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Coats IBS-2000 Wheel Balancer

1. 26 Safety Interlock Switch Replacement 26 On Off Switch Replacement 26 27 Circuit Breaker Replacement 27 Power Supply Board Replacement 27 Motor Controller Board Replacement 27 CPU Board Replacement 27 Fan Motor Assembly Replacement 28 Rotary Shutter Replacement 28 Optical Encoder Assembly Replacement 28 Drive Motor Assembly Replacement 28 29 Faceplate amp Shaft Assembly Replacement 29 Piezo Assembly Replacement 29 Capacitor Assembly Replacement 30 Signal Harness Replacement 30 A D Arm Repair and Replacement 30 31 A D Arm Replacement 56 A Gear Assembly Replacement 57 Small D Gear Assembly Replacement 57 Large D Gear Replacement 58 A D Arm Subassembly Replacement 58 Parts Identification 32 35 IBS 2000 Parts lllustration 32 33 IBS 2000 Wiring Diagrams 36 39 Service Manual COATS Model IBS 2000 iii 1 IMPORTANT SAFETY INSTRUCTIONS READ ALL INSTRUCTIONS Eye and face protection recommendations Protective eye and face equipment is required to be used where there is a reasonable probability of injury that can be prevented by the use of such equipment O
2. 111059 REF D 112240 PIN 6 BLU 12V PIN S GRN GND REF PIN 2 VIO 5V PIN 1 0RG 12V RED H 305050 REF RED V INTER LOCK 3 QR SWITCH ORANGE JUMPER PHASE 220V PHASE 440V 112356 CAPACITOR ASSY 1 220V 111879 POWER PLUG 220V 1 PHASE 305076 REF X BLACK Y RED G GREEN 143127 REF POWER PLUG BLACK 220V 3 PHASE 140786 REF X BLACK Y RED Z WHITE G GREEN GROUND 143127 REF INE IMO 3 nl BLACK RED LINE D gt NOTE THIS IS A 5 CONDUCTOR WIRE ONE DF THE BLACK WIRES BLUE WHITE NEUTRAL DO IS UNUSED YELLOW GREEN GREEN GROUND Y BLACK ci Z BLUE GROUND G YELLOW GREEN EXPORT DOMESTIC 111848 REF 38 e Service Manual COATS Model IBS 2000 PIN 1 Be ey 4 0RG 12V eae Jm EN m PIN 2 GRN E 89 a PIN 3 VIO PIN 1 SPIN PIN 4 DRG PIN 3 SV PIN 6 BRAKE mi tere CH 112079 REF 112201 lt 112248 112200 2 REF z 5 L i 4 REF REF a an 305050 RE Di lt p L 112233 REF 112200 6 REF es NUN MODEL 2000 REV 112200 5_REF 12200 5 PIEZO Service Manual COATS Model IBS 2000 39 9112388 12 00 rev 1 Copyright 1998 Hennessy Industries and COATS All Rights Reserved Printed in USA
3. COATS Model IBS 2000 10 20 21 22 23 Wear proper clothing Safety toe non slip footwear and protective hair covering to contain hair is recommended Do not wear jewelry loose clothing neckties or gloves when operating the balancer Keep work area clean and well lighted Cluttered and or dark areas invite accidents Avoid dangerous environments Do not use power tools or electrical equipment in damp or wet loca tions or expose them to rain Avoid unintentional starting Be sure the balancer is turned off before servicing Disconnect the balancer before servicing Use only manufacturer s recommended acces sories Improper accessories may result in per sonal injury or property damage Repair or replace any part that is damaged or worn and that may cause unsafe balancer operation Do not operate damaged equipment until it has been examined by a qualified service technician Never overload or stand on the balancer Do not allow untrained persons to operate machinery To reduce the risk of fire do not operate equip ment in the vicinity of open containers or flamma ble liquids gasoline Adequate ventilation should be provided when working on operating internal combustion engines Keep hair loose clothing fingers and all parts of body away from moving parts Use equipment only as described in this manual Use only manufacturer s recommended attach ments
4. 8 Install weight tray and weight tray shield and plug in balancer 9 Perform FUNCTION CHECKS Optical Encoder Assembly Replacement 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Remove rear end bell cover 4 Remove rotary shutter B Disconnect optical encoder cable from the CPU Board 6 Slide optical encoder from aluminum rear end bell casting Note Some motors will have a plastic shim behind the optical encoder Leave this shim in place when replacing the optical encoder 28 e Service Manual COATS Model IBS 2000 7 Install new optical encoder 8 Install rotary shutter 9 Install rear end bell 10 Connect optical encoder cable to the CPU Board 11 Perform FUNCTION CHECKS 12 Install weight tray and weight tray shield and plug in balancer Drive Motor Assembly Replacement 1 Unplug the balancer 2 Remove weight tray weight tray shield and motor cover 3 Disconnect fan motor from the Motor Controller Board 4 Disconnect optical encoder cable from the CPU Board 5 Disconnect motor wires from P2 of the Motor Controller Board 6 Remove the four 4 piezo springs and piezo spring retainers 7 Remove the two 2 1 2 18 X 1 washer head screws and washers lift out the motor assembly 8 Position the motor on its side or back and remove the four 4 3 8 16 washer head screws holding the flex plate to the motor 9 Remove the flex plate 10 Remove the four
5. 2 Connect the red positive lead to the piezo tap 3 Connect the black negative lead to ground the bottom of the piezo assembly 4 The meter may indicate a fluctuating or negative reading ignore the reading at this time 5 Apply firm downward pressure to the front of the motor if out of the balancer apply pressure directly to the piezo and note the signal 6 If the piezo is good the signal should read positive at the instant pressure is applied for right piezos 7 f the piezo assembly is upside down the signal will read negative at the instant pressure is applied for right piezos Note When checking the eft piezo the readings in step 6 and 7 will be opposite 24 e Service Manual COATS Model IBS 2000 Balancer Display Diagnostics This is a diagnostic menu that should only be accessed by authorized Hennessy service personnel It allows you to perform tests on the components within the POD To access this menu you press the PLANE 2 key on the WEIGHT LOCATOR display and turn the power on simultaneously You may use the RS232 cable or a spare test cable The menu will display several tests Each test will display step by step instructions Tests on this Menu Include e KEY PAD TEST e LCDTEST e LEDTEST e RAMTEST Note This is not the same RAM test on the main diagnostic menu This RAM test is for the LCD board e SOFTWARE REVISION e SERIAL LOOPBACK TEST Serial Loopback Test Th
6. 6 Replace defective CPU Board and reinstall in reverse order 7 Plug in the balancer 8 Perform FUNCTION CHECKS Note The CPU board contains a replaceable E PROM chip for software revision This chip should be replaced in conjunction with the E Prom chip on the display board unless speci fied by the manufacturer Service Manual COATS Model IBS 2000 27 Fan Motor Assembly Replacement 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Disconnect fan motor plug from P1 of the Motor Controller Board 4 Remove rear end bell cover 5 Remove the two 2 nuts holding the fan motor to the drive motor and remove the fan motor assembly 6 Install new fan motor assembly and tighten nuts 7 Connect fan motor plug to P1 of the Motor Controller Board 8 Install weight tray and weight tray shield and plug in balancer 9 Perform PRELIMINARY INSPECTION amp FUNCTION CHECKS Rotary Shutter Replacement 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Remove rear end bell cover 4 Remove the 3 8 by 3 8 shoulder bolt and the rotary shutter Note Some motors will have a plastic shim part number 8 143988 between the motor and the rotary shutter Leave this shim in place when replacing the rotary shutter B Install the new rotary shutter 6 Put Loctite 242 or equivalent on the 3 8 shoulder bolt threads install and tighten 7 Install rear end bell cover
7. Le IBS 2000 Interactive Balancing System Service Manual and Troubleshooting Guide with Parts Identification HENMESS Y INDUSTRIES INE PO Box 3002 1601 J P Hen ergne TN USA 37086 oe 7533 6359 Manual Part No 9112388 HENNESSY INDUSTRIES INC ufac COATS BADA Aut Equipment and Tools Revision 12 00 rev 1 ii e Service Manual COATS Model IBS 2000 Introduction 1 Safety Notes 1 Principal of Operation 1 Component Functions amp Benefits 2 2000 Balancer Simplified Block Diagram 3 Servicing i ii cose EUR seule 4 Equipment Needed vs oe navy u oe oe ERR 4 Voltage amp Phase Checking Procedure 4 Installation Instructions Unpacking and 5 Hood Installation 5 Faceplate Assembly Installation 5 Preliminary Inspection 5 Functional Checks Operational CHECK xu o 6 Calibration Procedures Balancer Calibration 6 7 Plane Separation Accuracy Check 7 Optimizing A Distance Guage Tape Placement 7 Arm Calibration Li 7 8 Accuracy Problems 8 Rotation Check 8 Cycle Counters 8 Total Accuracy Verification TVA 9 Error Codes
