CHAPTER 5 CORDLESS CHAPTER 5 CORDLESS GENERAL The Cordless aligner offers the users the capability to perform all alignment functions without the use of cables leading from the wheel sensors to the console. Each wheel sensor operates independently and does not require that any other sensor be identified with the console to operate therefore there is no Master sensor. Each wheel sensor has a radio pod inside the module and communicates with the console through a radio pod that is connected into the back of console through any of the 6 cable connections. The radio pod has a magnet built into the case that can easily be affixed to the back of the console cabinet or placed anywhere within the cables length. The cable used is a standard cable (EAW0235J09A). The radio pod does not have to be within the line of sight of the wheel sensors. Each wheel sensor is powered by two 3.6V batteries that are easily inserted into the rear of each wheel sensor. There are no special requirements necessary to configure a system to run cordless. The system is capable of running either corded or cordless. Should a cordless component inside a wheel sensor malfunction it is acceptable to run one or more wheel sensor(s) using a cable while the other wheel sensors use the cordless feature (Generation I only). Generation II must be run either all corded or cordless, they CANNOT be mixed. Once the cable is plugged into the module at the wheel sensor, communication would return to the cable providing the opposite end is plugged into the HIB. The cordless system can be purchased as a cordless unit or cordless updates kits are available to update existing CCD aligners. CORDLESS COMPONENTS 1. Charging Station (Battery Charger) 2. Radio Pod (Console Radio) 3. Wheel Sensor Module CHARGING STATION The charging station (Figure 1) for the cordless aligner is a stand alone station designed specifically for the batteries required to power the wheel sensors. Place the charging station near a 110VAC outlet to supply the station with power. For safety reasons it should be placed at least 18 above the floor surface. The charging station can charge up to (8) 3.6v at one time or it can charge as few as (1) battery at a time. The charging station has an internal 9 volt power supply that supplies the Battery PCB with the necessary voltage to charge the batteries. The Battery PCB consist of 8 charging ports to charge each battery. Each of these charging port operate independently. There are 8 LED charging indicators mounted on top of the charging station. Once the battery is placed into the charging station the battery will automatically go into a full charging mode (LED on). Once the battery has reached a full charge the battery voltage will drop Figure 1 slightly, this will switch the battery port into a trickle charge mode (LED off) to maintain a fully charged battery. It is acceptable to leave the spare batteries in the charger until needed. RADIO POD (CONSOLE RADIO) The console radio (Figure 2) bridges the gap between the PC and the wheel sensor. Power and communication from the console pod to the PC is made via the use of a wheel sensor cable connected at either one of the six wheel sensor connections. The power is then routed through a battery PCB inside the console pod which powers the radio PCB. There are a bank of 6 dip switches located on the battery PCB. Switch one identifies whether the battery PCB is a console radio or a wheel sensor radio (see dip switch Figure 2 Page 5-1
CHAPTER 5 CORDLESS settings below). Switches 2 through 5 set the channel in which the unit operates. Switches 2 through 5 must be set identical to the switches inside each wheel sensor module to communicate. Switch 6 is N/A. There are no service requirements inside the console pod. The unit is serviced as a complete system. The communication frequency from the console pod to the wheel sensors operates at 2.4Ghz. Dip Switch Setting: Version II 1 - Off 4 - Off 2 - Off 5 - Off 3 - Off 6 - On Dip Switch Setting: Version I 1 - On 4 - On 2 - On 5 - On 3 - On 6 - Off WHEEL SENSOR MODULE Each wheel sensor has a cordless module (Figure 3) inside that contains a battery PCB and a radio PCB. Each wheel sensor is powered by two 3.6v batteries. The batteries are inserted through a rear access panel of the wheel sensor. There are a bank of 6 dip switches located on the battery PCB. Switch one identifies whether the battery PCB