Manatec Lx wb-vl-65 dsp User manual

VIDEOGRAPHIC WHEEL BALANCER

WB-VL-65 DSP Premium /Premium+

OPERATING MANUAL

(Ver.1.6)

Dear Customer,

Congratulations, for selecting Videographic Wheel balancer as your Wheel balancing equipment.

It is an user friendly system which can be used effectively for balancing Car / LCV wheels.

We take special care to ensure that every Videographic Wheel balancer leaving our Factory is in

the best operating condition. This OPERATING MANUAL has been prepared to help you in

getting the best performance out of the equipment. Still, if you have any doubt, please do not

hesitate to contact us.

Read the Operating manual carefully before starting to use the equipment

Every attempt is made in this manual to guide the User on the effective use of the

Equipment. Any suggestion may please be sent to us for improvement.

INDEX Page No.

1. WARRANTY –STATUTORY CLAUSE 1

2. SAFETY 2

2.1. INTENDED USE 2

2.2. SAFETY INSTRUCTIONS FOR COMMISSIONING 2

2.3. SAFETY INSTRUCTIONS FOR OPERATION 3

2.4. SAFETY INSTRUCTIONS FOR SERVICING 3

2.5. SAFETY FEATURES 4

2.5.1. WHEEL GUARD AND ITS SAFETY INTERLOCK SWITCH 4

2.5.2. HOME POSITION INDICATOR FOR DISTANCE MEASURING ROD 4

2.5.3. DOUBLE CLICK OF KEYS FOR SPINNING OF WHEEL 4

2.5.4. CONTROL FUSE 4

2.6. SAFETY LABEL INFORMATION 4

3. FEATURES & SPECIFICATIONS 6

4. INSTALLATION 8

4.1. REQUIREMENTS 8

4.1.1. LOCATION 8

4.1.2. SPACE REQUIREMENTS 8

4.1.3. POWER REQUIREMENTS 8

4.1.4. TOOLS REQUIREMENTS 8

4.2. UNPACKING 9

4.3. FOUNDATION 10

4.4. INTEGRATION 10

4.4.1. MONITOR 10

4.4.2. WHEEL GUARD 11

4.4.3. WIDTH MEASURING ROD 11

4.4.4. MCD 11

4.5. INITIAL OPERATION 11

5. OPERATING PRINCIPLE 12

5.1. UNBALANCE OF WHEEL 12

5.2. STATIC BALANCING (Single plane balancing) 12

5.3. DYNAMIC BALANCING (Two plane balancing) 13

5.4. PRINCIPLE OF OPERATION 13

5.5. WHEEL BALANCING WEIGHTS 13

6. DESCRIPTION OF MAIN PARTS 14

6.1. MAIN CABINET 14

6.2. ROTOR 14

6.3. DISPLAY UNIT 15

6.4. CONTROL PANEL 15

6.5. WHEEL GUARD 15

6.6. STANDARD ACCESSORIES 16

6.7. OPTIONAL ACCESSORIES 17

7. OPERATION 18

7.1. DEFECTS / MALFUNCTIONS 18

7.2. PREPARATION OF WHEEL FOR BALANCING 18

7.3. MOUNTING OF WHEEL ON MCD 18

7.3.1. BACK CONE MOUNTING 19

7.3.2. FRONT CONE MOUNTING 19

7.3.3. LCV WHEEL MOUNTING 20

7.3.4. LCV UNIVERSAL FLANGE MOUNTING 21

7.4. BALANCING 22

7.4.1. RIM PARAMETERS 23

7.4.2. WHEEL RUN 26

7.5. SPECIAL FUNCTIONS 28

7.5.1. SPLIT WEIGHTS (SPOKES / HIDDEN WEIGHT) FUNCTION 28

7.5.2. OPTIMIZATION FUNCTION 29

8. SETTINGS 31

9. OPTIONS 32

9.1. WEIGHT CALIBRATION 32

9.1.1. SPINDLE ZERO 33

9.1.2. TYRE ZERO 34

9.2. DIAMETER CALIBRATION 36

9.3. WIDTH CALIBRATION 37

9.4. WHEEL TRACKING TEST 39

9.5. DISTANCE ROD TEST 39

9.6. SELF TEST 39

9.7. SENSOR TEST 39

9.8. LASER & TORCH SETTING (Applicable for Premium+ model) 39

9.9. DUTY CYCLE TEST 39

9.10. KEYPAD TEST 40

9.11. BACKUP FACTORY DATA 40

9.12. CUSTOMER INFOROMATION 40

9.13. RESET JOB NUMBER 40

9.14. RESTORE FACTORY CALIBRATION 40

9.15. WEIGHT CUTOFF 40

10. LANGUAGE SETTINGS 40

11. SOFTWARE UPDATE 40

12. MAINTENANCE 41

12.1. CONTROL PANEL 41

12.2. MCD 41

12.3. WHEEL MOUNTING ACCESSORIES 41

12.4. WHEEL GUARD 41

12.5. TOP COVER 41

12.6. DISTANCE MEASURING ROD 41

13. TROUBLE SHOOTING 42

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 1

1. 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:

1. Ensure that proper power supply with protective Earthing is provided for the equipment.

Any high voltage may damage the components, leading to system failure or electrical

hazards.

Power supply

For 230V 50/60Hz operation: Single Phase, 230VAC ±10%, 50/60Hz +N +PE