8. SAVE THESE INSTRUCTIONS Introduction This service manual contains the functional checks troubleshooting adjustment and part replacement instructions for COATS Model IBS 2000 Wheel Balancer Exploded views illustrations and an indexed parts list facilitate parts location ordering and replace ment All adjustments and replacements can be ren dered with mechanic s or electrician s tools Safety Notes HIGH VOLTAGES HIGH TORQUE MOTORS and HIGH SPEED ROTATING WHEELS are present in COATS wheel balancers Follow the SAFETY RULES when servicing any balancer 41 DISCONNECT BALANCER from power source before starting any parts replacement or internal adjust ment 2 LOWER GUARD HOOD before starting cycle 3 DO NOT WEAR LOOSE CLOTHING such as neck ties while servicing the balancer 4 LONG HAIR should be worn UP or under a HAT 5 WHEELS MUST BE MOUNTED PROPERLY e Cones must be centered in the wheel before tightening e The wheel must be forced up firmly against the faceplate e The hub nut must be engaged by a minimum of four 4 full threads e Tighten the hub nut rotating the wheel and strik ing a spoke of the hub nut with the heel of the hand Caution Failure to tighten the hub nut could result in serious injury Principle Of Operation The model IBS 2000 Wheel Balancer utilizes the prin ciple that any rigid body rotating about an axis through the body can be balanced using weights mounted in tw
9. 2 5 amp 250V fuse which can be replaced if blown However if the fuse does blow there could be some other problem with the machine Make sure to fol low all trouble shooting procedures after replacing a board Motor Controller Board Replacement 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Disconnect the incoming power from T1 of the MC board If single phase disconnect the capacitor from P4 of the MC board i 1 W w LI E mar amp Disconnect the CONTROL from 5 Disconnect the power supply from P6 6 Disconnect the fan motor from P1 7 Disconnect the motor from P2 8 Unscrew both SSR s from the power panel 9 Disconnect switch from P5 10 Disconnect the Interlock switch from P7 only mod els after 12 22 97 11 Compress plastic standoffs and carefully remove the board 12 Replace defective Motor Controller Board and rein stall in reverse order 13 Install weight tray and weight tray shield and plug in balancer 14 Perform FUNCTION CHECKS CPU Board Replacement 1 Unplug the balancer 2 Disconnect the Power Supply Board from P10 of the CPU 3 Disconnect the RS232 cable Caution If this cable is not plugged in or does not have a good connection after repair you will get a WARNING message 4 Remove all other phone type cables CONTROL HOOD ENCODER and PIEZOS 5 Compress plastic 5 standoffs and carefully remove the board
10. 4 3 8 16 washer head screws holding the cradle to the motor 11 Remove the cradle from the motor 12 Apply Loctite 242 to the threads of the 3 8 16 washer head screws and install the cradle on the new motor 13 Clean and apply Loctite to the surface of the flex plate and the cradle where they mate 14 Apply Loctite 242 to the threads of the 3 8 16 washer head screws and install the flex plate on the cradle 15 Ensure balls are inserted into each piezo assembly 16 Make sure the piezo ball protectors are installed over the piezo balls see piezo replacement procedures if replacing new PIEZOS or balls 17 Install motor 18 Install 1 2 18 X 1 washer head screws holding flex plate to chassis Caution Make sure both washers are per fectly aligned before tightening the bolts mis alignment could cause motor interference 19 Install piezo springs piezo retainers and 3 8 16 nyloc nuts 20 Tighten the nyloc nuts until the distance from the top of the motor cradle to top of the piezo spring retainer 15 two 2 inches 21 Connect fan motor to P1 of the Motor Controller Board 22 Connect optical encoder cable and piezo cables to the CPU Board 23 Connect drive motor plug to P2 of the Motor Controller Board 24 Install the weight tray weight tray shield and motor cover and plug in the balancer Caution Always make sure there is nothing touching the motor or motor housing This can affect wei
11. DESCRIPTION ITEM NO DESCRIPTION 1 8106301 1 4 20 St Hhcs 50 8112329 Assembly Distance Gauge Mount 2 8108852 3 8 16 St Hhcs 51 8112054 Screw 1 4 28 X 5 8 Lg Shcs 3 8112122 Rubber Protector Cone Storage 52 8112332 Label Top Dead Center 4 8112060 Sleeve Accessory Peg 53 8106302 3 8 16 Hhcs 5 8112128 Painted Column 54 8112182 Flex Plate 6 8112154 Cover Column 55 8112153 Fan Assembly 230 Vac 7 8112185 Caution Patent Decal 56 8301084 8 Kep Nut 8 8111059 Circuit Breaker 1 Amp 57 8308817 Disk Encoder 9 8112194 Assembly Circuit Breaker Mounting 58 8112215 Assembly Optical Encoder Plate 59 8301016 Bolt 3 8 X 3 8 Shoulder 11 8111542 8 32 X 5 8 Lg Phms Bx 60 8301032 3 8 Washer Flat 12 8112019 Upper Column Cover 61 8104200 3 8 Washer Internal Lock 13 8112159 Lower Column Cover 62 8307008 Spring Piezo 14 8112187 Assembly 2 5 Tube 63 8308036 Retainer Piezo 15 8110789 U Bolt 2 5 Tube 64 8108727 Rod Threaded Piezo 16 8181183 5 16 18 Lock Nut 65 8301033 Nut 3 8 Jam 17 8112027 Bracket Pod Mounting 66 8106303 Nut 3 8 16 Whiz Lock 18 8112028 Bracket Pod Adjustment 67 8112203 Piezo Assembly 19 8112029 Clamp Pod Tube 68 8120325 5 16 18 Whhcs 20 8112179 1 4 20 X 3 Lg Hhcs 69 8301121 1 2 Washer Flat 21 8112030 Pod Plastic 70 8112318 Cord Power 22 8143168 1 4 20 Wh Screw 71 8150128 Relief Power Cord Strain 23 8143169 1 4 20 Wh Nut 72 8140786 Plug Electrical 230v Only 24 8301035 3 8 16 Hh Lock Nut 8305076 Plug Electrical 230v 1 Only 25
12. LED Erion Odes Aye Ep 9 LCD eG T 9 10 Troubleshooting Flow Charts Pre diagnostic Check 11 Wheel Does Not Spin 12 Wheel Does Not Stop 13 No Communications 14 Keypad Problems 15 Nov LCD DISS AY s rette om d 16 LCD Contrast Won t 17 No LCD Back Light ee 18 No LED Display silicone see 19 EESEBR uen Me LC P 19 A amp D Arm Problems 20 Diagnostic Procedures Motor and Motor Controller Checking Procedure o eee ND CASE PS EER 21 Spin and Stop Diagram 21 Motor Controller Diagram 22 Optical Encoder Checking Procedure 23 Rotary Shutter Checking Procedure 23 Piezo Output 5 23 Piezo Crystal Checking Procedure 24 Balancer Display Diagnostics 24 Serial Loopback TEST ni 4 Dr hy oes 24 Replacement Procedures for Model IBS 2000 Balancer 25 30 Display Board Assembly Replacement 25 E Prom Replacement 25 LCD Board Replacement 26 Start Switch Replacement 26 Touch Panel Replacement 26 Hood Magnet Replacement 26 Hood Switch
13. LED for the outside right plane should be flashing when the weight is at bottom dead center The display will now read CALIBRATION COMPLETE PRESS ANY KEY TO CONTINUE Plane Separation Accuracy Check 1 Remove the 4 oz weight from the wheel 2 Use putty to fine balance the test wheel to obtain 0 00 0 02 weight readings on both planes If unable to balance to zero See REPEATABILITY PROBLEMS Note If the customer balances mostly larger wheels you may use a larger wheel for cali bration 3 Place a 4 oz weight on the outside of the wheel 4 Press start or lower the guard hood The readings for this cycle should be as follows Inner Left Plane 0 00 0 15 oz Outer Right Plane 4 00 0 15 oz Outer Position flashing 4oz at bottom dead center 1 2inch 5 Move the 4 oz weight directly across to the inside plane Press start the reading should be as follows Inner Left Plane 4 00 0 15 oz Outer Right Plane 0 00 0 15 oz Inner Position flashing 4oz at bottom dead center 1 2 inch 6 f the above results are not achieved check the A W and D dimensions The ARM must be OPTIMIZED Perform the ARM CALIBRATION 7 If the above results are still not achieved check the placement of the distance tape see OPTIMIZING A Distance Tape Placement 8 f specified results are not achieved see ACCU RACY PROBLEMS Optimizing A Placement Note Perform this procedure if the PLANE SEPARATIO
14. than 4VDC Refer to the wiring diagram Rotary Shutter Checking Procedure This procedure will detect movement of the rotary shutter during a spin cycle Slippage of the shutter wheel can cause the weight location to change result ing in weight chasing or spin error messages as a result of an incorrect encoder count 1 Mount a balanced wheel on the machine Add a 4 oz weight to the outside plane and spin the wheel 2 Rotate the wheel so the center position LED light is on Mark the tire or wheel with respect to the wit ness mark on the motor 3 Spin the wheel again then rotate the wheel so the center position light comes on again Note the position of the mark you made on the tire or wheel You may need to make several spins 4 f the position changes the rotary shutter has slipped Refer to the Rotary Shutter Replacement pro cedure to tighten and recheck Note This procedure can be used to check for loose faceplate however mark the face plate instead of the wheel Piezo Output Test This procedure allows you to look at the piezo output readings to diagnose a problem with any of the piezos Piezo problems can cause incorrect weight readings resulting in weight chasing problems 1 Go to the main menu and select DIAGNOSTICS press enter 2 Select PIEZO OUTPUTS press enter The screen will now display the piezo readings Each piezo is meas ured individually L