is a console radio or a wheel sensor radio (see dip switch settings below). Switches 2 through 5 set the channel in which the unit operates. Switches 2 through 5 must be set identical to the switches inside the console pod to communicate. Switch 6 is N/A. There are no service requirements inside the console pod. The unit is serviced as a complete system. Dip Switch Setting: Version II 1 - Off 4 - Off 2 - Off 5 - Off 3 - Off 6 - Off Dip Switch Setting: Version I 1 - Off 4 - On 2 - On 5 - On 3 - On 6 - Off Figure 3 TESTING THE CORDLESS The CCP software has a cordless sensor screen for testing and verifying the sensor strength. The screen offers the technician a quick reference guide for testing all 4 wheel sensors and console sensor simultaneously. 1. Boot the alignment software to the Main Menu and click on the Maintenance tab (Figure 4). 2. Choose the Measurement Data icon (Figure 5). 3. Choose the Sensor Voltage icon on the toolbar (Figure 6). Figure 4 Figure 5 Page 5-2
4. Checks should be made that all 4 wheel sensors have a minimum battery voltage of 6.9 volts. Each wheel sensor will stop communicating with the console once the battery voltage has reached 6.8 volts and will not re-establish communication until the voltage reaches at least 7.2 volts. The chart (Figure 7) also indicates the signal strength between each sensor and the console. The higher strength indicates that the sensors are operating at an acceptable level. Should the sensor strength drop on all 4 sensors the operator should try moving the console pod to a different location to see if the signal strength increases. Figure 6 CHAPTER 5 CORDLESS 5. Battery voltage can also be checked at each wheel sensor. Press and hold the electronic level / battery button (Figure 8) on the keypad. Look at the LED indicators for a quick reference of the battery voltage (Figure 8). 3 lights indicate a full charge, 2 lights indicate 1/2 charge, 1 light indicates 1/4 charge. Figure 7 Figure 8 UPGRADING TO CORDLESS Both SUN and JBC offer a cordless upgrade kit that can be installed in existing units. The following instructions list the parts needed and tools for installing the cordless kit JBC (EAK0222J70A-115V / EAK0222J71A 230V) SUN/Hof (EAK0222J72A - 115V / EAK0222J73A - 230V). Kit Contents: Part Number Qty Description 1-25306A 8 Screw - Pan Hd M5-.8mm X 20mm EAA0305J72A 2 Accessory - Cordless Module, LH EAA0305J73A 2 Accessory - Cordless Module, RH EAA0305J70A 1 Pod Accessory - Cordless EAA0305J71A 1 Battery Charger Assembly EAA0287J34A 16 Battery - 3.6v EAC0055J25A 4 Door - Access, Battery EAM0007J22A 12 Counterweight - Fixed (JBC only) 1-18941A 8 Flat Washer -.195 x.619 x.06 thick (SUN only) EAW0235J09A 1 Cable Accessory - Head I/C, Short EAX0039J00A 1 Cord - Power, 115v Tools Required: #1 Phillips Screwdriver Small Diagonal Cutters 4 Small Plastic Tie Straps 1. Remove the side cover from each wheel sensor to expose the internal components. Set the cover aside until step 8. Page 5-3
CHAPTER 5 CORDLESS 2. Disconnect the main cable connector at the toe board (Serial Comm/Power Supply) (Figure 9). It is the single connector at the end nearest the cross toe sensor. Power Cable 3. Remove the module and the black metal cover plate (at the rear) from the wheel sensor assembly. Store the take-off parts in a secure location. Prep the four modules for installation by pressing the power switch through the cavity about half an inch. This will allow the module to clear the aluminum head skeleton. (Figure 10) Figure 9 4. Install the new radio module and battery interface board into the wheel sensor assembly. The modules are configured for LF/RR and RF/LR so that the input connector is in the correct orientation. (Figure 11). Figure 10 Figure 11 5. Route the cable down the boom tube and connect at the Serial Comm/Power Supply connector on the toe board. Once in place, press the power switch back into position from the bottom of the wheel sensor. Dress the cables as shown in Figure 12 and secure with a small plastic tie. Cables should be routed to avoid pinching the wires during wheel sensor assembly. Figure 12 Page 5-4
