marposs P7WB Owner's manual

P7_D291W001UD_44.doc 22/04/09
PROGRAMMING MANUAL
Wheel Balancing / GAP&Crash
Manual Code: D291W001UD

This product is in conformity with the EMC requirements as for the directive
2004/108/CE
This product is intended to operate in industrial locations; it is not intended for connections to a
public mains network but is intended to be connected to a power network supplied from a high
or medium voltage transformer.
This product is in conformity with the “Electrical Safety” requirements as for the directive
2006/95/EC
SAFETY WARNINGS
Follow the grinder manufacturer’s safety procedures.
Follow all safety procedures at the gauge system location.
There are NO Customer serviceable parts inside the P7WB. Always call technical service
MANUFACTURER:Marposs S.p.A.
ADDRESS:Via Saliceto 13, Bentivoglio (BO) Italy
www.marposs.com
SYSTEM SOFTWARE:V4.4
P7WB SYSTEM – MODEL:885YW______________
HARDWARE CODE:885_________________
SOFTWARE CODE:CM168______________
MANUAL CODE NO.: D291W001UD
DATE OF ISSUE:May 2005
EDITION:April 2009
ISSUED BY:Marposs S.p.A., Via Saliceto 13, Bentivoglio (BO) Italy
MARPOSS S.p.A. does not take on the obligation of notifying possible further changes to the product.
The descriptions reported in this book do not authorize any tampering by non-authorized personnel.
The warranty on the equipment will decay if such tampering is found.
© Copyright MARPOSS S.p.A. 2005-2009

– Programming Manual 3
About the Directive 2002/95/EC “RoHS” regulating the presence of certain hazardous
substances in electrical and electronic equipment
The Member States of the European Community are in the process of completing the
national reception and enforcement of the Directive 2002/95/EC regulating the presence of
certain hazardous substances in electrical and electronic equipment.
The Directive explicitly excludes from its scope of application finished products such as
those manufactured and sold by Marposs. It is still indeed a widely debated matter whether
the complete removal of the regulated substances could affect the reliability of the product.
Marposs shares in the social responsibility of continuously supporting every form of
innovation that reduces or minimizes any risk of adverse impact on human health and the
environment.
Marposs is therefore voluntarily pursuing the progressive removal of the regulated
substances from our products. Marposs will do so with the clear understanding that any
improvement achieved on the protection of health and the environment should not come as a
compromise for the quality and reliability of our products.
Marposs will put the greatest consideration in any initiative that our Customers
undertake with the purpose of reducing the environmental risk. Our commitment is the
support of their effort developing products that be of the highest quality and reliability.

4– Programming Manual

– Programming Manual 5
TABLE OF CONTENTS
1. INTRODUCTION..............................................................................................................10
1.1. Interface between Gauge and User............................................................................10
1.2. Programming manual .................................................................................................10
2. FRONT PANEL................................................................................................................11
2.1. Keys............................................................................................................................13
2.2. Keypad .......................................................................................................................13
2.3. Combination of keys...................................................................................................14
2.4. Panel test / Viewing the software version...................................................................14
3. HOW THE SYSTEM IS ORGANIZED..............................................................................15
3.1. Operating modes........................................................................................................15
3.2. Software structure ......................................................................................................15
3.2.1. Password Control ............................................................................................................. 15
3.2.2. Folders.............................................................................................................................. 16
3.2.3. Sub-folders ....................................................................................................................... 17
3.2.4. Pages................................................................................................................................ 17
3.2.5. Messages and info section............................................................................................... 18
4. USE..................................................................................................................................19
4.1. F keys.........................................................................................................................19
4.1.1. Defining the HOT keys...................................................................................................... 20
4.1.2. Deleting the HOT keys...................................................................................................... 20
4.2. Getting around the Program.......................................................................................21
4.2.1. Cursor controls ................................................................................................................. 21
4.2.2. Hot keys............................................................................................................................ 22
4.2.3. Defining the HOME key.................................................................................................... 22
4.2.4. If you get lost .................................................................................................................... 22
5. HOW TO PROGRAM.......................................................................................................23
5.1. Selecting predefined values........................................................................................23
5.2. Programming numerical values ..................................................................................23
5.3. Undoing programming................................................................................................23
5.4. Resetting all the programmed data.............................................................................24
6. DEFINING THE SETS......................................................................................................25
6.1. How to define the sets at the first power-on................................................................25
6.2. How to define a new Set.............................................................................................27
6.3. How to select an already defined Set .........................................................................28
6.4. How to delete a set.....................................................................................................29
7. ENABLING THE P.I.P. WINDOW (PICTURE IN PICTURE)............................................30
8. MENU MAPS (MANUAL MODE )................................................................................32
8.1. “Utilities” folder ...................................................................................................32
8.2. “Programming” folder ..........................................................................................34
8.3. “Inputs & Outputs” folder ....................................................................................35

