2Index Contents How to test the measurement heads 3 HOW TO CALIBRATE MEASUREMENT HEADS6- Preparation of the calibration- User calibration procedureAssign the ID to the measurement heads13Bluetooth Driver installation14Bluetooth pairing diagnosis16Associate the measuring heads with the PC18Replacement of the PCB20
3Description of equipment MEASURING HEADangles, processes the measurements and sends them to the PC, and receives the operator keyboard commands.The measuring head is the heart of the wheel alignment system: it contains the sensors that measure the alignmenta. Toe camerab. Alignment camerac. Logic boardd. Bluetooth board (radio models)e. Accelerometer boardf. Batteries (radio models)g. Counterweight (radio models)h. Counterweight (cable models)i. Toe beam armj. Electronic housingk. Keyboardl. Handlem. Pin (of clamp)n. PlugsThe front right measuring head is identical to the left rear one; the front left measuring head is identical tothe rear right one, apart from the adhesives. The two pairs of measuring heads differ as regards the shapeof the electronic housing and the plastic cover, both of which are specular.The electronic boards and cables inside the measuring heads are identical for all four.Exceptions to this are the calibration parameters and the position allocated to the measuring head (memorisedin the logic board) and the Bluetooth address (radio models only, memorised in the Bluetooth board)
4Assembly precautions: A measuring head can be replaced in a set of other measuring heads without problems of internal electronicscompatibility. In this case, the measuring head should be calibrated, even though this is not strictlynecessary.Assembly precautions:Take care not to crush or bend the delicate keypad connectorBefore connecting or disconnecting the Bluetooth board to or from the logic board, disconnect thebattery in order to avoid voltage surges.Correctly center the connection between Bluetooth and logic boards! Danger of damages to the logicboard.MeasurementsEach measuring head contains 4 sensors, each of which measures a different angle:Toe (T): horizontal angle between the axis of the measuring head (axisof the hole in which the clamp pin is inserted) and the beam of lightemitted by the opposite measuring head along the track of the vehicle.The angle is positive if the beam of light points towards the vehicle.Alignment (A): horizontal angle between the perpendicular of themeasuring head axis and the beam of light emitted by the oppositemeasuring head along the wheelbase.The angle is positive if the beam of light points towards the vehicle
5Camber (C): angle between the direction of gravity (Z) and the vertical axis of the measuring head; positive if the wheel “falls” towards themeasuring head.Level (L): angle between the horizontal plane and the direction ofthe toe beam arm of the measuring head; positive if the arm facesupwards.Toe and Alignment are measured by their respective cameras.Camber and Level are measured by the accelerometer board.Starting from these measurements, the software calculates the characteristic angles of the vehicle. As canbe imagined, some measured angles are related to the characteristic angles of the vehicle:T has a similar value, but generally not identical, to the partial toe angleC is the camberL determines the level indicated on the keyboard LEDsA has not direct relationships but it is used together with other measurements to calculate theremaining characteristic angles of the vehicle.
6Calibration parameters The calibration parameters are used to convert the electrical signals from the sensors into the correspondingangles. 8 parameters, the Zero and Gain of each of the 4 sensors of the measuring head, are stored in the logicboard.The electrical signals of the sensors are converted using a proportional formula:Angle = Gain x Signal + ZeroZeros can be calibrated on site by means of a special calibration bar, while Gains can only be factoryset. Gains are generally calibrated just once during in the lifetime of a sensor because, unless thecomponents are faulty, Gains remain stable over time and, in any case, affect precision much less thanthe Zeros.In the following, "Calibrating the measuring heads" will have to be intended as calibrating the Zerosonly, by mean of the calibration bar.CamerasThere are two cameras:Toe: along the trackAlignment : along the wheelbaseThe toe and alignment cameras are identical and are therefore interchangeable.Functions:Measuring toe (T) and alignment (A) anglesEmitting light to allow the measurement of the adjacent camera to be measured
7LED: emits lightCCD: measures the angleThe light emitted by the LEDs is infrared and therefore invisible. To check whether a LED is on or off, view it with adigital camera.Unlike the alignment camera, the toe camera has just one LED on. The second is not required as the track is shorterthan the wheelbase.The camera reveals the brightness according to the angle of incidence, as shown in the Test page. The measuredangle corresponds to the centre of gravity of the peak of the function.If there is more than one LED in the field of vision of the CCD, the function will have more than one peak. However,only the highest peak, generally corresponding to the nearest LED, is considered.Artificial light, daylight and infrared and non-infrared light emitters that are not the LEDs of the measuring heads(lamps,…) are filtered.