15. 112200 3 gt E era 112203 amp 1 RF 112200 5 gt Gesa PIEZO POWER CORD 112203 amp PLUG AC MALE 1 PH 305076 O PIEZO L 112203 8 112356 Assy 230 1 112318 3 nam O t H NOTE The screws should be facing up When refering to the picture OR POWER CORD PLUG AC MALE 3 PH 140786 i 112224 cl 2 DE T 112233 GREEI ACITOR R 2 112318 MOTOR CONTROLLER z motor 3 112184 MOTOR CAVE 112083 j P2 n N 2 E 230 VAC 1 aa ewer lt EE v FAN MOTOR c nia i SR2 SRI Pe lt FI seme ommo CONTROL P6 POWSUP 112200 1 112204 IBE 112207 Hm CIRCUIT BREAKER 112319 CHASSIE GND L Rower Supply NOTE ALL DC VOLTAGE 812661 READINGS MUST BE FROM CIRCUIT GND NOT 12V PIN T CHASSIE GND GND PIN son g lt PING PIN 1 TO PIN 1 ORANGE 412 V ro dur eN HENNESSY INDUSTRIES DR TJE 1 10 97 LIGHT BL 12V 1601 JP Henni Drive I aVergne Uem eua WIRING DIAGRAM 2000 BALANCER s Document Namba 112368 E Dae Friday May 09 1897 Eneet i Service COATS Model IBS 2000 37 112081 BREAKER
16. 8106302 3 8 16 WI Hhcs 73 8112053 A D Arm Clamp 26 8143044 3 8 16 Hh Tinnerman Nut 74 8112054 112054 1 4 28 X 5 8 Lg Shcs 27 8110817 Knob 3 8 16 Thrd 75 8112205 112205 Cable Modular A amp D Arm 28 8301032 3 8 Flat Washer 76 8112058 Bushing 29 8112032 1 5 Dia Pod Tube 77 8112148 Scale Distance Gauge 30 8112176 3 8 16 X2 1 2 Lg Shcs 78 8106301 1 4 20 St Hhcs 31 8112175 Tube Pod Locator 80 8301142 1 4 Lock Washer 32 8106303 3 8 16 Wh Nut 81 8112118 Housing Left A D Arm 33 8112034 Assembly Weight Tray Plastic 82 8112115 Housing Right A D Arm 34 8112036 Labels Weight Tray 83 8112120 Clamp Large 35 8112178 Cover Rear Harness 84 8112059 Assembly Potentiometer 36 8112038 Shield Weight Tray 85 8112249 Strain Relief Modular Cable 37 8106304 1 4 20 Tinnerman Clip 86 8112062 Gear A 38 8112040 Wheel Guard Plastic 87 8112061 Gear D Small 39 8112041 Weldment Hoodbar 88 8112056 Sub Assembly A amp D Body 40 8305050 Switch Reed 89 8112067 Sub Assembly A D Arm Sleeve 40a 8111820 Interlock Switch 90 8112071 Gear Large D 41 8301063 6 32 Phms 92 8112074 Handle A D Arm 42 8301066 6 Nut 93 8112139 Tip Distance Gauge 43 8309008 Stop Molded Hood 94 8112140 5 16 18 X 7 8 Lg Fhms 44 8301120 1 2 13 X 2 5 Lg Hhcs 95 8112141 1 4 20X1 1 2 Lg Bhms 45 8301121 1 2 Washer 96 8181369 1 4 20 Nylon Insert Locknut 46 8301122 1 2 13 Lock Nut 97 8112075 Spring A D Arm 47 8112233 Motor Assy Wired 98 8112077 Machined Complete A D Arm Rod 48 8308513
17. A OPTI MIZATION Service Manual COATS Model IBS 2000 7 4 Enter the D value from the tire It should be within 10 of the reading from the automatic arm if not the D pot should be adjusted refer to A amp D ARM REPAIR PROCEDURES Manually enter the value 5 After both values have been manually entered move the distance arm to the rim and hold it in position while pressing CONTINUE 6 Rotate the arm out and around to a second posi tion on the rim Holding the tip against the rim flange press CONTINUE Arm Calibration is now complete When the arm is returned to the HOME position the balancer will return normal operating mode 7 verify the calibration pull the arm out and hold the tip against the rim flange The A amp D readings auto matically displayed should be 0 20 of the values entered during calibration If not see OPTIMIZING A DISTANCE TAPE PLACEMENT and A amp D Arm Problems Accuracy Problems Mounting Errors Causes comebacks but not detectable with the balance Check the runout of the shaft faceplate and cones Wheel Slipping During Rotation Causes repeated spins or inability to balance the wheel Check by mark ing the wheel amp faceplate correct by tightening the hub nut or using front cone Improper Wheel Parameters or Inaccurate Wheel parameters such as approximate ALU modes Causes inability to balance the wheel Enter more accurate parameters and or mount hidden weight
18. COATS Model IBS 2000 LCD Contrast Won t Adjust Perform pre diagnostic check balancer must be displaying merchandising message to proceed heck 12 vdc o power suppy Yes Is hardware adjustment potentiometer present on display board Adjust potentiometer on back of display board Does this correct the problem P1 a Replace display board CPU Check 12v se set up menu Replace CPU Yes Disconnect 0 power on the Refer to DC wiring diagram 112368 again djust contrast No Replace display board Troubleshooting complete NOTE Turn the power off While holding down the first from the left rim weight locator key Turn the power back on This will get you into the contrast adjustment mode Adjust as necessary and Save setting Service Manual COATS Model IBS 2000 17 No LCD Back Light Preform pre diagnostic check balancer must be displaying merchandising message to proceed Is LED backlight i No Plug cable in and recheck Check for 4 vdc P4 2 of the display board No Replace display board Yes Replace LCD module Yes i Troubleshooting complete 18 Service Manual COATS Model IBS 2000 No LED Display Perform pre diagnostic check balancer must be displaying merchandising message to proceed Does LCD display work Yes Adjust L
19. Cover Rear End Bell 99 8111032 Washer Fender 1 4 Bx 1050 49 8112191 10 24 X 1 2 Lg Hhms 100 8111055 6 Lock Nut 34 e Service Manual COATS Model IBS 2000 PART ITEM NO DESCRIPTION ITEM NO DESCRIPTION 101 8112079 Display Pcb 152 8106303 3 8 16 Wh Nut 102 8112220 Lcd Display 154 8109945 Retainer Hood Tube 103 8112225 Touch Panel Sub Assembly 155 8307014 Bearing Flanged 105 8308017 Rubber Plunger Black 156 8109944 Hood Washer 106 8301063 6 32 Phms 157 8112048 Spring Hood 107 8112219 Manual Start Pcb Assembly 158 28590 10 24 X 1 2 Lg Phms Phillips 108 8112248 Cable Assy 159 8112110 Bracket Captive Back Cone 109 8110560 Ground Screw Green 161 8112142 Gram Decal Sheet 110 8112317 10 32 Nut 162 8112097 Face Plate Stub Shaft 40mm Id 111 8112237 Bracket Assy Power Panel 163 8110514 Retainer Pressure Cup 1 125 112 8112208 Plastic Standoff 164 8112098 Cone Small 40 Mm Id 113 8301084 Nuts 8 32 165 8112099 Cone Medium 40 Mm Id 114 8112081 Power Supply 166 8112100 Cone Large 40 Mm ld 115 81122001 Cable Assy 167 8112101 Adapter Large 40 Mm ld 116 8112082 Main Cpu Board 168 8112102 Ring No Mar 40 Mm Id 117 8112083 112083 Motor Controller 169 118 8112223 Heat Sink 170 8112103 Nut Hub 40 Mm Id 119 8301063 36 32 Phms 171 8112107 Spring Back Cone 40 Mm ld 120 8301092 138 32 X 1 2 Lg Phms 172 8112106 Pressure Cup 40 Mm ld 121 8301066 6 32 Nut 174 8112114 Retainer Pressure Cup 122 3420 6 Washer 175 8112132 Pa
20. S H A 1910 133 a Protective gog gles safety glasses or a face shield must be pro vided by the owner and worn by the operator of the equipment Care should be taken to see that all eye and face safety precautions are followed by the operator ALWAYS WEAR SAFETY GLASSES Everyday glasses only have impact resistant lenses they are not safety glasses Do not disable hood safety interlock system or in any way shortcut safety controls and operations Be sure that wheels are mounted properly the hub nut engages the arbor for not less than four 4 turns and the hub nut is firmly tightened before spinning the wheel Read and understand this manual before operat ing Abuse and misuse will shorten the functional life Be sure the balancer is properly connected to the power supply and electrically grounded Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged until it has been examined by a qualified serv iceman Do not let cord hang over edge of table bench or counter or come in contact with hot manifolds or moving fan blades If an extension cord is necessary a cord with a current rating equal to or more than that of the equipment should be used Cords rated for less current than the equipment may overheat Care should be taken to arrange the cord so that it will not be tripped over or pulled Keep guards and safety features in place and in working order iv e Service Manual
21. amp a 3 8 nut driver 8 Chip extractor tool Ammco part 29977 9 A dial indicator runout gauge Ammco part 2850 or 29752 10 Sockets 3 8 7 16 3 4 1 2 9 16 inch a speed han dle or ratchet 11 A drill and 1 8 drill bits pop rivet gun and 1 8 rivets 12 A 7 16 3 8 box end wrench and cutters for banding Voltage amp Phase Checking Procedure 1 Unplug the Balancer from the power source 2 Perform all voltage checks shown in the appropriate diagram and chart at the power receptacle If one or all voltage measurements is faulty be sure to check the sta tus of the circuit breakers that supply the Balancer 3 Check from one of the power terminals to the ground terminal to verify a ground is present The voltage measurement should be approximately one half of the available voltage i e 220V should read 110V Note If any faults are found in the above pro cedure it is the responsibility of the owner COATS authorized service personnel are not responsible for wiring within the building 4 Plug the balancer into a power source B Use an Ohmmeter to check the resistance between the frame of the balancer and the building ground The resistance should be less than 1 ohm If the resistance measurement is greater that one 1 ohm check the power cord plug and frame connection for proper contact GROUND A B GREEN RED BLACK SINGLE PHASE VOLTAGE REQUIREMENTS INFORMATION 208V 220V 230V 19