6– Programming Manual
8.4. “External Info” folder ......................................................................................... 36
9. MENU MAPS (AUTOMATIC MODE ) ......................................................................... 37
9.1. “View” folder ...................................................................................................... 37
9.2. “Inputs & Outputs” folder ................................................................................... 38
10. UNIT SET-UP ........................................................................................................ 39
10.1. Home position ................................................................................................. 41
10.2. Manual balancing procedure with weights ...................................................... 44
10.2.1. RPM sensor control ..........................................................................................................45
10.2.2. Manual balancing procedure with fixed weights/variable angles......................................46
10.2.3. Manual balancing procedure with variable weights /fixed angles.....................................50
10.3. Procedure for frequency spectral analysis ...................................................... 52
10.4. Archive of frequency spectral analysis .............................................................. 55
11. MEASUREMENT ADJUSTMENT .................................................................. 57
11.1. Manual balancing ........................................................................................... 58
11.2. Automatic balancing ........................................................................................ 61
11.3. Double automatic Balancing ........................................................................... 62
11.4. View acceleration ........................................................................................... 63
11.5. Noise measurement ........................................................................................ 64
11.6. Gap&Crash graphic representation and dynamic set-up ................................. 65
11.6.1. Time base.........................................................................................................................67
11.6.2. Vertical scale.....................................................................................................................67
11.6.3. Trace Source and Position................................................................................................69
11.6.4. Numerical values ..............................................................................................................69
11.6.5. Gap&Crash graphical thresholds......................................................................................70
12. VIEW DATA ......................................................................................................... 71
12.1. Viewing data relevant to set (wheel/cycle) .............................................................. 73
12.2. Viewing unbalance limit values ............................................................................... 73
12.2.1. Viewing asymmetric filter on vibration signal....................................................................74
12.3. Viewing data of integrated Gap & Crash function.................................................... 75
12.3.1. Gap control data .....................................................................................................76
12.3.2. Crash control data ..................................................................................................76
12.4. Viewing supervision data ........................................................................................ 77
13. PROGRAMMING ................................................................................................. 78
13.1. Programming a simple set (1 logical channel) ................................................ 79
13.2. Programming a double set (2 logical channels) ........................................... 80
13.3. Programming unbalance limit values ............................................................. 81