For 110V 60/50Hz operation: Single Phase, 110VAC ±10%, 60/50Hz +N +PE

Warranty ceases if this condition is not satisfied

2. Power supply to the equipment should be connected only through a CVT of 1KVA

capacity to avoid any failure of electronic parts due to instantaneous high voltage.

PLEASE AVOID CONNECTING WHEEL BALANCER DIRECTLY TO MAINS.

3. Ensure that any heavy electrical equipments like Compressor / Welding machines /

Medical equipments etc., are not connected to same power line.

4. All regulations in force concerning the safety at work must be complied when choosing the

installation location. In particular, the equipment must be installed and operated in

protected environments where there is no risk of dripping (or) direct sunlight.

5. Ensure that any equipment which produces Ultra Violet rays is not available in the same

premises.

6. The operating location must be free from heavy magnetic field.

7. Do not attempt to open or service the equipment under any circumstances.

Warranty ceases if the equipment is opened or serviced by un-authorized personnel

8. While handling the PCBs, make sure to wear ESD wrist band.

9. Ensure the PCBs are packed in ESD safe cover during transportation for service or any

other purpose.

10. Warranty ceases if this equipment is used for any purpose other than the intended

use.

11. The equipment must be installed Indoor away from Sunlight, rain / moist areas

Warranty ceases if the equipment is exposed to direct Sunlight, Rain / Water

12. Make the warranty registration by duly signing the counterfoil of the warranty card sent

along with the equipment.

13. If transportation, lifting, unpacking, assembly, installation, start up, testing, repair and

maintenance have been performed by un-authorized personnel, the manufacturer shall

not be responsible for injury to personnel or damage to objects.

14. DO NOT remove or modify any parts of the equipment as this could compromise the

equipment's intended use. For any modifications / repairs consult the Manufacturer.

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 2

MAXIMUM WHEEL WEIGHT : 65 kg

MAXIMUM WHEEL DIAMETER: 39" (990 mm)

MAXIMUM WHEEL WIDTH : 21" (533 mm)

ATTENTION

2. SAFETY

Thoroughly read all Safety labels and Manual instructions before installing, operating and

maintaining the Wheel balancer. They are provided to prevent personal injury and property

damage. Replace any label unreadable or missing on the Wheel balancer. Refer Part No. given

for each labels for ordering. Always keep the Manual in a prominent place for quick reference.

Injury to personnel and damage to property incurred due to non-compliance with these safety

instructions are not covered by the product liability regulations.

SYMBOLS

Failure to comply with instructions could result in personal injury

Failure to comply with instructions could result in property damage

Important information

2.1. INTENDED USE

Always observe the rated load capacity of

the Wheel balancer.

Use the Balancer as described in this

Operating manual only.

Wheel guard must be kept closed during

spinning of wheel in the Balancer.

Use only the accessories recommended by the manufacturer.

Always use appropriate accessories for mounting various types of wheels.

2.2. SAFETY INSTRUCTIONS FOR COMMISSIONING

1. Only authorized service personnel are allowed to install and commission the

Wheel balancer.

2. DO NOT HOLD the shaft or its base for lifting / moving the Balancer. Even the

slightest bend of the shaft will affect the accuracy of the equipment. Use Lifting

handles for lifting the Balancer.