22. closer to the PRESET position for hidden weights Uncalibrated Data Entry Arm Causes repeated spins to balance Perform Plane Separation Accuracy Check Uncalibrated Balancer Causes repeated spins to balance Perform a PLANE Separation Accuracy Check Something Touching The Motor Or Distance Arm Causes inability to calibrate the balancer or achieve acceptable PLANE SEPARATION Check for anything touching the motor Rotary Shutter Slipping Causes weight position to change repeat spins or inability to balance Perform Rotary Shutter Checking Procedure 8 Service Manual COATS Model IBS 2000 Rotation Check Note This procedure must be performed with a Hub Centric wheel It should be performed as part of every routine calibra tion procedure 1 Remove the 40z weight from the inner rim and perform a fine balance to obtain 0 00 02 weight readings on inner and outer plane 2 Position valve stem at 6 o clock Loosen hub nut just enough to allow the wheel to move While holding the faceplate so it cannot turn rotate the wheel 90 degrees relative to the faceplate Tighten hub nut 3 Press START Weight readings should be 0 32 oz or less 4 Repeat steps 2 amp 3 At 180 and 270 degrees weight readings should be 32 oz or less B f the specified results are not achieved see ROTA TIONAL PROBLEMS Cycle Counters These counters can be accessed through the DIAG NOSTICS menu Each cycle
23. coast for several revolutions and then brake to a stop If the machine fails to brake and continues to coast see BAL ANCER DOES NOT STOP 6 Service Manual COATS Model IBS 2000 11 The balancer should now have weight values and position lights displayed 12 Rotate the wheel so the top and bottom position LED s for the outside right plane are flashing 13 Note the position of the 4 oz weight and the weight readings for both planes 14 Now rotate the wheel so the center LED for the outer right plane is flashing The 4 oz weight should now be at or near the 6 00 position 15 Perform five 5 cycles and note the positions and weight readings after each spin The weight readings should repeat within 2 oz and the position within 1 2 inch If they do not see ACCURACY PROBLEMS Note If the customer has problems with a specific wheel assembly only make sure there is no water or debris inside the assembly Calibration Procedures Balancer Calibration 1 Turn the power switch ON 2 Mount your test wheel to the machine 3 Enter the wheel parameters using the A D arm and the rim calipers 4 If the machine is in ROUND OFF mode go to the SET UP menu and select NON ROUND OFF B If the machine is not in OUNCE mode go to the SET UP menu and select OUNCES Note This procedure can be performed using GRAMS or OUNCES If using GRAMS refer to a conversion chart for weight con versions 6 Go to the M
24. has occurred Calibration information counters etc Replace CPU board Service Manual COATS Model IBS 2000 9 8 Internal Error Code Displayed at power up when the data on the EE PROM is different than when the unit was turned off Recalibrate the Balancer and the A D Arm If this message continues replace the CPU board 9 An Invalid Model Selection Has Been Made Displayed when the dipswitches on the CPU board are not set correctly or the connections are bad Check the dipswitch settings they should all be in the ON posi tion and reset if necessary If this does not correct the problem replace the CPU 10 The Automatic Arm Is Not Present Displayed during Arm Calibration when the CPU cannot detect the arm Check the arm cable PCB connections or the CPU connector 11 The A amp D Pots Are Not Properly Adjusted Displayed during Arm Calibration if the pots were not properly adjusted Press CONTINUE to readjust or CANCEL to quit 12 The A Pot Is Not Properly Adjusted Displayed when the A pot is not reading correctly Same as 11 except for the A pot only Press CONTINUE to readjust or CANCEL to quit 13 The D Pot Is Not Properly Adjusted Displayed when the D pot is not reading correctly Same as 12 except for the D pot only Press CONTINUE to readjust or CANCEL to quit 14 The Hood Was Raised During The Measurement Cycle Displayed if the hood is raised during the cycle Lower the hood a
25. pod tube 7 Install new signal harness 8 Connect signal harness connections inside chassis 9 Connect plugs to TOUCH PANEL assembly 10 Install TOUCH PANEL assembly 11 Install weight tray and weight tray shield 12 Perform BALANCER CALIBRATION and ARM CALIBRATION 13 Perform FUNCTION CHECKS 30 Service Manual COATS Model IBS 2000 A D Arm Repair And Replacement The IBS 2000 uses an automatic Distance A and Diameter D Gauge Assembly however it is different from the 1050 The arm assembly is repairable and you should refer to the A amp D Arm Exploded Parts View in this section and illustrated parts list in this manual for individual parts identification A D Arm Replacement Important Arm Calibration And Balancer Calibration Must be performed after any repair to the A D arm 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Disconnect the A D arm cable from P7 Inner Arm of the CPU Board 4 Remove the screw and nut from handle assembly and slide it off 5 Loosen the four 4 Allen head screws from the arm bracket and take off the cover Note the locating pin in the lower bracket 6 Slide the arm back so it clears the cabinet and remove note the locating hole in the arm rod 7 Install new or repaired gauge assembly 8 Connect cable to P7 Inner Arm of the CPU Board 9 Plug in the balancer 10 Perform A amp D Arm Calibration Procedure 11 Install weight t
26. 0 1050 has 110v Piezos Function Measures the weight imbalance in a wheel Benefit Proven Technology reliable Also Same as in the 1050 but different connector and isolated Encoder Function Aids in measuring the imbalance location in a wheel Determines rotational speed and direction Benefit Proven technology Same as a 1050 but different connector Motor Function Used for mounting and rotating the wheel Benefit Direct drive no need to balance No belts less noise interference Replaceable faceplate and shaft assembly Optional 40mm faceplate and shaft assembly Indicates electronic components which carry a three year warranty 2000 Simplified Block Diagram Phase Converter or Jumper AC Power Motor Controller Interlock Switch NO Closed with hood down NW Hood Switch NO Closed with hood down Manual Start Note Interlock switch only on models produced after 12 22 97 LCD Board Note NC Normally Closed NO Normally Open The normal position is when the magnet is next to the switch Service Manual COATS Model IBS 2000 3 Servicing Service should be performed only by a factory trained COATS Service Technician The troubleshooting and service procedures in this manual are arranged to allow rapid and thorough service The steps are e Preliminary Inspection e Functional Checks Repair O
27. 5 250 Plug Hubbell Installed Required Hubbell 5462 or Mating Outlet Installation Instructions Unpacking and Setup 1 Remove the staples from around the bottom of the carton and carefully remove the box 2 Unstrap and remove the hood accessory box and all packing 3 Inspect the unit and all accessories for damage Note Report any damaged or missing parts to the Hennessy Order Entry Department imme diately CALL 1 800 688 6359 4 Remove the three 3 hold down brackets from the machine amp pallet Do not discard Retain for the customer he may wish to use them to bolt his unit to the floor 5 Remove the balancer from the pallet Caution This unit is very heavy and will require assistance for lifting and moving DO NOT DROP DO NOT LIFT BY THE MOTOR SHAFT Note If there is a bolt on the back of the hood support bracket near the bottom right side of the accessory column REMOVE IT It will inter fere with the hood installation 6 Remove the Allen head bolt at the bottom of the pod tube and retain for later use 7 Loosen the four 4 bolts on the tube brackets and slide the tube into position with the locating ring 8 Install the Allen head bolt Caution Be careful not to damage the wire harness 9 Snug the bolts on the tube brackets but do not overtighten The Pod should swing with some resistance but not loosely 10 Push the harness into the pod tube and install the plasti
28. AIN menu and select CALIBRATE BAL ANCER to enter the calibration mode The status bar should now read CAL O Follow the instructions on the display 7 Push the START button or lower the hood The machine should now cycle This cycle is referred to as the zero spin cycle 8 The balancer should come up to speed coast for several revolutions and then brake to a stop 9 The status bar should now read CAL 1 Follow the instructions on the display 10 Position the wheel so the display for the center position LED on the outside right plane is flashing 11 Place a 4 oz weight at the 12 o clock position on the outside right of the wheel Note If a weight is already in this position place the 4 oz weight as close to the indi cated location as possible Rotate it to the 12 o clock position and then press the Star key 12 Push the START button or lower the hood The balancer should now cycle and come to a stop 13 The outer right weight display should read 4 00 02 oz and the center position LED for the outside right plane should be flashing when the weight is at bottom dead center The display will now read CALI BRATION COMPLETE PRESS ANY KEY TO CON TINUE 14 Perform PLANE SEPARATION if specified results are achieved calibration is complete If specified results are not achieved OPTIMIZE THE A 15 Make sure to write down the new A value to use in the ARM CALIBRATION procedure Center position