– Programming Manual 7
13.3.1. Programming wheel vibration tolerance limits.................................................................. 81
13.3.2. Programming a limit on acceleration value....................................................................... 83
13.3.3. Type of balancing algorithm..............................................................................................83
13.3.4. Programming asymmetric filter on vibration signal ................................................. 84
13.4. Programming the integrated Gap&Crash .......................................................85
13.4.1. Selecting a Frequency Band............................................................................................. 85
13.4.2. Gain selection................................................................................................................... 86
13.4.3. Programming Gap control data ............................................................................... 87
13.4.4. Programming Crash control data ........................................................................... 90
13.5. Supervision programming ..............................................................................92
14. I/O TEST ..............................................................................................................94
14.1. I/O Byte test.............................................................................................................95
14.2. I/O bit test................................................................................................................98
14.3. Field Bus test.........................................................................................................100
15. MOTORS TEST ...................................................................................................103
15.1. Value of the temperature between transmitter and receiver..................................105
16. VOLTAGE SETUP ..............................................................................................106
16.1. Viewing the receiver supply voltage.......................................................................107
16.1.1. RPM sensor checking..................................................................................................... 108
16.2. Check voltage under load......................................................................................108
17. HEADS CONNECTION ...................................................................................110
17.1. Connection of balancing channels.........................................................................111
17.2. Characteristics of heads connected to balancing channels...................................112
18. BALANCING HEADS INFO .............................................................................113
18.1. Parameters for manual balancing with weights .............................................115
18.1.1. Wheel rotation direction (RPM) / Angle evaluation direction (°)...................................... 115
18.1.2. Number of holes ............................................................................................................. 116
18.1.3. Weight value................................................................................................................... 117
18.1.3.1. Copy data ................................................................................................................................118
18.1.4. Test weight ..................................................................................................................... 118
18.2. Heads parameterization ................................................................................119
18.3. Heads programming .....................................................................................120
18.4. Balancing algorithm parameters ....................................................................120
19. MACHINE DATA ..................................................................................................122
19.1. Selecting unit of measure and language ......................................................124
19.1.1. Selecting unit of measure (micron/inch) ......................................................................... 124
19.1.2. Selecting the language................................................................................................... 124

8– Programming Manual
19.2. Software Codes .......................................................................................... 125
19.3. Password ..................................................................................................... 125
19.3.1. Definition of User’s Password.........................................................................................126
19.3.2. Changing the User’s Password.......................................................................................127
19.3.3. Eliminating the User’s Password ....................................................................................128
19.4. Info about hardware unit .............................................................................. 130
19.5. Programming the communications ................................................................ 131
20. VIEW PROGRAMMED SETS (AUTOMATIC OPERATION)...................................... 132
21. VIEW MEASUREMENTS (AUTOMATIC OPERATION) ............................................ 133
21.1. View noise measurement ............................................................................. 134
21.2. View automatic balancing cycle ................................................................... 135
21.3. View double automatic balancing cycle ......................................................... 136
21.4. View acceleration ......................................................................................... 137
22. APPLICATION EXAMPLES....................................................................................... 138
22.1. Manual balancing with weights ..................................................................... 138
22.2. Manual balancing with weights + automatic balancing .......................... 139
22.3. Automatic balancing on two channels simultaneously .................................. 140
23. GAP & CRASH FUNCTION ............................................................................. 142
23.1. Programming......................................................................................................... 142
23.1.1. Hardware setup ...................................................................................................143
23.1.2. Software setup ......................................................................................................146
23.1.2.1. GAP control programming .......................................................................................... 148
23.1.2.2. CRASH control programming ..................................................................................... 150
23.2. Gap & Crash control setting.................................................................................. 151
23.2.1. Page for GAP and CRASH controls setting ..........................................................151
23.2.2. GAP control setting ..............................................................................................153
23.2.3. CRASH control setting .........................................................................................155
24. DIAGNOSTICS........................................................................................................... 157
24.1. Fatal errors at power-on........................................................................................ 159
25. ROUTINE MAINTENANCE ........................................................................................ 160
25.1. Cleaning the electronic unit................................................................................... 160
25.2. Forced air cooling system maintenance................................................................ 160
25.3. Fans replacement ................................................................................................. 162
25.4. Data back-up batteries.......................................................................................... 162
25.5. Calling Marposs Service ....................................................................................... 164

– Programming Manual 9

10 1.Introduction – Programming Manual
1. INTRODUCTION
The Wheel balancing & Supervision process control allows continuous monitoring of
the grinding wheel condition with immediate compensation of possible unbalance
during the cycle.
It can be customized to a variety of applications and balancing heads.
1.1. Interface between Gauge and User
The software uses graphics and/or icons to show the various functions and make
comprehension and use easy and intuitive.
Other conventions used in this program are:
Numbers or text inside a dotted line can be changed.
Icons or text that appear as a phantom image (or grayed out) cannot be selected
on that page or are not available for the application and its options.
1.2. Programming manual
This guide was written for the gauge system programmer. It will also be useful for
plant personnel who must perform maintenance and for assistance technicians.
In order to make this guide easy to use, several typographical conventions were
chosen:
Folders, sub-folders and page names are in Italics.
Numbers or choices that can be changed are within quotes; i.e. “100 µm".
Front panel keys or software buttons are shown using the current icon.
Names of operator functions are followed by their icon.