3. The Balancer should not be installed outdoors or in moist rooms.

4. To reduce the risk of fire, the equipment should not be installed at hazardous

locations or in the vicinity of explosives or flammable liquids.

5. The floor should be properly leveled beneath the Balancer and should be free of

heavy equipment vibration.

6. The Balancer must be anchored to the floor, since large unbalance in wheels can

cause heavy vibration which leads to repeated runs for balancing.

7. The electrical main supply to the Balancer must be connected through a CE

certified MCB with ratings as given below:

For 230V 50/60Hz operation: Two pole, Type C, 6A MCB

For 110V 60/50Hz operation: Two pole, Type C, 10A MCB

8. Proper Earthing must be provided.

9. If an Extension power cord is required, a cord with correct rating equal to or more

than that of the equipment should be used.

10. Care should be taken to route the Power mains cord properly so that it is not

tipped over or pulled.

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 3

2.3. SAFETY INSTRUCTIONS FOR OPERATION

1. Read the Operating manual thoroughly.

2. Only permit qualified personnel to operate, maintain or service the Balancer.

3. Always keep the Balancer and the surrounding work area clean and free of

Tools, Parts, Debris, Grease etc.

4. Do not operate, if the equipment has been dropped or damaged until it has been

examined by qualified service personnel.

5. Do not operate the equipment with damaged Power cord.

6. Always unplug the equipment from electrical outlet when not in use. Do not pull

on the cable, always pull the plug directly out of the socket.

7. Avoid dropping of wheels heavily on the shaft while mounting and removing,

which may affect the accuracy of the equipment and also damage the shaft

threaded area.

8. The wheels must be mounted properly on the shaft, as the quality of balancing is

directly depended on the mounting of the wheels. The Quick Change Lock Nut

(QCLN) must be firmly tightened before spinning the wheel.

9. Do not hammer or hit any part of the equipment with Weight plier, Tools etc.

10. Do not lift the Wheel guard until the wheel rotation is completely stopped.

11. Never overload the Balancer.

12. Do not keep heavy objects over the system, except limited quantity of Wheel

balancing weights.

13. Keep hair, loose clothing, fingers, and all parts of body away from rotating /

moving parts.

14. Always wear Safety glasses and Gloves while operating the equipment.

15. DO NOT apply the Mechanical brake while the Motor is running. It should be

used only for adding weights or mounting/removing wheels.

16. Always comply with the applicable accident prevention regulations.

2.4. SAFETY INSTRUCTIONS FOR SERVICING

1. Inspect the Wheel balancer on daily basis.

2. Only authorized personnel are allowed to service the Balancer.

3. Turn OFF the switch and unplug the Balancer before doing any maintenance or

repair work.

4. Only certified electricians are allowed to service the electrical & electronic parts of

the equipment.

5. Do not remove / disable / override any safety device / interlocks.

6. The use of cleaning agents which attack coating or sealing materials could result

in equipment damage.

7. Ensure the disposal of ecologically harmful substances in accordance with the

appropriate regulations.

8. Use recommended spare parts only to guarantee the reliable function and to

ensure safety of the equipment.

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 4

2.5. SAFETY FEATURES

2.5.1. WHEEL GUARD AND ITS SAFETY INTERLOCK SWITCH

The Wheel guard prevents flying out of the weights added on the Wheel rim or

stone / foreign particles sticking to the tyre in any direction except towards the

floor. A safety Interlock switch is provided to ensure that the Wheel guard is

closed during spinning of wheel. If the Wheel guard is not closed during

spinning, an error message “Wheel Guard Not closed” will be displayed. By

closing the guard, error message will disappear and the wheel starts spinning.

This feature is to ensure the safety to the operator.

2.5.2. HOME POSITION INDICATOR FOR DISTANCE MEASURING ROD

To avoid the wheel from hitting the Distance measuring rod while running ie., if

the Distance measuring rod is not in home position, the wheel run will not be

carried out and an Error code “Distance rod is not in Home position” will be

displayed. Move the Distance measuring rod to home position to continue.

2.5.3. DOUBLE CLICK OF KEYS FOR SPINNING OF WHEEL

During Balancing run, for spinning the wheel the key must be pressed

twice within a second. This is to avoid accidental spinning of wheel.