29. ATION and BALANCER CALIBRATION 12 Perform FUNCTION CHECKS Small D Gear Assembly Replacement Note The D Potentiometer Adjustment pro cedure is included in this section 1 Unplug the balancer 2 Remove the weight tray and weight tray shield 3 Unplug the arm cable from P7 Inner Arm of the CPU board 4 Loosen the clamp screw and remove the plastic arm housing 5 Disconnect the D pot Diameter from the Arm PCB 6 Loosen the set screw in the D gear with an Allen wrench Pull the arm subassembly back enough so the small D gear clears the large D gear Slide the gear off 7 Loosen the 1 2 retaining nut on the D pot and slide the pot out 8 Reinstall in reverse order 9 Adjust the D pot by sliding the arm sub assembly back so the small gear clears the large D gear 10 Rotate the small gear until it is with in the appropri ate range Refer to the ARM CALIBRATION procedures 11 Perform ARM CALIBRATION and BALANCER CALIBRATION 12 Perform FUNCTION CHECKS Large D Gear Replacement 1 Unplug the balancer 2 Remove the weight tray and weight tray shield 3 Disconnect the arm cable from P7 Inner Arm of the CPU board 4 Loosen the screw on the clamp and remove the plastic arm housing 5 Remove the screw and nut from the handle assembly and slide it off 6 Loosen the four 4 Allen head bolts from the arm bracket and remove the bracket cover 7 Slide the arm sleeve with the larg
30. Do not exceed 70 humidity Do not apply DC Voltage see notes in PIEZO REPLACEMENT procedures 1 Unplug the balancer 2 Remove the four 4 nuts on the back of the pod 3 Disconnect the red start switch wire from the switch 4 Disconnect the grey LCD wire from P4 of the Display Board 5 Disconnect the LCD ribbon from the LCD board 6 Remove the four 4 screws holding the LCD Board to the Touch Panel Note The LCD board has a locating arrow on the back in the upper right corner Make sure the arrow is in the UP position before rein stalling the new LCD To adjust the contrast there is an adjusting potentiometer on the top of the display board 7 Install rubber O rings between the LCD board and the Touch Panel standoffs Refer to the Instruction sheet provided with the new part 8 Replace the defective LCD Board and reinstall in reverse order 9 Plug in balancer 10 Perform FUNCTION CHECKS Start Switch Replacement 1 Disconnect balancer 2 Remove the four 4 screws on the back of the pod 3 Disconnect the red start switch wire from the switch 4 Remove the three 3 screws from the start switch 5 Replace the defective switch and reinstall in reverse order 6 Plug in balancer 7 Perform FUNCTION CHECKS Touch Panel Replacement 1 Disconnect balancer 2 Follow all procedures for Display Board and LCD Board replacement 3 Replace defective Touch Panel 4 Plug in balancer 5 Per
31. ED brightness Yes Troubleshooting complete Troubleshoot LCD Replace display board Do pre diagnostic check balancer must be displaying merchandising message to proceed urn unit off then on Does EE ERR go away Replace display board Troubleshooting complete Service Manual COATS Model IBS 2000 19 Check Potentiometer adjustments See ARM CALIBRATION Are the potentiometer readings within tolerance Check Cable connections at CPU board and Arm Replace the cable Troubleshooting comptete Calibrate the arm Calibrate the balancer amp D Arm Problems Perform pre diagnostic check 15 the arm in HOME position Adjust the potentiometers Are the readings stable Yes See KEYPAD flow chart Return the arm to HOME Is the W now flashing Use VOM to check supply voltage on the A amp D potentiometers Between pins 1 amp 3 for D and 4 amp 6 for A Is voltage stable Use VOM to check voltages on the potentiometers between 2 amp 3 for D and 5 amp 6 for A Are the readings stable Yes Use VOM to check voltage on P7 of CPU board between pins 1 amp 2 and 4 amp 5 Are the readings stable Replace CPU board 20 Service Manual COATS Model IBS 2000 Troubleshooting complete Return to operation Check connections or replace the potentiometers Troubleshooting complete Calibrate t
32. HAS BEEN Disrupted Check Serial Cable Note The display board contains a replace able E prom chip for software revision The above procedures should be followed in order to access this chip Actual chip replacement procedures are detailed next E Prom Replacement Caution Touch the balancer to discharge any static electricity in your body before servicing an E Prom A static strap should be worn Static electricity can damage the chip 1 Unplug the balancer 2 Follow the DISPLAY BOARD REPLACEMENT pro cedures Once you disconnect the keypad ribbon you can turn the board over and access the E prom chip 3 Note the orientation of the chip before removing The top right corner is not square but cut diagonally and there are two locator dots top left and bottom right on the chip 4 Insert the jaws of the chip extractor Ammco 29977 into the slots of the E Prom chip Remove the chip B Install new chip the same way note the orienta tion Caution Be careful not to damage the con nector pins Note The CPU Board also has an E Prom chip which should be replaced at the same time unless specified by the manufacturer 6 Reinstall display board 7 Plug balancer in 8 Perform FUNCTION CHECKS Service Manual COATS Model IBS 2000 25 LCD Board Replacement Caution This is a liquid crystal display do not bend or apply direct pressure Store in a static bag at temperatures between 32 F 95
33. Hood Stop 149 8111447 5 16 18 Nylon Bolt 151 8109950 3 8 Washer Flat Nylon Service Manual COATS Model IBS 2000 35 IBS 2000 Wiring Diagrams vee 5 V LOGIC VBB 5 LED VDD 412 V VEE 12 V 1 SITU E v ev V PIN 1 TO PIN 4 112200 4 112248 3262 Bs r3 FE N 1 frst vw ORR Start ene L SWITCH DISPLAY c BOARD ca py XS 112079 es al 1 BACKLIGHT 4i v LCD 112220 12202 112219 MANUAL START Van TEST RS 232 CONTROL HOOD ENCODER mm RUNOUT OUTER De E ASD LERRA MAIN CPU 112082 INNER RR PIEZO RF PIEZO L PIEZO ASD PINS 265 ONLY PINS 2 amp 5 PINS 265 ONLY ONLY 36 e Service Manual COATS Model IBS 2000 REVISION pres E BY 7 DATE PONI RELEASE 27258 SWTOH 112201 ENCODER 112200 2 112215 8 2 5V Plugged in 1 12V Unplugged 159 P GND B Y 112205 5 V LOGIC 5 V LED 12 V 212 112250 1 VDD an A 12218 DIAMETER 5 K OHMS 112250 2 112200 6 12218 DISTANCE 5 K OHMS 1 2 Pind
34. N Accuracy Check fails 1 Place a 4oz wt on the inside of the wheel try entering an dimension 1 higher than the one used originally Spin the wheel If the plane separation gets worse try using an dimension 1 lower than the one used originally Distance Gauge Tape 2 If the plane separation gets better keep increasing or decreasing the A dimension until an acceptable value is achieved 3 Calibrate the machine and perform the PLANE SEPARATION CHECK Repeat this procedure until the outer plane weight reading is at a minimum 4 Once the A is Optimized and the distance tape moved you must perform ARM CALIBRATION and BALANCER CALIBRATION with the new A value Also recheck the PLANE SEPARATION 5 Move the distance tape to this position to allow for proper A dimension entry Arm Calibration 1 Go to the menu and select CALIBRATION select CALIBRATE ARM Follow the instructions on the dis play The A amp D pot readings are displayed on the LCD display With the arm in the HOME position the read ings should be within the tolerance brackets ANGEL If not the potentiometers should be adjusted Refer to the A amp D Arm Repair Procedures 2 Place the arm in the home position see decal on the motor Follow the instructions on the display screen The A value is obtained by moving the distance arm out to the rim and manually entering the new A value obtained from the PLANE SEPARATION and
35. R TIGHTEN Over tight ening will result in damage to the motor shaft 5 Dial indicate the faceplate and shaft assembly there should be not more than 002 inch on the faceplate and not more than 001 runout on the shaft If so refer to Faceplate Assembly Replacement procedures Preliminary Inspection 1 The floor should be a solid flat surface that does not allow the balancer legs to set into a recess in the floor or sink into the floor itself 2 Ihe balancer should sit on all three 3 legs Make sure the legs have not filled with dirt wheel weights or any foreign matter that may prevent a leg from making contact with the floor 3 Inspect all cones hub nut pressure cup motor shaft faceplate and shaft assembly for damage Missing parts or accessories should be reported immediately to Hennessy Order Entry Department at 1 800 688 6359 4 Check the power supply to the balancer Refer to the VOLTAGE CHECKING PROCEDURE B Check the operation of the cooling fan on the drive motor The fan should run as soon as the balancer is turned on If not check the breaker on the Accessory Column of the balancer If it has tripped reset it If it will not reset refer to the PRECHECK procedure 6 Check the rotation of the motor Press START does the motor spin clockwise If not for a 3ph Balancer switch any two of the hot leads on the plug Service Manual COATS Model IBS 2000 5 Functional Checks Operational Check 1