– Programming Manual 2. Front Panel 11
2. FRONT PANEL
The front panel allows the programmer to customize the gauge system to a specific
measurement application. The keypad is used to access the various program pages.
Three types of front panel are available:
Standard panel (in local or remote version)
3HE 19" panel (in remote version only)
3HE ½19" panel (in remote version only)
The function of the panels is similar, they differ just in the keys arrangement.
Standard panel
Hot key menu Shift key
F keys
Display
Manual/Automatic
key
Keypad
F keys

12 2.Front Panel – Programming Manual
3HE 19" front panel
3HE ½19" front panel
F keysDisplayF keys
Hot key menu
Shift key
Manual/Automatic key
Keypad
NOT enabled key
Hot key menu
Shift key F keys
Display
Manual/Automatic
key
Keypad
NOT enabled key
F keys

– Programming Manual 2. Front Panel 13
2.1. Keys
ICON NAME FUNCTION
F Keys
F1 to F6 keys can be used in two ways: as Hot keys or as
Function keys. Hot keys are shortcuts for moving through
the various pages and can be assigned by the operator
using the keypad, see section 4.1.1. Function keys are
predefined to do a one task on page.
Hot Key
Menu Display the Hot keys on the screen and removes them.
Automatic
Manual Switch the gauge system between Automatic and Manual
modes.
Shift
Shift Key used with other keys (see section 2.3 “Combination
of keys“, page 3).
----------- NOT enabled key
2.2. Keypad
ICON NAME FUNCTION
Home Return the program to the Home page. The Home page
can be defined using the keypad, see section 4.2.3
?
?View the software version number at power up and test
the panel (see section 2.4 on page 3).
Arrows Move the cursor around the screen.
TAB Move the cursor through data groups on page. Used with the Shift key to choose the Wheel/Cycle, see section 6.3
page 3.
Esc Move up one level of the program. During a programming
session aborts all changes made.
Enter
Enter Enter data. Move down one level of the program.
Minus
Decrease data values one digit at a time (with autorepeat
function).
In case of predefined data, allow scrolling parameters or
icons to view the desired one.

14 2.Front Panel – Programming Manual
Plus
Increase data values one digit at a time (with autorepeat
function).
In case of predefined data, allow scrolling parameters or
icons to view the desired one.
2.3. Combination of keys
COMBINATION OF KEYS FUNCTION
Shift
+ In Manual mode enable the Wheel/Cycle selection.
Shift
+ Upon programming they abort all the changes made
before confirmation.
Shift
+
Enter
Upon programming these key disable/restore (with the
last programmed value) the selected data, for the data
allowing for it.
Shift
+ Enable P.I.P. window (Picture In Picture) on display
(see section 7 on page 3).
2.4. Panel test / Viewing the software version
Hold down the
?
key at the system power-on: the following appears:
<F1> Press to test the keyboard (follow the directions appearing on
display)
<F2> Press to test the display (follow the directions appearing on display).
A sequence of five pages is displayed (three pages in the basic colors
RGB for color display, a black page and a white page for the b/w display)
to carry out a visual check of the display efficiency.
<Escape> Press to continue.
SOFTWARE VERSION
Firmware:1.9A
<F1> For keyboard test
<F2> For display test
<Escape> To continue
Software version
(example)

– Programming Manual 3. How the system is organized 15
3. HOW THE SYSTEM IS ORGANIZED
3.1. Operating modes
The operating modes are: Manual and Automatic.
The active operating mode is indicated at the bottom right.
Examples:
The operating mode is selected either with the dedicated key , or through signals
from the machine’s logic.
3.2. Software structure
The Software is divided into folders. Similar functions are grouped into sub-folders.
Related sub-folders are contained in folders. Each matter takes one or more pages of
a sub-folder.
3.2.1. Password Control
The pages for programming/changing data are protected by password.
There are two password levels:
System Password (access to system data). This password is always active and
cannot be disabled by Programmer (reserved to Marposs’ or
Technical Personnel). At the password request, press
to access data viewing.
User’s Password (access to application data). Password that can be either
programmed or disabled by the Operator (see 19.3
“Password “, page 3).
When the password is requested, if you press
Enter
without
having typed the password or after typing a wrong
password, the data can be only read.
Manual
operation Automatic
operation