2.5.4. CONTROL FUSE

Control fuses are incorporated to protect the electronic assemblies against

short circuit & high current. AC (Inlet) socket with Fuse holders is mounted on

the rear side of Main cabinet which can be easily accessed from outside for

replacing the blown fuse. Always replace the Control fuse with same type and

rating of CE marked Fuse.

2.6. SAFETY LABEL INFORMATION



Sticker, Operation,

Safety & Rating

(LCV)

(Part No. H3711)

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 5



Sticker, Electrical

safety

(Part No.

B2945/B2946)



Safety instruction

for operation-II

(Part No. H3635)



Indicator for

direction of rotation

of wheel

(Part No. H3636)



Mechanical brake

attention

(Part No. H3632)



Foundation

Warning

(Part No. B2941)

CAUTION

DO NOT HAMMER

or HIT

ROTATION

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 6

3. FEATURES & SPECIFICATIONS

Sl.

No.

Description

Premium

Premium+

Features

Suitable for balancing of Cars & LCV wheels



Optical Encoder for acquiring wheel parameters input by wheel

rotation



RLS sensor for automatic measurement of Wheel Dia & Width



Automatic Rim Type detection for the hassle of selection the

exact Rim type



High precision Piezo Sensor for unbalance measurement



Low RPM & Centrifugal Switchless Motor for high reliability &

vibration less balancing



DSP (Digital Signal Processor) technology for processing

wheel data



Linux Operating System compatible computing hardware &

balancing program



Built-in Mini UPS for safe shutting down of the Operating

system



Automatic Electrical braking system



Additional Mechanical braking system (Foot pedal operated) to

facilitate weight addition



High resolution LED Monitor



Icon based User friendly balancing program



Graphical User I/F for live balancing



Optimized balancing sequence



Compact & simplified Membrane keypad



Safety Warning messages



On-screen help notes/messages



Fully automatic start, measurement and braking



Static (Single plane) & Dynamic (Two plane) Balancing



Two modes of measurement - Normal and Fine



Seven modes of Alloy wheel functions



Automatic Distance input mechanism



Automatic measurement of Rim diameter



Automatic measurement of Rim width



Split weights function (Spokes / Hidden weight Program)



Optimization function



Laser line indication for Unbalance position for Sticker weights



Torch light for illumination of Inner plane



Sticker weight holder for easy addition of Sticker weight





Input parameter entry confirmation through Beep sound



Auto unbalance recalculation without wheel Run on input

parameters change



Adjustable Unbalance threshold (Weight cutoff)



Simultaneous display of Inner and Outer plane results



Dimension setting in "Inch" or "mm"



Unit conversion in "grams" / "ounces"



Self diagnostic, On-line error display



Self Calibration



Mid Centering Device for positioning of wheels accurately



Quick Change Lock Nut to ensure fast mounting & removal of

wheels



Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 7

Sl.

No.

Description

Premium

Premium+

Automatic start with wheel guard closure



Universal AC power input socket



Technical specifications



MCD shaft diameter

40 mm

Maximum wheel weight

65 kg

Maximum Wheel diameter

39" (990 mm)

Maximum Wheel width

21" (533 mm)

Rim distance

By Distance measuring rod

By Keypad entry

4 to 300 mm

0 to 550 mm

Rim diameter *

10" to 24" (254 to 610 mm)

Rim width *

1.5" to 20" (38 to 508 mm)

Maximum unbalance measurement

300 gm

Diameter measurement resolution

0.1” / 1mm

Unbalance Resolution

For Car / LCV

Fine Normal

1 gm 5 gm

Unbalance Accuracy - For Cars / LCV

1 gm

Position accuracy

± 1°

Balancing speed - For Cars / LCV

175rpm

Spin time - For Cars / LCV

10 sec. (min.)

III

Electrical specifications



Motor

230V 50/60Hz operation

110V 60/50Hz operation

0.35HP, 1 , 50/60Hz

0.35HP, 1, 60/50Hz

Motor speed

230V 50/60Hz operation

110V 60/50Hz operation

960rpm

1200rpm

Power supply

230V 50/60Hz operation

110V 60/50Hz operation

230VAC ±10%,1, 50/60Hz +N+PE

110VAC ±10%,1, 60/50Hz +N+PE

Current rating

230V 50/60Hz operation

110V 60/50Hz operation

2 Amps

6 Amps

Power

230V 50/60Hz operation

110V 60/50Hz operation

700W

General specifications



Machine dimensions - Unpacked (LxBxH) (approx.)

