cup, motor shaft,
faceplate, and shaft assembly for damage. Missing parts
or accessories should be reported immediately to
Hennessy Order Entry Department at 1-800-688-6359.
4. Check the power supply to the balancer. Refer to the
VOLTAGE CHECKING PROCEDURE.
5. Check the operation of the cooling fan on the drive
motor. The fan should run as soon as the balancer is
turned on. If not, check the breaker on the Accessory
Column of the balancer. If it has tripped, reset it. If it will
not reset refer to the PRECHECK procedure.
6. Check the rotation of the motor. Press START, does
the motor spin clockwise? If not, for a 3ph Balancer -
switch any two of the hot leads on the plug.
Direct Drive

6 • Service Manual — COATS Model IBS 2000
Direct Drive
Functional Checks
Operational Check
1. Turn the power switch ON. The display should read
as follows:
LCD: Grams/Ounces - Defaults to last selection.
Mode - Round off ON
Hood Start - Hood Start ON
A, W, D -0.00
PRESS ANY KEY TO CONTINUE
If the LCD Does Not Light, see flow chart for No LCD
Display.
LED: Weight Displays -0.00
Mode - Dynamic
Operator - A
If the LED's do not light, see flow chart for No LED
Display.
2. Mount your test wheel (described in EQUIPMENT
NEEDED) on the balancer.
3. Enter the wheel parameter data using the auto-
matic A/D arm.
Note: If you do not get proper wheel param-
eters from the A/D Arm, check the A&D
potentiometers found in the CALIBRATION
MENU, follow the procedures for Arm cali-
bration. If the A/D arm has failed, you may
manually enter the data. If the Keypad does
not work, see TOUCH PANEL PROBLEMS.
4. If the balancer is in round off mode, go to the SET
UP menu, select NON-ROUND OFF and press enter.
5. Go to the SET UP menu, select the desired weight
mode (this procedure may be performed in either
mode) GRAM or OUNCE and press enter.
6. Install a 4 oz./100 gram weight on the outer rim of
the test wheel.
7. Choose the DYNAMIC balancing mode.
8. Lower the guard hood. (if HOOD START is on, the
balancer will automatically cycle at this time, if not see
step 9).
9. Push the START button. The machine should now
cycle. If the machine does not cycle, see BALANCER
DOES NOT SPIN.
10. The balancer should come up to speed, coast for
several revolutions, and then brake to a stop. If the
machine fails to brake and continues to coast, see BAL-
ANCER DOES NOT STOP.
11. The balancer should now have weight values and
position lights displayed.
12. Rotate the wheel so the top and bottom position
LED's for the outside (right) plane are flashing.
13. Note the position of the 4 oz. weight and the
weight readings for both planes.
14. Now rotate the wheel so the center LED for the
outer (right) plane is flashing. The 4 oz. weight should
now be at (or near) the 6:00 position.
15. Perform five (5) cycles and note the positions and
weight readings after each spin. The weight readings
should repeat within .2 oz. and the position within + 1/2
inch. If they do not, see ACCURACY PROBLEMS.
Note: If the customer has problems with a
specific wheel assembly only, make sure there
is no water or debris inside the assembly.
Calibration Procedures
Balancer Calibration
1. Turn the power switch ON.
2. Mount your test wheel to the machine.
3. Enter the wheel parameters using the A/D arm and
the rim calipers.
4. If the machine is in ROUND OFF mode go to the
SET UP menu and select NON-ROUND OFF.
5. If the machine is not in OUNCE mode go to the
SET UP menu and select OUNCES.
Note: This procedure can be performed
using GRAMS or OUNCES. If using GRAMS,
refer to a conversion chart for weight con-
versions.
6. Go to the MAIN menu and select CALIBRATE BAL-
ANCER to enter the calibration mode. The status bar
should now read CAL 0. Follow the instructions on the
display.
7. Push the START button, or lower the hood. The
machine should now cycle. This cycle is referred to as
the zero spin cycle.
8. The balancer should come up to speed, coast for
several revolutions, and then brake to a stop.
9. The status bar should now read CAL 1. Follow the
instructions on the display.