36. Supply Function Supplies regulated voltage to operate the electronics used on the PCB s 12 vdc VDD 12 vdc VEE 5 vdc VBB Benefit Separate PCB reduces board replacement cost Also Input voltage is AC line voltage routed through the Motor Controller PCB Display Board Function Controls the lighting of all LED s Benefit Separate PCB reduces board replacement Also Manual start switch connects to this PCB Power for the LCD back light and control signals come from this PCB Has contrast pot adjustment Has 5 vcc VCC regulator LCD Function Displays operator interactive instructions Benefit Makes the unit easier to operate and calibrate Single PCB replacement Proven technology 2 e Service Manual COATS Model IBS 2000 Main CPU Function Receives data from all input devices piezos encoder A D pots hoodswitch Processes the information and sends it to the appropri ate PCB Benefit Separate PCB reduces board replacement cost Latest microprocessor design Also Has 5 vde VCC regulator Phase Converter Function Allows three phase motor to be used on sin gle phase power Benefit Allows the use of three phase motors in all balancers Easy to convert from one phase to three phase Uses same capacitor as 1050 but different connectors Fan Function Keeps the motor from overheating Benefit Allows us to use direct drive motors Also These fans are 220v 95
37. Turn the power switch ON The display should read as follows LCD Grams Ounces Defaults to last selection Mode Round off ON Hood Start Hood Start ON A W D 0 00 PRESS ANY KEY TO CONTINUE If the LCD Does Not Light see flow chart for No LCD Display LED Weight Displays 0 00 Mode Dynamic Operator A If the LED s do not light see flow chart for No LED Display 2 Mount your test wheel described in EQUIPMENT NEEDED on the balancer 3 Enter the wheel parameter data using the auto matic A D arm Note If you do not get proper wheel param eters from the A D Arm check the A amp D potentiometers found in the CALIBRATION MENU follow the procedures for Arm cali bration If the A D arm has failed you may manually enter the data If the Keypad does not work see TOUCH PANEL PROBLEMS 4 f the balancer is in round off mode go to the SET UP menu select NON ROUND OFF and press enter B Go to the SET UP menu select the desired weight mode this procedure may be performed in either mode GRAM or OUNCE and press enter 6 Install a 4 07 100 gram weight on the outer rim of the test wheel 7 Choose the DYNAMIC balancing mode 8 Lower the guard hood if HOOD START is on the balancer will automatically cycle at this time if not see step 9 9 Push the START button The machine should now cycle If the machine does not cycle see BALANCER DOES NOT SPIN 10 The balancer should come up to speed
38. c cover 11 Check the power plug with the phase of the machine on the serial tag Make sure the plug matches the customers outlet Hood Installation 1 Install the hood magnets two sets for hood switch and interlock switch to the holes on the hood cam The nylon washer goes between the magnets and the cam Do not over tighten or the magnets will break 2 Slide one of the nylon bushings onto the hood bar flange to the cam 3 Lift the hood up and slide the bar into the machine you may need assistance Let it rest on the hood stop 4 Slide the other nylon bushing into position from the inside slide on the washer and the retaining ring B Attach the hood spring The straight end goes at the bottom of the machine the hook end into the hood Note The hood must be in the raised position to install the spring For Safety you should have someone support it Faceplate Assembly Installation 1 Remove the hub nut and cones from the threaded shaft Store on the accessory pegs 2 Clean the contacting surfaces of both the motor shaft and faceplate assembly with a soft cloth Note the wit ness marks on both these should be aligned before installing 3 Slide the 6 inch socket head bolt included in the parts bag and the 5 16 X 6 Allen wrench extension into the faceplate assembly Hand tighten 4 Attach the torque wrench Hold the faceplate with one hand to keep from turning Tighten to 20 ft Ib Caution DO NOT OVE
39. counter is different They may be beneficial to the shop owner as a management tool User Counter can be reset at any time by anyone to determine number of spins per day hour or per user Calibration Counter this automatically resets each time the balancer is calibrated It can be a useful tool to see how often the balancer is being calibrated As a routine this should be checked when a customer com plains of weight chasing or calibration problems A low count could indicate the customer is calibrating too often or calibrating incorrectly Total Counts counts the total number of cycles on the balancer It is not resetable however if the CPU board is ever replaced it will reset Total Accuracy Verification TVA Total Accuracy Verification or TAV means that when the balancer shows zeros in the weight display after balancing the wheel it is truly balanced The model IBS 2000 includes software that will allow the user to check the accuracy of his machine periodically The procedure is detailed below 1 Go to the Main Menu and select SETUP Press enter 2 Arrow through the selections to TAV Press enter The menu will now display several preset selec tions to choose from or the customer may wish to SPECIFY Press Enter 4 f SPECIFY is selected the menu will prompt to enter the number of cycles desired Enter the number and press enter Note If the preset number is less than 250 the first message will appea
40. e D gear on it off the arm rod 8 Remove the three 3 gear retaining screws 9 Remove the large D gear and flange bearing 10 Replace large D gear and reinstall in reverse order 11 Adjust D pot within tolerance See SMALL D GEAR REPLACEMENT 12 Perform ARM CALIBRATION and BALANCER CALIBRATION 13 Perform FUNCTION CHECKS A D Arm Subassembly Replacement 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Follow the steps for ARM REPLACEMENT 4 Loosen the clamp screw and remove the plastic arm housing 5 Remove the screw and retaining washer from the back of the arm rod 6 Remove the spring 7 Follow the instructions for the A GEAR amp POT REPLACEMENT 8 Follow the instructions for the D GEAR amp POT REPLACEMENT 9 Slide the subassembly casting and flange bearing off the arm rod 10 Install new subassembly and reinstall in reverse order 11 Adjust A amp D pots 12 Perform ARM CALIBRATION and BALANCER CALIBRATION 13 Perform FUNCTION CHECKS Service Manual COATS Model IBS 2000 31 Parts Identification IBS 2000 Parts Illustration 133 134 135 32 e Service Manual COATS Model IBS 2000 45 45 147 172 145 170 pr nd p 139 164 h 140 165 e 146 171 141 166 D 142 167 143 168 Service Manual COATS Model IBS 2000 33 NO
41. ew Repair Procedure The model IBS 2000 is dif ferent from other Coats balancers in that it contains five 5b separate boards which can be replaced individ ually Always refer to the Trouble Shooting section for diagnostic instructions to isolate the defective assem bly Note ALWAYS REFER TO THE WIRING DIA GRAM 112368 in the back of this book for the following procedures Display Board Assembly Replacement 1 Unplug the balancer 2 Remove the four 4 nuts on the back of the pod 3 Disconnect the power supply wire from P1 4 Disconnect the RS232 connector from P3 B Disconnect the red start switch wire from P8 6 Disconnect the grey LCD backlight wire from P4 7 Disconnect LCD ribbon from P5 8 Remove the four 4 screws from the display board 9 Carefully raise the board and disconnect the key pad ribbon Caution DO NOT raise the board more than 4 5 inches or you will destroy the keypad rib bon 10 Replace the defective Display board and reinstall in reverse order 11 Plug balancer in 12 Perform FUNCTION CHECKS Caution If the red start switch wire P8 and the grey LCD backlight wire P4 are not con nected in the correct location of the Display Board the LCD will work and the LED s will light momentarily The start switch will not work then the LED s will blank Caution If the RS232 Cable is in the wrong port the communication is disrupted and you will get a WARNING COMMUNICATION
42. f Failure e Replacement Or Adjustment e Functional Checks Identification of replacement parts required can be accomplished by using the pictorial breakdown and index in this manual It is important that the FUNCTIONAL CHECKS be performed IN SEQUENCE and the PROB LEM ISOLATED If an adjustment is made the entire FUNCTIONAL CHECK must be performed SUCCESS FULLY before the balancer can be considered available for service Equipment Needed 1 AC DC Volt Ohm meter DVM 2 Test Wheel Domestic 14 x 6 steel wheel with a center hole suitable for mounting with a back cone A new 195 70 14 tire properly mounted and inflated bal anced to within 0 02 ounces should be part of this wheel assembly The lateral run out of this wheel should be less than 1 8 Modeling clay and 4 oz test weight 3 Flat and Phillips screw drivers and dead blow hammer 4 Tester for phone cables and jacks Modapt adaptor Contact East Part 118 785 call 1 800 225 5334 to order B Thread locking anaerobic Loctite 242 or equivalent Retaining compound Loctite 601 or equivalent GROUND X Y 2 RED THREE PHASE VOLTAGE REQUIREMENTS INFORMATION Y 2 Hubbell 2421 Hubbell 2431 Installed Required Hubbell 2420 or Mating Outlet Equivalent 4 Service Manual COATS Model IBS 2000 Hubbell 2430 or Equivalent 6 Torque Wrench amp a 5 16 X 6 hex socket for the torque wrench 7 Small Allen wrenches pot adjusting tools