Without Wheel guard

With Wheel guard (in Open condition)

With Wheel guard (in Closed condition)

1100x1130x1350mm

1350x1140x1720mm

1350x1140x1350mm

Machine dimensions - Packed (LxBxH) (approx.)

Cabinet with Accessories

1120x710x1170mm

Machine weight - Unpacked (approx.) - (without Wheel guard)

120kg

Wheel guard weight - Unpacked (approx.)

15kg

Machine weight - Packed (approx.)

165kg

Operating temperature

0°C –50°C

Storage temperature

-20°C to 70°C

Humidity

RH below 90% Non condensing

Ingress Protection rating

IP-20

NOTE :

*- Rim diameter & Rim width is the dimension entered with reference to the place of addition

of balancing weight on the Rim

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 8

4. INSTALLATION

Wheel balancer installation should be done only by qualified Service personnel.

4.1. REQUIREMENTS

4.1.1. LOCATION

The Wheel balancer should not be installed outdoors, in moist rooms, at

hazardous locations, or in the vicinity of explosives or flammable liquids.

Choice of a suitable location is the owner's responsibility

4.1.2. SPACE REQUIREMENTS

The floor should be properly leveled beneath the Balancer and should

be free of heavy equipment vibrations.

The clearances from side walls and roof should be adequate so that the

Wheel guard can be opened completely and the mounting / removal of

wheels can be done easily as shown in Fig.1.

Fig. 1

4.1.3. POWER REQUIREMENTS

For 230V 50/60Hz operation: Single Phase, 230VAC ±10%, 50/60Hz +N +PE

For 110V 60/50Hz operation: Single Phase, 110VAC ±10%, 60/50Hz +N +PE

Supply to the equipment must be connected through a CE certified MCB with

ratings as given below:

For 230V 50/60Hz operation: Two pole, Type C, 6A MCB

For 110V 60/50Hz operation: Two pole, Type C, 10A MCB

Proper Earthing must be provided. Also ensure that live phase is on right side

point of socket. It is strongly recommended to use a CVT of 1KVA capacity.

Neutral to Line Voltage should be 230VAC ±10% (for 230V operation)

Neutral to Line Voltage should be 110VAC ±10% (for 110V operation)

Neutral to Earth should be less than 3V AC

4.1.4. TOOLS REQUIREMENTS

Provision of handling means such as Forklifts etc. is the owner's

responsibility

Following accessories and tools are required for the proper installation:

Screw drivers, Spanner set and Allen key set

Measurement Tape, 5mtr

Chalk liner/Marker pen –For marking

Strip cutter –to Open Carton banding

Knife –For opening Cartons

Plastic cable ties –for proper routing of cables

Multimeter –For verifying supply voltage

Nylon Hammer

Hammer Drill and 12mm Drill bit

„U‟ type Shims (required quantities) – 0.5mmT & 1.0mmT

600

700

1720

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 9

4.2. UNPACKING

1. Unpack the Main cabinet corrugated box

2. Un-wrap the VCI sheet from Main cabinet.

3. Remove all the four bolts from Main cabinet base to take it out from pallet.

4. Ensure the contents as per the packing list:

Package

No.

Package description

Package contents

Qty

Main cabinet corrugated

box

1. Main cabinet assembly

1 No.

2. Monitor

1 No.

3. Monitor column

1 No.

4. Wheel guard with pipe & DMR

1 No.

5. Width caliper

1 No.

6. Width measuring rod

1 No.

7. Accessories box (Cabinet right side)

containing:

a) MCD & QCLN parts

b) Cone holding stem

c) Wheel seating cones

d) Wheel guard bracket

e) DMR spacer, ALU-2P/3P

f) Rubber hub cover

g) Wheel balancing weight

h) Foundation fasteners

i) Glass fuses

1 Set

3 Nos.

5 Nos.

1 No.

1 Set

Fig. 2

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 10

4.3. FOUNDATION

Proof of safe floor load capacity is the owner's responsibility

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

1. Place the Cabinet at designated location & mark its foundation fixing holes.

2. Move the Cabinet. Bore the marked holes using a Hammer drilling machine

equipped with a 12mm concrete drill bit to required depth in the floor considering

the foundation bolt length with sufficient length above the floor level for fixing

cabinet. Clean the dust in the foundation area and holes.