Service Manual — COATS Model IBS 2000 • 7
10. Position the wheel so the display for the center
position LED on the outside (right) plane is flashing.
11. Place a 4 oz. weight at the 12 o'clock position on
the outside (right) of the wheel.
Note: If a weight is already in this position,
place the 4 oz. weight as close to the indi-
cated location as possible. Rotate it to the
12 o'clock position, and then press the Star
(*) key.
12. Push the START button, or lower the hood. The
balancer should now cycle and come to a stop.
13. The outer (right) weight display should read 4.00
± .02 oz. and the center position LED for the outside
(right) plane should be flashing when the weight is at
bottom dead center. The display will now read CALI-
BRATION COMPLETE! PRESS ANY KEY TO CON-
TINUE.
14. Perform PLANE SEPARATION, if specified results
are achieved calibration is complete. If specified results
are not achieved , OPTIMIZE THE A.
15. Make sure to write down the new A value to use
in the ARM CALIBRATION procedure. Center position
LED for the outside (right) plane should be flashing
when the weight is at bottom dead center. The display
will now read CALIBRATION COMPLETE! PRESS ANY
KEY TO CONTINUE.
Plane Separation (Accuracy Check)
1. Remove the 4 oz. weight from the wheel.
2. Use putty to fine balance the test wheel to obtain
0.00 (+0.02) weight readings on both planes. If unable
to balance to zero See REPEATABILITY PROBLEMS.
Note: If the customer balances mostly larger
wheels you may use a larger wheel for cali-
bration.
3. Place a 4 oz. weight on the outside of the wheel.
4. Press start, or lower the guard hood. The readings
for this cycle should be as follows:
Inner (Left) Plane = 0.00 ± 0.15 oz.
Outer (Right) Plane = 4.00 ± 0.15 oz.
Outer Position flashing = 4oz. at bottom dead center
± 1/2inch
5. Move the 4 oz. weight directly across to the inside
plane. Press start, the reading should be as follows:
Inner (Left) Plane = 4.00 ± 0.15 oz.
Outer (Right) Plane = 0.00 ± 0.15 oz.
Inner Position flashing = 4oz. at bottom dead center
± 1/2 inch
6. If the above results are not achieved check the A,
W, and, D dimensions. The ARM must be OPTIMIZED.
Perform the ARM CALIBRATION.
7. If the above results are still not achieved, check the
placement of the distance tape, see OPTIMIZING
A(Distance Tape Placement).
8. If specified results are not achieved see ACCU-
RACY PROBLEMS.
Optimizing A (Distance Gauge Tape
Placement)
Note: Perform this procedure if the PLANE
SEPARATION (Accuracy Check) fails.
1. Place a 4oz. wt. on the inside of the wheel, try
entering an A dimension .1 higher than the one used
originally. Spin the wheel. If the plane separation gets
worse, try using an A dimension .1 lower than the one
used originally.
2. If the plane separation gets better, keep increasing
or decreasing the A dimension until an acceptable
value is achieved.
3. Calibrate the machine and perform the PLANE
SEPARATION CHECK. Repeat this procedure until the
outer plane weight reading is at a minimum.
4. Once the A is Optimized and the distance tape
moved, you must perform ARM CALIBRATION and
BALANCER CALIBRATION with the new A value. Also
recheck the PLANE SEPARATION.
5. Move the distance tape to this position to allow for
proper A dimension entry.
Arm Calibration
1. Go to the menu and select CALIBRATION, select
CALIBRATE ARM. Follow the instructions on the dis-
play. The A & D pot readings are displayed on the LCD
display. With the arm in the HOME position, the read-
ings should be within the tolerance brackets.
If not, the potentiometers should be adjusted. Refer
to the A & D Arm Repair Procedures.
2. Place the arm in the home position (see decal on
the motor). Follow the instructions on the display
screen.
3. The A value is obtained by moving the distance arm
out to the rim, and manually entering the new A value
obtained from the PLANE SEPARATION and A OPTI-
MIZATION.
Direct Drive