43. form FUNCTION CHECKS 26 Service Manual COATS Model IBS 2000 Hood Magnet Replacement 1 Remove the rubber hood stop from the hood bracket on the chassis 2 Lean the hood back as far as it will go 3 Remove the magnet from the hood bar 4 Install the new magnet Make sure the nylon washer is between the magnet and the bracket DO NOT OVER TIGHTEN B Place the hood in the down position and install the rubber hood stop 6 Check to make sure that the motor starts with the hood down but not with it up The IBS 2000 automati cally defaults with HOOD START on 7 Perform FUNCTION CHECKS Hood Switch Replacement 1 Unplug the balancer 2 Remove the UL cover on the back of the hood sup port bracket by drilling out the pop rivets 3 Remove two 2 screws holding hood switch to hood bracket and remove hood switch 4 Disconnect two 2 wires going to hood switch B Connect wires to new hood switch and install 6 Plug in the balancer 7 Check to make sure that the motor starts with the hood down but not with it up 8 Perform FUNCTION CHECKS Safety Interlock Switch Replacement 1 Unplug the balancer 2 Remove the UL cover on the back of the hood sup port bracket by drilling out the pop rivets 3 Remove two 2 screws holding interlock switch to hood bracket and remove interlock switch 4 Disconnect two 2 wires going to hood switch B Connect wires to new hood switch and install 6 Plug i
44. ght readings 25 Perform FUNCTION CHECKS Note Always check the adjustment of the Left Front threaded piezo motor rod This adjust ment is critical to the correct operation of the A amp D arm It should be adjusted so that the tip is 5 75 Inches from the motor plate Faceplate amp Shaft Assembly Replacement Note This procedure should be performed by Authorized Hennessy service personnel Improper installation could result in damage to the motor shaft which would require a new MOTOR ASSEMBLY 1 Remove the old faceplate assembly 2 Clean the contacting surfaces of the motor shaft and inside the faceplate assembly with a soft cloth 3 Check the runout of the shaft at two points A amp B the runout should not exceed 0006 6 ten thousandths at either point If runout exceeds this measurement see MOTOR REPLACEMENT 4 Slide the six inch socket head bolt included with new assembly and the Allen wrench into the shaft HAND TIGHTEN B Attach the torque wrench Hold the faceplate with one hand to keep from slipping Tighten to 20 ft Ibs Caution DO NOT OVER TIGHTEN Over tight ening will result in damage to the motor shaft 6 Check the runout on the faceplate The runout should not exceed 002 Check the shaft on the inside portion behind the threads This runout should not exceed 001 1 thousandths 7 If the runout is excessive loosen socket head bolt and rotate the faceplate assembly 90 degrees 1 4 tur
45. h panel The wheel parameters are then entered for distance width and diameters appropriate for the correction planes selected The measurement is started by pushing the START switch or lowering the hood The display PCB responds to the START command by sending the command to the CPU which begins the measurement cycle The CPU turns the SPIN SSR ON which powers the motor in the forward direction As soon as the motor reaches the measurement speed the power is removed and the wheel coasts while the signal from the piezos is being measured When the measurement is completed the CPU turns on the BRAKE SSR which reverses the motor and brings the wheel to a stop The WEIGHT and POSITION readings for each plane are sent from the CPU to the Display PCB where they are displayed The correction planes can be changed if desired and the dis plays are updated automatically Service Manual COATS Model IBS 2000 1 Component Functions amp Benefits Motor Controller Function Controls the AC power for the spin and brake cycles of the motor Benefit Solid State Relay SSR replaces mechanical contactor e Eliminates contact arching RF interference e Eliminates mechanical problems e Eliminates multiple wire connections Also AC power is routed through this board for the e On Off Switch Cooling Fan e Power Supply PCB e Phase Converter The SSR is electrically HOT any time the unit is plugged into the wall Power
46. he Arm Calibrate the balancer Diagnostic Procedures Motor and Motor Controller Checking Procedure To verify the operation of the motor and motor con troller the SSR s Solid State Relays must be activated To do this it is necessary to simulate the signal pro duced by the CPU Note Use of an in line adapter is recom mended for this procedure like the one from Contact East part 4118 785 Modapt Modular Adapter For ordering information call 1 800 225 5334 Caution If the spin and brake are activated at the same time the motor controller will be destroyed Note Use CIRCUIT GROUND for checking voltages Refer to the wiring diagram 112368 in the back of this book 1 Check for 5 vdc on the CPU location P12 CON TROL pins 1 3 and 6 Tabs 2 4 and 7 of the Modapt Adapter If Voltage is not present refer to the DC volt age checks 2 activate the spin connect a jumper to circuit ground and touch pin 1 of P12 CONTROL Tab 2 of the Modapt adapter The motor should run clockwise If the motor fails to respond refer to the WHEEL DOES NOT SPIN trouble shooting guide CAUTION DO NOT perform this procedure for more than Two 2 seconds 3 activate the brake connect a jumper to circuit ground and touch pin 6 of P12 CONTORL Tab 7 of the Modapt Adapter The motor should spin counter clock wise If the motor fails to respond refer to the WHEEL DOES NOT STOP trouble shooting guide Caution DO NOT perf
47. il the distance from the top of the motor cradle to the top of the retainer is two 2 inches 12 Connect the fan motor plug to P2 of the Motor Controller Board 13 Connect the optical encoder cable and the piezo cables 14 Install weight tray weight tray shield motor cover and plug in balancer 15 Perform BALANCER CALIBRATION and ARM CAL IBRATION 16 Perform FUNCTION CHECKS Service Manual COATS Model IBS 2000 29 Capacitor Assembly Replacement 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Disconnect plug to capacitor assembly from P4 of the Motor Controller Caution Discharge stored electricity from capacitor before proceeding 4 Remove the screw and washer holding the capac itors inside the panel 5 Install new capacitor assembly 6 Connect plug to P4 of the Motor Controller 7 Install weight tray weight tray shield and plug in balancer 8 Perform PRELIMINARY INSPECTION and FUNC TION CHECKS mis Note Only one capacitor should have a resis tor connected across its terminals If both new capacitors have resistors cut one out Signal Harness Replacement 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Remove TOUCH PANEL assembly 4 Disconnect plugs from TOUCH PANEL assembly 5 Disconnect signal harness connections inside chassis 6 Pull harness through the chassis then out through the accessory column and through the
48. inted Weight Tray Support 123 8112224 Wiring Jumper For 3 Phase 176 8112001 Chassis Painted 124 8112207 Wiring Assy PS To Motor Control 177 8110430 Motor Cradle Dampner Assembly 125 8112319 Wire Assembly Ground 178 8111537 Coats Accessory Catalog 126 8112236 Capacitor Washer 179 8112095 Owners Manual 127 8112240 Wire Assy Fan 181 8112268 Sliding Weight Tray 128 8112209 Wiring Harness Chassis 182 8112260 Accessory Side Tray 129 8112084 Vibration Isolators 183 8112190 Rubber Shelf Pad 130 8112206 Wiring Harness Pod 184 8112255 Plastic Cover Side Tray 131 8112161 Motor Cover Shield Assembly 185 8112196 Panel Assembly Pod Tube Backing 132 8305802 Switch On Off 186 8112189 Pad Panel Pod Tube Backing 133 8112091 Machine Hold Down 187 8112199 Sleeve Accessory Peg 134 8109950 3 8 Washer Flat Nylon 188 8112356 Capacitor Assembly 230v 1 Only 135 8112152 3 8 16 X 1 1 4 Lg Whcs 189 8112352 Capacitor Kit 136 8112129 Assembly Face Plate Stub Shaft 190 8112120 Large Clamp 1 125 Id 8112414 Magnet 137 8112121 3 8 16 X 6 Lg Shcs 8112415 Magnet Spacer 138 8309011 Wheel Calipers 8112373 Switch Cover 139 8112167 Cone Small 1 125 Id 140 8112168 Cone Medium 1 125 Id 141 8112169 Cone Large 1 125 Id 142 8112170 Adapter Large 1 125 Id 143 8308105 Ring No Mar 1 125 Id na si Note used models with interlock switch 146 8308820 Spring Back Cone 1 125 Id produced amot 1 98 147 8110542 Pressure Cup 1 125 Id 148 8109947 Magnet