8A non-faulty camera can give problems in the following rare cases: Direct sunlight “blinds” the CCD. Measurement not performed. Put the CCD in the shade.The camera beam is reflected by the bodywork of the vehicle or by a highly reflective metal panel.Brightness vs. angle has more than one peak. Cover the surface with a cloth.Two lifts are side by side so that the toe CCD frames the toe LED of the other lift. Brightness vs. anglehas more than one peak. Separate the lifts with a panel.If a camera is replaced its Zero must be calibrated.Logic BoardFunctions of the logic board:Process sensor measurementsProcess commands and control the keyboard LEDsReceive power from the cables or battery (radio models) and distribute it to the other boardsCommunicate with the PC through the cables (cable models) or Bluetooth board (radio models)Memorise and update the firmware (measuring head management programme)Memorise the sensor calibration parametersMemorise the position allocated to the measuring head
9The sequence of replacing the logic board: Connections:a. Toeb. Alignmentc. Accelerometerd. Bluetoothe. Battery (only used in the radio models)f. Power plugs and, only for cable versions, signalg. Keyboardh. Firmware updateOther:i. Jumper for radio-cable switching (availablefrom May 2006)j. Firmware versionk. Board codeThe silver bands on the keyboard connector must face towards the outside of the board, as shown in thefigure:When replacing the logic board:it is possible to maintain the existing cameras and the accelerometer board . (the Gains of the various cameras are sufficiently similar.)the Zeros must be calibrated and the position of the measuring head allocated.The sequence of replacing the logic board:Replace the main board then assign the appropriate ID with DIP switch.the Zeros must be calibrated with the calibration procedure.
10Bluetooth board (radio models) Bluetooth board functions:Communicate with the PC via BluetoothManage battery rechargingStore the Bluetooth addressThe Bluetooth address is a code which differentiates the board from the others or from other Bluetooth devices.To communicate with the PC, the Bluetooth address of the board must be saved to the PC. This operation is called“associating the measuring head with the cabinet”.
11Accelerometer boardFunctions: measuring Camber (C) and Level (L) angles.When replacing the accelerometer board:The logic board must also be replaced with one that has stored the gains of the new accelerometer.The zero must be calibratedBattery (radio models)The battery of the radio models comprises 6 1.2V AA NiMh batteries in series; total capacity 1700 – 2000 mAh.The charge of new batteries lasts a whole day of full-time work.If the batteries are used correctly, their working life is 1 years.Due to normal physical phenomena, charging and usage times gradually decrease until they become too short forapplication.This undesired phenomena can be greatly accelerated by incorrect battery management.To achieve a working lifetime of 1 years:Fully recharge the batteries (at least 4 hours) and only when they are flat (red or yellow indicator on the monitor)Recharge the batteries at least once every 3 months
12HOW TO TEST THE MEASUREMENT HEADS 1. Press F12. Press F33. Press F5 or click “Diagnosis” button then the software will ask the password.4. Then input the password “service” then press “confirm”.