8 • Service Manual — COATS Model IBS 2000
Direct Drive
4. Enter the D value from the tire. It should be within
.10 of the reading from the automatic arm, if not the D
pot should be adjusted (refer to A & D ARM REPAIR
PROCEDURES). Manually enter the value.
5. After both values have been manually entered,
move the distance arm to the rim and hold it in position
while pressing CONTINUE.
6. Rotate the arm out and around to a second posi-
tion on the rim. Holding the tip against the rim flange,
press CONTINUE.
Arm Calibration is now complete. When the arm is
returned to the HOME position, the balancer will return
normal operating mode.
7. To verify the calibration, pull the arm out and hold
the tip against the rim flange. The A & D readings auto-
matically displayed should be +0.20 of the values
entered during calibration. If not, see OPTIMIZING A
(DISTANCE TAPE PLACEMENT) and A & D Arm
Problems.
Accuracy Problems
Mounting Errors - Causes comebacks but not
detectable with the balance. Check the runout of the
shaft, faceplate and cones.
Wheel Slipping During Rotation - Causes repeated
spins or inability to balance the wheel. Check by mark-
ing the wheel & faceplate, correct by tightening the
hub nut or using front cone.
Improper Wheel Parameters - or Inaccurate Wheel
parameters such as approximate ALU modes. Causes
inability to balance the wheel. Enter more accurate
parameters and or mount hidden weight closer to the
PRESET position for hidden weights.
Uncalibrated Data Entry Arm - Causes repeated
spins to balance. Perform Plane Separation (Accuracy
Check)
Uncalibrated Balancer - Causes repeated spins to
balance. Perform a PLANE Separation (Accuracy
Check).
Something Touching The Motor Or Distance Arm -
Causes inability to calibrate the balancer or achieve
acceptable PLANE SEPARATION. Check for anything
touching the motor.
Rotary Shutter Slipping - Causes weight position to
change, repeat spins, or inability to balance. Perform
Rotary Shutter Checking Procedure.
Rotation Check
Note: This procedure must be performed
with a “Hub Centric” wheel. It should be
performed as part of every routine calibra-
tion procedure.
1. Remove the 4oz. weight from the inner rim and
perform a fine balance to obtain 0.00 (+.02) weight
readings on inner and outer plane.
2. Position valve stem at 6 o'clock. Loosen hub nut
just enough to allow the wheel to move. While holding
the faceplate so it cannot turn, rotate the wheel 90
degrees relative to the faceplate. Tighten hub nut.
3. Press START. Weight readings should be 0.32 oz.
or less.
4. Repeat steps 2 & 3. At 180 and 270 degrees
weight readings should be .32 oz. or less.
5. If the specified results are not achieved see ROTA-
TIONAL PROBLEMS.
Cycle Counters
These counters can be accessed through the DIAG-
NOSTICS menu. Each cycle counter is different. They
may be beneficial to the shop owner as a management
tool.
User Counter - can be reset at any time by anyone to
determine number of spins per day, hour, or per user.
Calibration Counter - this automatically resets each
time the balancer is calibrated. It can be a useful tool to
see how often the balancer is being calibrated. As a
routine this should be checked when a customer com-
plains of weight chasing or calibration problems. A low
count could indicate the customer is calibrating too
often or calibrating incorrectly.
Total Counts - counts the total number of cycles on
the balancer. It is not resetable, however if the CPU
board is ever replaced it will reset.