3. Insert the M12x125mm Lg. Anchor bolt into the holes. Insert the foundation pin

into the Anchor bolt and hammer to lock it.

4. Place the cabinet over the Foundation bolts by providing M16 Spring washer

(Flat type) between the Cabinet and Floor.

5. Fix the Cabinet with foundation bolts using Nut & Washer that comes along with

Anchor bolt.

6. Check of any tilt. Use required quantities & thickness of „U‟ type shims (0.5mmT

& 1.0mmT) in between the Spring washer & Floor for compensation, if required.

Fig. 3

4.4. INTEGRATION

4.4.1. MONITOR

1. Fix the Monitor column with Main

cabinet at the rear side (Centre)

using respective Allen screw &

Spring washer (2 Nos.) each.

Ensure the column is

perpendicular to the Cabinet.

2. Fix the Monitor with Monitor

plate using WH-PH screw (4

Nos.) firmly and ensure the

straightness.

3. Connect one end of the Monitor

power cord with Monitor and

other end to the socket provided

at rear (Right) side of cabinet.

4. Connect the HDMI end of

Monitor cable from the SBC

(Raspberry Pi) board with Monitor. Fig. 4

5. Verify all the connectors are proper and without any loose contact. Close

the Top cover.

Nut for

Anchor bolt

Washer for

Anchor bolt

Cabinet base

Shim

Spring washer

Top

cover

Monitor

cable

routing

cutout

Monitor

column

Monitor

plate

Monitor

power

socket

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 11

Square

pipe

Wheel

guard

Wheel

guard

pipe

Bracket

Spring

Width

Rod

Dia

board

housing

Width

Assy

4.4.2. WHEEL GUARD

1. Fix the Wheel guard bracket at the rear side of

cabinet using Bolt & Spring washer.

2. Fix the Square pipe with the bracket using Allen

screw & Spring washer.

3. Fix the Wheel guard with pipe using Allen button

head screw, Nut, Spring & Plain washer.

4. Fix the Wheel guard & pipe assy with

Square pipe using Nut, Spring & Plain

washer. Ensure Wheel guard is without

any tilt.

5. Verify & ensure the limit switch functions of

Wheel guard by opening & closing the guard.

Fig. 5

6. Hook one end of the Wheel guard spring with Square pipe and the other

end with the Cabinet. Ensure the Wheel guard assembly is

perpendicular to cabinet.

4.4.3. WIDTH MEASURING ROD

1. Remove the Bracket back sheet from Bracket.

2. Insert the Safety cover into Wheel guard bracket & then fix Width rod

with bracket using Allen screw & Spring washer by matching the Arrow

stickers. Ensure the Width rod is perpendicular to cabinet.

3. Route the Outer dia wire through the Dia board housing and then fix it to

the Outer dia board. Connect the housing assembly with the Width rod.

4. Remove Width board back cover. Connect Width wire to width board.

5. Bring the Width assembly cable through the bracket and connect Male

end of Wire from Width measuring rod to female end provided below the

Bracket at the rear side of cabinet.

6. Fix the Safety cover with the Bracket using WH-PH screw. Ensure Width

cable is covered by Safety cover without touching any moving parts.

7. Fix the Bracket back sheet with Bracket using WH-PH screw.

8. Insert the Width rod at the sliding block in the Wheel guard properly.

4.4.4. MCD

1. Insert the Threaded shaft into Tyre seating cone and fix the assembly

with Rotor Main shaft firmly using Allen screw & Spring washer (1 No.)

each by matching the Arrow stickers pasted in both the Tyre seating

cone & Main shaft.

2. Ensure the Rotor shaft is free from Runout. Else correct it.

Fig. 6

Fix the Cone holding stems with left side of cabinet and locate the Wheel seating cones

with the respective Stem as shown below:

Finally verify & ensure the cabinet is free from tilt again.

4.5. INITIAL OPERATION

1. Provide power supply and switch ON the equipment.

2. Press key twice to run the Empty shaft and ensure the „0‟ value is displayed

in both windows.