16 3.How the system is organized – Programming Manual
3.2.2. Folders
The following folders are available:
FOLDER NAME ICON FUNCTION MODE
Viewing Access the following environments:
-viewing of programmed data,
-viewing of measurement values and
cycles stages.
Utilities Access the following environments:
-unit setup,
-measurement adjustment,
-viewing of programmed data.
Programming Access to the environment where the
cycles are parameterized.
Inputs & Outputs Select the I/O’s involved in the bit test
function and access the “Motor Test”
and “Voltage setup” functions.
External Info View the current configuration for the
specific application.
The highlighted icon indicates the current folder. The message in the lower left
corresponds to the highlighted icon (current folder).
Current folde
r
highlighted
Folders (Manual mode)
Name o
f
highlighted folde
r

– Programming Manual 3. How the system is organized 17
3.2.3. Sub-folders
The sub-folders are the second level of the software structure and contain pages with
similar functions.
Use or to highlight the sub-folder icon and press
Enter
to access. The
message in the lower left is the name of the highlighted sub-folder.
3.2.4. Pages
The pages are the third level of the software structure. Each contains a separate
function with information and function keys to perform that task.
Each page has three sections:
An icon at the top indicating the page function.
Function information in the middle including function keys.
Messages and information along the bottom.
Example:
The example above shows the page relevant to "Automatic balancing".
Selected
sub-folde
r
Sub-folders
Name of selected
sub-folde
r
Page data
Messages &
Information
Function Keys
Page icon

18 3.How the system is organized – Programming Manual
3.2.5. Messages and info section
ICON NAME FUNCTION
1Message Either the name of the highlighted icon or button or
instructions on which button to press.
2Wheel
number Currently selected wheel number The software can
handle up to 16 different wheels.
3Cycle number Currently selected cycle number. The software can
handle up to 16 different cycles.
Application A graphical representation of the application with a
logical channel.
4Application A graphical representation of the application with two
logical channels
Data display The Operator is viewing data.
5Data entry The Operator is changing data.
6Wheel
Balancing Indication of the process control shown on display.
Manual
7Mode Automatic
1 4 65
2 73

– Programming Manual 4. Use 19
4. USE
4.1. F keys
to keys on the front panel can be used either as Function keys or Hot keys.
Note: Function keys have an F number in the upper left corner of the icon.
Function Keys
Function keys are only available on a specified page. They are predefined to do a
specific task on that page and cannot be changed.
Note: Function keys are available only after the page is selected. To select the
page, press
Enter
.
Hot keys
These are shortcuts to any page of the program at any moment and are defined by
the operator via keypad. This allows customization of the gauge system to specific
needs or preferences. Six Hot keys are available in Automatic mode and another six
in Manual mode. For instructions on how to define these keys, see section 4.1.1 page
3.
Hot keys are available at the folder, sub-folder or page level as shown below. Press
to view the Hot keys currently defined. These are examples of typical hot key
definitions.
Function key Hot key
F number
Function Keys

20 4.Use – Programming Manual
folder
sub-folder
page
4.1.1. Defining the HOT keys
1. Get to the desired page using the menu maps. Highlight the page icon.
2. Press and hold the desired “F#” key down until the icon is no longer highlighted,
about 5 seconds.
3. Release “F#”: the Hot Key is now defined.
4.1.2. Deleting the HOT keys
1. With the hot key to be deleted, call out the page currently stored.
2. Press to highlight the page icon.
3. Press and hold the desired “F#” key down until the icon is no longer highlighted,
about 5 seconds.
4. Release “F#”: the Hot Key is deleted.