Service Manual — COATS Model IBS 2000 • 9
Total Accuracy Verification (TVA)
Total Accuracy Verification or TAV means that when
the balancer shows zeros in the weight display after
balancing the wheel it is truly balanced. The model IBS
2000 includes software that will allow the user to check
the accuracy of his machine periodically. The procedure
is detailed below.
1. Go to the Main Menu and select SETUP. Press
enter.
2. Arrow through the selections to TAV. Press enter.
3. The menu will now display several “preset” selec-
tions to choose from, or the customer may wish to
SPECIFY. Press Enter.
4. If SPECIFY is selected, the menu will prompt to
enter the number of cycles desired. Enter the number
and press enter.
Note: If the preset number is less than 250
the first message will appear at the preset
number. Subsequent messages will also
appear at that interval.
Example A:
Cycles Since
Last Calibration Message
10 The preset number of TAV cycles has
been reached, do you wish to per-
form TAV?
20 The preset number of TAV cycles has
been exceeded, do you wish to per-
form TAV?
5. If NO is selected, the balancer will resume normal
operation.
Note: If the preset number is equal to or
greater than 250, the first message will
appear at the preset number and again
every 250 cycles.
Example B:
Cycles Since
Last Calibration Message
500 The preset number of TAV cycles has
been reached, do you wish to per-
form TAV?
750 The preset number of TAV cycles has
been exceeded, do you wish to per-
form TAV?
7. If YES is selected, the balancer will automatically
enter the calibration mode. Follow the instructions on
the display.
Error Codes
LED Error Codes
When the balancer is powered up, several communi-
cation checks are made. If the data is incorrect, or not
received the balancer generates the following error
codes in the weight amount LED's on the display.
LCD ERR - unable to communicate with LCD:
Displayed when the Display board is unable to commu-
nicate with LCD board. This halts the program. Check
the LCD ribbon, and all connections. Most likely the rib-
bon is not installed properly, backwards or on wrong
pins. Possibly the LCD board.
EE ERR - unable to communicate with the EE PROM:
Displayed when the EE PROM (on the display board)
cannot read or write. It cannot restore display settings,
this is a combination of messages 7 and 8. Replace the
display board.
LCD Error Codes
The following list of error codes, are Built In Safety
Features. When the balancer is cycled several operat-
ing parameters are checked. If one of these parameters
is not within tolerance, the machine will generate an
error message displayed on the LCD readout. An expla-
nation of these messages and troubleshooting proce-
dure is listed below:
#1 - The Motor Speed Was Excessive: Displayed
when the motor exceeds normal operating speed at
any time during the cycle. Check the SSR (solid state
relay).
#2 - Time To Reach Minimum Operating Speed Too
Long: Displayed when time to reach the minimum
operating speed is greater than 20 seconds. Check
cables, SSR, or CPU.
#3 - Time To Reach Maximum Operating Speed Too
Long: Displayed when time to reach maximum operat-
ing speed exceeds 14 seconds. Check cables, SSR, or
CPU.
#4 - The Measurement Time Was Too Long: Displayed
after the motor gets up to speed but the time to set
GAIN (an internal measurement) is too long. Check
cables, optical encoder, or CPU.
#5 - The Measurement Time Was Too Long: Displayed
when the time to FILTER (an internal process) is too
long. Check cables, optical encoder, or CPU.
#6 - Not Used.
#7 - Internal Error Code: Displayed when a write error
on the EE PROM (of the CPU board) has occurred.
Calibration information, counters, etc. Replace CPU
board.
Direct Drive

10 • Service Manual — COATS Model IBS 2000
Direct Drive
#8 - Internal Error Code: Displayed at power up when
the data on the EE PROM is different than when the
unit was turned off. Recalibrate the Balancer and the
A/D Arm. If this message continues replace the CPU
board.
#9 - An Invalid Model Selection Has Been Made:
Displayed when the dipswitches on the CPU board are
not set correctly, or the connections are bad. Check the
dipswitch settings (they should all be in the ON posi-
tion) and reset if necessary. If this does not correct the
problem, replace the CPU.
#10 - The Automatic Arm Is Not Present: Displayed
during Arm Calibration when the CPU cannot detect
the arm. Check the arm cable/PCB connections, or the
CPU connector.
#11 - The A & D Pots Are Not Properly Adjusted:
Displayed during Arm Calibration if the pots were not
properly adjusted. Press CONTINUE to readjust, or
CANCEL to quit.
#12 - The A Pot Is Not Properly Adjusted: Displayed
when the A pot is not reading correctly. Same as #11
except for the A pot only. Press CONTINUE to readjust,
or CANCEL to quit.
#13 - The D Pot Is Not Properly Adjusted: Displayed
when the D pot is not reading correctly, Same as #12
except for the D pot only. Press CONTINUE to readjust,
or CANCEL to quit.
#14 - The Hood Was Raised During The Measurement
Cycle: Displayed if the hood is raised during the cycle.
Lower the hood and respin.
#15 -The Motor Ran In Reverse At Start Up: Displayed
when the motor accelerated in reverse at start up.
Check phase, AC power, or MC (motor controller).
#16 - The Arm Was Not In The Correct Position:
Displayed during Arm Calibration if you get out of
sequence. Press CONTINUE to repeat or CANCEL to
quit.
#17 - No Encoder Pulses At Start Up: Displayed when
no encoder is detected at start up. Check cable, AC
power and motor. Refer to “Wheel Does Not Spin”
flow chart.
#18 - No Phase A Encoder Pulse At Start Up: Same as
#17, but for Phase A only. See “Wheel Does Not Spin”
flow chart.
#19 - No Phase B Encoder Pulse At Start Up: Same as
#17, but for Phase B only. See “Wheel Does Not Spin”
flow chart.
#20 - The Hub Nut Is Loose Or There Is No Wheel
Mounted: Displayed when the hub nut is not tight and
the wheel slips, or the faceplate assembly is not tight
on the motor shaft. Recheck the hubnut or refer to
“Faceplate Assembly Installation” on pg. 5. Press
CONTINUE to proceed.
#21 - The Wheel Is Turning Too Fast For A
Measurement To Be Made: The motor speed is greater
than the maximum operating speed.
#22 - The Wheel Turned In Reverse After The Motor
Was Started: Displayed when something interferes
with the rotation of the wheel after start up (someone
holding the wheel). Press CONTINUE to proceed.
Check cables or SSR. Press CONTINUE to proceed.
#23 - The Wheel Turned Too Slow: Displayed under
similar conditions as #22 . Check cables or SSR. Press
CONTINUE to proceed.
#24 - The Motor Accelerated Forward During
Breaking: Displayed when there is a phase problem
with the SSR, very rare. Check loose shutter wheel or
loose faceplate. Check encoder cable, AC power,
motor, and SSR. Press CONTINUE to proceed.
#25 - The Time Required To Stop The Motor Was Too
Long: Displayed if a phase is lost on the SSR. Check AC
power, cables, and SSR. Press CONTINUE to proceed.