3. Mount a wheel (Refer Chapter 7.3) & balance the same (refer Chapter 7.4). Add

a known weight on both sides (Inner and Outer). Check for its value and position

are displayed correctly. If not, perform calibration (refer Chapter 9.1) and again

conduct balancing operation.

TYRE SEATING

CONE WITH STUD

ALLEN KEY

(10mm)

WHEEL CLAMPING

SHAFT - THEAD SIDE ALLEN

SCREW

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 12

5. OPERATING PRINCIPLE

5.1. UNBALANCE OF WHEEL

In normal condition unevenly worn out tyre causes uneven mass (weight) distribution

with respect to wheel centre. Even Brand new tyres may have small amount of uneven

mass distribution i.e., Unbalance.

When the wheel is in motion, the unbalanced mass causes a centrifugal force. This

force when meeting the road squeezes the tyre momentarily.

This force is directly proportional to speed square (F N2) ie., as the speed increases,

the force increases in square proportion causing patch wear of the tyre. An unbalance

in Front wheels, will give a vibration that can be felt through the steering wheel. At high

speeds, the effect can be felt more. Unbalance in the rear wheels will result in a

vibration that can be felt through the vehicle body. This unbalance can have a

detrimental effect on the various joints and suspension of the vehicle.

To eliminate the unbalance, balancing of the wheel has to be carried out. Balancing is

the process of finding out the „Mass‟ which causes unbalance and the location (phase)

of the mass, and adding equal weight in the directly opposite location (180º away).

Fig. 7

5.2. STATIC BALANCING (Single plane balancing)

Static balancing is the process of adding equal amount of balancing weight at 180º

position opposite to the position of the Unbalance. Static balancing is applicable only

for thin wheels of less than 3” width (Motorcycle Wheels). Normally the unbalanced

weight will be added on the rim of the wheels though the unbalance may be anywhere

in the width as shown in Fig.8. To get perfect balancing the weight must be added in

the same plane at 180º opposite position (Inner position).

In Static balancing Method, though the weight is not added in the same plane, the

Dynamic forces caused will be very minimal when the wheel width is small. But in the

case of wider wheels, the distance between the plane of unbalance and the plane of

the weight addition will be more and for this reason a Force couple will be formed and it

will create a rocking effect on the bearings of the wheels. This kind of situation

requires a Dynamic balancing technique.

Fig. 8

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 13

5.3. DYNAMIC BALANCING (Two plane balancing)

In Dynamic balancing, the weight will be added in two planes as indicated in Fig.9.

This kind of adding weights in two planes will eliminate the possibility of Force couple.

With the result, there will not be any undesirable dynamic forces left out in the wheels.

Since the weights are added in two planes, this is also called as Two Plane Balancing.

Normally for Four Wheelers, Two plane balancing is recommended and today's

computerized Wheel balancing equipment are following this technique only.

Fig. 9

5.4. PRINCIPLE OF OPERATION

Wheel balancer is a DSP based Wheel balancing equipment. The Balancer calculates

the unbalanced mass and the position of unbalance over the width of the wheel.

The two planes of the wheel are the Inner and Outer faces of the wheel (in the case of

normal rims) where the balancing weights can be fixed. In Alloy rims the location of

weights will be different based on the configuration of Alloy rim (refer Chapter 7.4.1).

The Diameter, Width of the Rim and the Rim distance are the inputs to the equipment

for calculating the unbalance. When the distance from the equipment and the inner

face of rim is entered the system takes it as the Inner plane location of the Balancer.

When the Rim width is entered the system adds the width with the inner plane distance

and takes it as the outer plane location. When the Diameter is entered the system

takes it as radial distance from the centre of wheel to where the weights to be added.

When the wheel is rotated the system detects any unbalance on the shaft. The Inner /

Outer unbalance window displays the unbalanced mass in the respective planes. The

measurement will be taken if only the set RPM is reached.

5.5. WHEEL BALANCING WEIGHTS

The weights must be fixed firmly on to the rim for proper balancing and to

avoid repeated runs

TYPES OF WHEEL BALANCING WEIGHTS

Clip-on type weight

Sticker (adhesive) type weight

Clip-on type Wheel balancing weights can

be used for Steel rims with less thickness

Sticker type Wheel balancing weights can

be used for Alloy rims with more thickness

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 14

6. DESCRIPTION OF MAIN PARTS

The System consists of Main Cabinet, Rotor, Electronic assemblies, Display unit, Control panel,

Mechanical brake, Distance/Dia measuring rod, Width measuring rod, Wheel guard, Standard

accessories and Optional accessories.