6. Install the plastic battery access door in the location where the black metal plate was removed during step 3. Be sure to orient the door (Figure 13) such that the handle is positioned toward the rear of the wheel sensor and is at the bottom. This is the only orientation that will allow the door to slide to it s full open position for battery access. CHAPTER 5 CORDLESS Figure 13 7. Remove the bar weight along with the mounting bracket and screw from the wheel sensor cover removed in Step 1. Remove the screw holding the single plate weight in place (Figure 14). Mounting Bracket Bar Weight JBC - 8a SUN - 8b Single weight 8a. Leave the plate weight and add three additional plate weights using two Pan Head Screws M5 -.8mm x 20mm screws provided. There should be a total of 4 plate weights attached to the cover side of the wheel sensor (Figure 15). Figure 14 8b. SUN Modification - Remove the screw holding the single plate weight, discard both the screw and the weight. Add two (2).619 washers under the bar weight bracket. Replace the single screw through the bar weight bracket and washers and tighten securely. Additional Weight 9. Reassemble the wheel sensor in reverse order of disassembly taking caution to not over tighten the screws. Snug is sufficient, overtightening may cause inserts to pull free. Be very careful to not pinch any cables when placing the two halves of the wheel sensor together. Once completely assembled (including rubber bumper), open the sliding door at the rear of the wheel sensor and insert two batteries (Figure 16). The door will be snug and will not open accidentally. 10. Place each wheel sensor on a vehicle with the wheel clamp and balance the wheel sensor by inserting a flat screw driver into the hole just above the battery door. (Figure 16) Screwing in (clockwise) will move the adjustable weight to the rear of the wheel sensor, causing the boom tube to rise. Use the bubble level on the side of the boom tube to level the wheel sensor. Use the electronic bubble if the system has been previously field calibrated. Figure 15 Figure 16 Balance adjustment screw Page 5-5
CHAPTER 5 CORDLESS 11. Attach the console radio in a suitable metal location (it has a magnet on the bottom) on the cabinet or a nearby location. (Figure 17). Figure 17 12. Disconnect the wheel sensor cables from the console and store out of the way. Connect the single cable provided with the cordless kit to the radio receiver, connect the other end to one of the console interconnect ports (Figure 18). The radio cable is the same as the wheel sensor cables. Wheel sensor cables can be used in the event cordless feature fails and the wheel sensor need to be corded. Testing The System Figure 18 1. Use the Sensor Voltage Screen (Figure 19) to verify communications from each wheel sensor when turned on. Access this screen from the Maintenance tab, measurement data screen, then select HotKey F8 labeled Sensor Voltage. 2. Place all 4 wheel sensors on a vehicle and confirm complete system operation. Figure 19 3. Place the battery charger in the bottom of the V2 cabinet next to the printer, or it can be placed anywhere that power is available and is 18 inches above the floor level. 4. Place spare batteries into the charger (Figure 20) and verify that the red LEDs illuminate while charging. LEDs will shut off when batteries are sufficiently charged. It is acceptable to leave batteries stored in the charger until needed. 5. Perform a complete field calibration procedure, do performance test and return the unit to service. Figure 20 Page 5-6
TROUBLESHOOTING - CORDLESS CHAPTER 5 CORDLESS COMPLAINT CORRECTIVE ACTION I. Wheel Sensor will not power up. Replace the batteries, did this fix the problem? NO-> Use sensor cable, did this fix the problem? NO-> Check J1pin 2 on the toe pcb is 7-9volts present NO-> Replace the Cordless Module. YES-> Replace toe pcb. II. No Wheel Sensor will power up. Plug the console pod cable into a different port, did this fix the problem? NO-> Replace the cable, did this fix the problem NO-> Plug a wheel sensor into the back of the unit did this fix the problem. YES-> Replace the Console Pod NO-> Check for 9volts on the HIB is it present? YES-> Check the USB connection between the HIB and the PC NO-> Replace 9volt power supply in HIB. III. Wheel Sensor is dropping in and out. Check all sensors strength are they at an acceptable level? YES-> Replace cordless module in wheel sensor. NO-> Relocate console pod, did this correct problem? NO-> Replace Console Pod. Page 5-7
Snap-on Diagnostic 355 Exchange Ave Conway, AR 72032 U.S.A. EEWA511A-C 08/2002 Rev B Rod Harrison David Cullum Rod Harrison David Cullum CCD Cordless Battery Charger 6-1 6-8