Service Manual — COATS Model IBS 2000 • 11
Pre-dia
g
nostic
check
Make sure the unit is
plu
gg
ed in.
No
Does the
balancer displa
y
appear?
No
Yes Yes
Turn the power on.
Continue troubleshootin
g
.
See induvidual troubleshootin
g
chart.
Does the fan
turn on? Is the fan connected?
Turn the power off,
unplu
g
the unit, and
connect the fan.
No
Troubleshoot the AC
power.
Yes
Direct Drive
Troubleshooting Flow Charts
Pre-diagnostic
Check

12 • Service Manual — COATS Model IBS 2000
Direct Drive
Wheel does not s
p
in
Perform pre-
dia
g
nostic check
(balancer must be
displayin
g
merchandisin
g
messa
g
e to proceed).
Check set-up to
verify auto-spin is
on. Attempt to spin
the wheel.
Cross reference
error messa
g
e to
table and
troubleshoot from
the
g
iven location.
Yes
Yes
No
No
Yes
No
Unplu
g
P3 on motor
controller. Check for
+5v on pin 3 of
CPU?
No
Replace the motor
controller.
Yes
Replace the CPU.
Does volta
g
e
on P12-1 drop to
+.45v when spin is
pressed?
Yes
Is the volta
g
e
correct on T1of
the MC board?
Yes
Troubleshoot AC. Replace motor
controller.
Yes
Does an error
messa
g
e appear?
Does the wheel
start to spin?
Does it
complete the
spin?
Check/Replace control
cable.
Replace motor
controller.
Yes
Did you enter
wheel
parameters?
Yes
No
Enter the
A/W/D
Check control
cable from main
CPU to MC Board.
Is it Plu
gg
ed in?
No
Plu
g
it in.
Check for +5v on
pin 1 of P12
(control) on the
main CPU
Check Interlock
switch cable on
P7of MC board. Is
It plu
gg
ed in?
Disconnect Interlock
switch from P7 on the MC
board. Check continuity
(with the hood down)
between pins 1&2. Do
you have continuity?
No
Yes
Replace
Interlock
switch.
Yes
No
No
No
Troubleshootin
g
Complete, calibrate.
Do you have
+5v on pin 3 P10
(power) on The
main CPU?
No
Wheel Does Not
Spin

Service Manual — COATS Model IBS 2000 • 13
Wheel does not stop.
Perform pre-
diagnostic check
(balancer must be
displaying
merchandising
message to proceed).
Cross reference
error message to
table and
troubleshoot from
the given location.
No
Yes
No
Yes
Check for +5v
on P12 (control) pin
6 of the CPU?
No
Do you
have +5v on
P12 pin 3 of
CPU?
Unplug
P3 on motor
controller. Check for
+5v on pin 3
CPU?
No
Replace the motor
controller.
Yes
No
Replace the CPU.
Does voltage
on P12-6 drop to
+.45v during stop
cycle?
Yes
No
Is the voltage
correct on T1?
Yes
Troubleshoot AC.
No
Replace motor
controller.
Yes
Does an error
message appear?
Do
readings appear
on display after
wheel has
stop?
Check/Replace control cable.
Replace motor controller.
Yes
Does wheel
attempt to stop?
Yes
No
Replace CPU
Direct Drive
Wheel Does Not
Stop