13Diagnosis PageThe Diagnosis page contains various useful service functions.It does the following:- Checks sensor operation and performs troubleshooting- Calibrate the Zero of the measuring heads- Checks communication between the measuring heads and the PC- Reads the firmware version of the measuring heads- Reads the software versionsCom. errorZero dataFirmware versionCalibration checkSave the default gainOpen/save zero data
14- Firmware version : It means the current firmware version. - Zero data : It means the saved zero data in the each sensor head.- Comm error : It means how many error occurs.Calibration check : NOTE. The detector calibration may be automatically called for by the software, check therefore the “CalCheck” reference parameter by placing the detectors on the calibration bar.The CalCheck parameter must show a very low, less than 0,50 value.If the parameter value is higher, calibration is recommended.With the detectors mounted on the Calibration bar or the vehicle, the values shown on the page shall always be as close as possible to zero.- Save default gain : Save the default gain to each sensor heads- Open zero data : use this when check the zero data- Save zero data : use this when save the zero data
15HOW TO CALIBRATE MEASUREMENT HEADS 1. Press F12. Press F33. Press F6 or click “Calibration” button then the software will ask the password.4. Then input the password “service” then press “confirm”.5. Press F6 or click “Next” button then the following calibration screen appears.
16Preparation the Calibration 1. The first screen requires the calibration bar to be positioned and leveled longitudinally (using the spirit level provided) by adjusting the feet.2. Install the two front measurement heads on the calibration tool as indicated on the screen3. Level the two measurement heads by positioning the supplied level on the arm of the measurement heads and then tighten the knobs fully to lock the heads in place4. Move on the next step by pressing F6 key.For radio models, in this and the following phases, check that the two measurement heads are not disturbed by the infrared sources of the other two measurement heads.
17User calibration Procedure Step 1 : calibrate the toe, level of the Front-left, right sensors1. Insert the pins provided into the bar lengthways.2. Position the front left and front right sensors (see small box, bottom left) on the bar as shown in the diagram.3. Level the two measurement heads by positioning the supplied level on the arm of the measurement heads and then tighten the knobs fully to lock the heads in placeTo improve level precision, position the level as close as possible to the large black plastic part.4. Continue by pressing the key to save the calibration data: the new zero values will be saved for: toe, level and camber of relevant sensors.5. Press and proceed with the phase described in the next chapter
18Step 2 : calibrate the toe, level of the rear-left, right sensors Remove the two front measurement heads.Install the rear left and rear right sensors (see small box, bottom left) on the bar as shown in the diagram.Level the two measurement heads by positioning the supplied level on the arm of the measurement heads and then tighten the knobs fully to lock the heads in placeTo improve level precision, position the level as close as possible to the large black plastic part.4. Continue by pressing the key to save the calibration data: the new zero values will be saved for: toe, level and camber of relevant sensors.5. Press and proceed with the phase described in the next chapter
19Step 3 : calibrate the alignment of the front-left, rear-left sensors Remove the two rear measurement heads.Insert the pins into the holes on the flat surface, setting the crowns of the pins flush against the flat surfaces. The tool appears as indicated in the following figures4. Install the two measurement heads(front-left, rear-left) on the right side as indicated on the screen (Bottom right)5. Level the two measurement heads with the aid of the level supplied or displaying the central green led on the measurement head keypad.6. Continue by pressing the key to save the calibration data: the new zero values will be saved for: alignment of relevant sensors.7. Press and proceed with the phase described in the next chapter
20Step 4 : calibrate the alignment of the front-right, rear-right sensors Remove two measurement heads on the left side.2. Install the two measurement heads on the right side as indicated on the screen (Bottom right)3. Level the two measurement heads with the aid of the level supplied or displaying the central green led on the measurement head keypad.4. Continue by pressing the key to save the calibration data: the new zero values will be saved for: alignment of relevant sensors.5. Press to complete all calibration procedures.