Fig. 10

Fig. 11

Sl.

No.

Description

Sl.

No.

Description

Main cabinet

Wheel seating cone-Ø94-Ø111.5mm

Wheel clamping threaded shaft

Wheel seating cone-Ø80-Ø97.5mm

Quick Change Lock Nut

Wheel seating cone-Ø66-Ø83.5mm

Control panel

Monitor column

Distance & Dia measuring rod

AC Input socket

Width measuring rod

On/Off Rocker Switch

Wheel guard

Laser (NA for Premium model)

Wheel guard bracket

Torch (NA for Premium model)

Mechanical brake

Sticker weight holder

Display unit

6.1. MAIN CABINET

Main cabinet is the housing for Electronic unit, Rotor, Motor and Control panel.

Mains power cable is situated at the rear side of Cabinet & ON/OFF switch is provided

at side of cabinet. Control fuses are incorporated to protect electronic assemblies

against short circuit & high current. AC (Inlet) socket with Fuse holders is mounted on

the rear side of Main cabinet which can be easily accessed from outside for replacing

the blown fuse. Always replace the Control fuse with same type and rating of CE

marked Fuse.

Control fuse - 1 No. is provided in Line & 1 No. is provided in Neutral

For –230V Specifications –3A, Dia 5mm x 20mm, Slow blow type Glass fuse

The Fuse will blow in 5 seconds (max.) for maximum current of 3A

For –110V Specifications –10A, Dia 5mm x 20mm, Slow blow type Glass fuse

The Fuse will blow in 5 seconds (max.) for maximum current of 10A

Turn OFF the switch and unplug the balancer before doing any maintenance or

repair work

6.2. ROTOR

The Rotor assembly consists of the Driven pulley mounted on the shaft located in the

Bearing housing, Mid Centering Device and the RPM encoder assembly.

17 17

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 15

6.3. DISPLAY UNIT

The Display unit is a High resolution Color LCD Monitor with DVI interface to display

the balancing process and functions in High definition video quality (HDMI). It contains

a Power indicator LED, Power ON/OFF switch and various adjustments. Refer the

Monitor manual / Soft media provided along with the equipment for adjustments.

Ensure that none of the Monitor air vents are blocked. Blocking them would

cause serious thermal problems

Clean the Monitor with a soft & clean cloth using water. Remove moisture

from the display quickly and keep the display dry. Long term exposure to

moisture may damage the display

The location of Monitor power indicator and controls may change depending

upon the make of the Monitor supplied. Refer the Monitor manual / Soft media

6.4. CONTROL PANEL

Control panel is a soft touch Membrane keypad for operating the equipment provided

on the Top cover. The various functions of the keys are as follows:

Fig. 12

Keys

Functions

To toggle the keypad control between Task

bar & Screen options

To select the SETTINGS button in

WELCOME screen

To proceed with next step/screen in

balancing operations

To clear error messages

Pressing the key twice (within a second)

will start balancing operation

To stop the Motor when balancing run is in

progress

To go back to previous screen

To increase the Wheel dimensions while

setting parameters

To navigate through the options listed

To decrease the Wheel dimensions while

setting parameters

To navigate through the options listed

6.5. 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. A

safety Interlock switch is provided to ensure that the Wheel guard is closed during

spinning of wheel. If the Wheel guard is not closed during spinning, “Wheel Guard Not

closed” message will be displayed. Press key to clear the error message and close

the guard to spin the wheel. This feature is to ensure the safety to the operator.

Always keep the Wheel guard closed during spinning of wheel

Do not lift the Wheel guard until the wheel is completely stopped

Do not apply the Manual brake until wheel is completely stopped

Ref.: WB-VL-65 DSP LX Premium - OM Ver.1.6 (B2927) 16

6.6. STANDARD ACCESSORIES

Uses only the Accessories recommended by the manufacturer and handle it

carefully. Failure to comply may cause injury to Operator

Handle the Weight removing plier properly and avoid placing fingers between

the teeth

Frequently inspect the accessories and clean and lubricate

Weight plier

(Code : B0539)

Caliper

(Code : B2850)

Rubber hub cover

(Code : B2851)