14 • Service Manual — COATS Model IBS 2000
Direct Drive
No Communications
Preform pre-
dia
g
nostic check
(balancer must be
displayin
g
merchandisin
g
messa
g
e to proceed).
Troubleshootin
g
complete.
No
Yes
Check serial cable.
Is it plu
gg
ed in?
Perform loop-back
test* with new cable?
Does unit work? No
Yes
Replace
communication
cable.
Yes
Plu
g
cable in and
recheck.
No
*Note: to perform loop-back
test refer to that section in
this manual
Replace
displa
y
board.
Replace CPU board.
Did you replace a
software chip?
Yes
Check for bent
pron
g
s, or repostion
the chip. Did this
correct the problem?
No No
Yes
Yes
Yes
No
Communications

Service Manual — COATS Model IBS 2000 • 15
Ke
yp
ad Problems.
Perform keypad test
from main menu
Dia
g
nostic. The
balancer must be
displayin
g
information
to proceed. Does this
indicate a problem?
Replace Keypad
No
Yes No
Yes
Check ke
y
pad
connections.
Does this correct the
problemt?
Was keypad locked
up at power up?
Cycle the power
a
g
ain. Does this
correct the problem?
Yes
No
Yes
Troubleshootin
g
complete.
Ke
yp
ad Problems.
Perform keypad test
from main menu
Dia
g
nostic. The
balancer must be
displayin
g
information
to proceed. Does this
indicate a problem?
Replace Keypad
No
Yes No
Yes
Check ke
y
pad
connections.
Does this correct the
problemt?
Was keypad locked
up at power up?
Cycle the power
a
g
ain. Does this
correct the problem?
Yes
No
Yes
Troubleshootin
g
complete.
Ke
yp
ad Problems.
Perform keypad test
from main menu
Dia
g
nostic. The
balancer must be
displayin
g
information
to proceed. Does this
indicate a problem?
Replace Keypad
No
Yes No
Yes
Check ke
y
pad
connections.
Does this correct the
problemt?
Was keypad locked
up at power up?
Cycle the power
a
g
ain. Does this
correct the problem?
Yes
No
Yes
Troubleshootin
g
complete.
Ke
yp
ad Problems.
Perform pre-
dia
g
nostic check
(balancer must be
displayin
g
merchandisin
g
messa
g
e to proceed).
Perform keypad test
from main menu
Dia
g
nostic. The
balancer must be
displayin
g
information
to proceed. Does this
indicate a problem?
Replace Keypad
No
Yes No
Yes
Check ke
y
pad
connections.
Does this correct the
problemt?
Was keypad locked
up at power up?
Cycle the power
a
g
ain. Does this
correct the problem?
Yes
No
Yes
Troubleshootin
g
complete.
NOTE:
When a ke
y
is shorted or locked down at power up,
1. the LCD ma
y
be li
g
hted but blank.
2. the "Press An
y
Ke
y
to Continue" messa
g
e ma
y
be
displa
y
ed.
3. the LCD ma
y
be in another mode such as:
ADJUST LCD CONTRAST
BALANCER DISPLAY DIAGNOSTICS
Direct Drive
Keypad Problems

16 • Service Manual — COATS Model IBS 2000
Direct Drive
No LCD Dis
p
la
y
Perform pre-
diagnostic check
(balancer must be
displaying
merchandising
message to proceed).
Yes
No
Is display
completely dark?.
Is LCD display
blank?
Are LED's
displa
y
in
g
the
merchandise
messa
g
e?
Is display
illedgible?
No
Yes
Does display
show LCD ERR?
Yes
Yes
Does it beep
5 seconds after
power on?
Replace display board
Adjust contrast
Yes
Yes
Check LCD cable
& LCD.
No
Adjust contrast.
Are all AC & DC
voltages correct
Troubleshoot power
supply and AC
voltages.
No
No
Yes
See KEYPAD
problems. Does
this correct the
problem?
No
No
No
Replace the
display board.
Adjust contrast. Turn
Power Off. Hold down
the first rim key while
turning the power
back on. or use the
potentiometer on the
top of the display
board.
No LCD Display