21After all calibration job, we will see the above screen. You can print out the all calibration data with before and after for the comparison.Complete whole procedure by pressing
22Assign the ID to the measurement heads After replacing the logic board or the entire measuring head, you should assign the appropriate ID to the logic board as following.2. Determine ID according to the following table and set the DIP switch on the PCB board.FLFRBLBR2ONOFF1
23Bluetooth Driver installation 1. Insert CD and install Bluetooth Driver & Software.2. After finishing installation, click on mouse(Right) at the bottom of your windows side bar. Select “Bluetooth Configuration”.3. Select Client Application Tab. Press “Add Com port” button.
244. Then press “OK” button to create the new port. 5. Once all procedures are completed, make sure that four serial port were created on the list box as the below screen.
25Bluetooth pairing diagnosis Double click My Bluetooth Place iconDouble click 'Find Bluetooth Devices' icon.
26This mark means that the bluetooth is paired correctly. If there is a problem, you must pair again.
27Associate the measuring heads with the PC 1. Start “HA-710” application then check the message “COM:X(Bluetooths)”2. Press F11 key to move on the bluetooth configuration screen.3. Switch on the four measuring heads to memorise and switch off all other measuring heads or Bluetooth devices.4. Press “Search” button and wait. After a few seconds, the left-top box shows the name of the measuring heads and any other reachable Bluetooth devices.If you already have any installed Bluetooth devices, remove all the devices by pressing “RemoveAll” button.
285. Select sensor module which name is “HSB_ALIGNER” or “BT_MODULE” and add that to the selected list box pressing “>>” button.If not all the measuring heads are found, make sure they are switched on and press “RemoceAll” button then press “search” button once again.If other measuring heads are found, switch them off and press “RemoceAll” button then press “search” button once again.6. Press “Port Map” button to map the serial port. If the message doesn’t appear, repeat the above steps once again.7. Press “Register” button to register Bluetooth devices to be selected.8. If all the devices are registered successfully, the items in the list box are like as follows.
29Replacement of the PCB Load calibration data (Sensor ▶ PC) At the factory, the default calibration data is stored in the C:\Aligner\Zero folder.There are three buttons on this screen ,”DEFAULT”, “OPEN”, “SAVE”.Each button will call the different calibration data from the PC.The function is as following.1. DEFAULT- Call the calibration data of the factory setting to this screen. You will see the default values in red color.2. OPEN- Call the calibration data which has been already stored before. You can select on the above dialogue box.3. SAVE- Call the calibration data from all four measuring heads then save these data on PC. Press SAVE button on the calibration page, then the calibration data will be saved as a file which name is followed the date.For example, if today is March 29th, 2008, then the file name will be 2008_0329.dat automatically.After uploading the above calibration data, you can download this data to the PCB board.F9 key (SAVE_ZERO) will write zero calibration data to the main logic board on each four measuring heads.F11 key(SAVE_GAIN_ALL) will write gain calibration data to the main logic board on each four measuring heads.
30Trouble shooting 배터리가 충전이 안되는 데는 두가지 원인이 있습니다. 1) 배터리 팩 쪽의 문제 1) 배터리 팩 쪽의 문제2) 센서 내부에 충전 PCB의 문제일단, 충전이1) 케이블을 연결할 때 **어떤 케이블을 연결 할 때요? 센서케이블?2) 별도 충전기에 연결할 때 **별도 충전기를 보냈는지요? 아니면 배터리 충전기의 다른 자리에 꽂아보라는 얘기인가요?두가지 모두 안 되는지 확인 부탁드리고요.둘다 안되면 배터리를 보내주는 것이 맞습니다.둘중의 하나가 된다면, 이것은 내부 PCB의 문제입니다.(가능 성은 조금 낮습니다.)이 경우는 불루투스 상판 PCB를 보내주어야 합니다.1) 센서 케이블이 맞습니다.2) 외장형 별도 충전기를 보냈습니다. 말씀하신 데로 다른 자리에 꽂아보면 좋겠습니다. 꽂았을 때 LED의 상태도 알려주세요 (예를 들어, 적색, 녹색, 적색 점멸)