49. is is a Display Board software communication test It checks the transmitted and received data Follow the instructions on the screen 1 Connect a cable between the CPU1 and TEST P2 connections on the top of the display board Refer to the wiring diagram 112368 on Press CONTINUE 2 The screen will not display the Transmit data and the Received data 3 You will then receive a PASSED or FAILED mes sage Note If the test FAILED check and replace the cable or the display board If the test PASSED but you still get a communication error check the CPU board RS232 cable or the CPU board itself Parts Replacement Procedures for Model IBS 2000 Balancer The procedures in this section will aid in replacing major subassemblies of the IBS 2000 balancer Do not disassemble adjust or replace any part before performing the PRELIMINARY INSPECTION and FUNCTIONAL CHECK PROCEDURES These proce dures along with the troubleshooting flow charts will isolate the necessary adjustment or replacement Perform checks in the order listed and exactly as spec ified Refer to the exploded parts view parts list and wiring diagrams in this manual for parts identification Standard commercial fittings and fasteners are used throughout and should be obtained locally Check all interconnecting wiring and connectors when an electrical malfunction is indicated Check all fittings and fasteners when a mechanical malfunction is indicated N
50. layed when the EE PROM on the display board cannot read or write It cannot restore display settings this is a combination of messages 7 and 8 Replace the display board LCD Error Codes The following list of error codes are Built In Safety Features When the balancer is cycled several operat ing parameters are checked If one of these parameters is not within tolerance the machine will generate an error message displayed on the LCD readout An expla nation of these messages and troubleshooting proce dure is listed below 1 The Motor Speed Was Excessive Displayed when the motor exceeds normal operating speed at any time during the cycle Check the SSR solid state relay 82 lime To Reach Minimum Operating Speed Too Long Displayed when time to reach the minimum operating speed is greater than 20 seconds Check cables SSR or CPU 3 Time To Reach Maximum Operating Speed Too Long Displayed when time to reach maximum operat ing speed exceeds 14 seconds Check cables SSR or CPU 4 The Measurement Time Was Too Long Displayed after the motor gets up to speed but the time to set GAIN an internal measurement is too long Check cables optical encoder or CPU 5 The Measurement Time Was Too Long Displayed when the time to FILTER an internal process is too long Check cables optical encoder or CPU 6 Not Used 7 Internal Error Code Displayed when a write error on the EE PROM of the CPU board
51. left RF right front and RR right rear The amplitude reading is the one we will refer to for diagnosis Only use the first number to the right of the decimal disregard all others 4 Using a balanced wheel put a 40z weight on the outside spin the wheel The left reading should be approximately 25 less than the right front and right rear readings Both right readings should be approxi mately the same 5 Spin the wheel for several revolutions and note the readings in between each spin Look for consistency in the readings 6 Now remove the 4 oz wt with a balanced wheel add a 10z weight to the outside of the wheel Spin the wheel and check the piezo outputs Add a 2 oz weight where the 1 oz was and spin the wheel The readings should double Add a 3 oz weight and the readings should triple Note If the readings fluctuate a great deal check the piezo connector and refer to the Piezo Replacement Procedures Service Manual COATS Model IBS 2000 23 Piezo Crystal Checking Procedure This procedure details how to check for an upside down piezo assembly the crystal has been assem bled upside down inside the piezo assembly This can result in various problems primarily high weight read ings or the position may read 180 degrees out The piezos may be checked in or out of the balancer The procedure below details checking them in the balancer 1 Using a Digital Volt Meter select the DC setting
52. n relative to the witness mark on the motor and retighten Repeat until minimum results are achieved Piezo Assembly Replacement Note The piezo assemblies used in the IBS 2000 are different from the other Coats bal ancers in that they have a 6 pin phone cable connector instead of a wire and spade con nector 1 Unplug the balancer 2 Remove weight tray weight tray shield and motor cover 3 Remove the four 4 3 8 16 Nyloc spring retaining nuts spring retainers and piezo springs 4 Remove the two 2 5 16 18 X1 washer head Screws 5 Disconnect the fan motor and optical encoder con nections 6 Disconnect cables to piezo assemblies 7 Lift up on the motor twist and lift the piezo assem blies to remove from the chassis Caution Always plug piezos in before loading the motor If the piezos are plugged after the motor is loaded it could discharge the elec tricity and short out the LCD BOARD Note Before replacing a piezo assembly e Refer to the PIEZO OUTPUT test e Always check the connecting cables e Clean piezo balls with emery cloth or replace with new balls and reinstall with AMMCO gel and plastic protectors 8 Use emery cloth to clean the mounting surfaces of the piezo assemblies and chassis install new piezo assemblies and connect cables 9 Install the two 2 5 16 18 X1 washer head screws 10 Install piezo springs spring retainers and Nyloc nuts 11 Tighten the Nyloc nuts unt
53. n the balancer 7 Check to make sure that the motor starts with the hood down but not with it up 8 Perform FUNCTION CHECKS On Off Switch Replacement 1 Unplug the balancer 2 Remove the four 4 bolts from the lower accessory column and remove the cover 3 Squeeze the retainers on the switch and push it through the opening in the accessory column 4 Disconnect wiring to the on off switch 5 Connect wires to the new switch and install into the column 6 Install lower accessory column cover and plug in bal ancer 7 Perform FUNCTION CHECKS Circuit Breaker Replacement 1 Unplug the balancer 2 Remove the lower accessory column cover 3 Remove the two 2 screws to the circuit breaker 4 Squeeze the retainers on both sides of the circuit breaker and push it through the accessory column B Install new circuit breaker Connect wires 6 Install lower accessory column cover 7 Plug in balancer 8 Perform FUNCTION CHECKS Power Supply Board Replacement 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Disconnect the Power Supply connector from the main harness 4 Disconnect the Powers Supply from the Motor Control board at P6 5 Disconnect Chassis ground 6 Compress the 4 plastic standoffs and carefully remove the board 7 Replace defective board and reinstall in reverse order 8 Plug in balancer and perform FUNCTION CHECKS Note This board contains
54. nd respin 815 The Motor Ran In Reverse At Start Up Displayed when the motor accelerated in reverse at start up Check phase AC power or MC motor controller 16 The Arm Was Not In The Correct Position Displayed during Arm Calibration if you get out of sequence Press CONTINUE to repeat or CANCEL to quit 17 No Encoder Pulses At Start Up Displayed when no encoder is detected at start up Check cable AC power and motor Refer to Wheel Does Not Spin flow chart 818 No Phase A Encoder Pulse At Start Up Same as 17 but for Phase A only See Wheel Does Not Spin flow chart 19 No Phase B Encoder Pulse At Start Up Same as 17 but for Phase B only See Wheel Does Not Spin flow chart 20 The Hub Nut Is Loose Or There Is No Wheel Mounted Displayed when the hub nut is not tight and the wheel slips or the faceplate assembly is not tight 10 Service Manual COATS Model IBS 2000 on the motor shaft Recheck the hubnut or refer to Faceplate Assembly Installation on pg 5 Press CONTINUE to proceed 4821 The Wheel Is Turning Too Fast For A Measurement To Be Made The motor speed is greater than the maximum operating speed 822 Ihe Wheel Turned In Reverse After The Motor Was Started Displayed when something interferes with the rotation of the wheel after start up someone holding the wheel Press CONTINUE to proceed Check cables or SSR Press CONTINUE to proceed 823 Ihe Wheel Turned Too Sl
55. o Do readings appea on display after wheel has stop Do you have 5v on P12 pin 3 of CPU Check for 5v on P12 control pin 6 of the CPU Yes Check Replace control cable Replace motor controller No Replace the CPU Yes No Does voltage on P12 6 drop to 45v during stop cycle Replace CPU Replace motor controller Is the voltage Yes correct on T1 Yes N UM No Troubleshoot AC Service Manual COATS Model IBS 2000 13 Communications Preform pre diagnostic check balancer must be displaying merchandising message to proceed Did you replace a software chip No No Check serial cable Is it plugged in Note to perform loop back test refer to that section in this manual Perform loop back test with new cable Does unit work Yes Replace communication cable Yes Troubleshooting complete 14 e Service Manual COATS Model IBS 2000 Check for bent prongs or repostion the chip Did this correct the problem Plug cable in and recheck Replace display board Replace CPU board Yes Yes Keypad Problems Perform pre diagnostic check balancer must be displaying merchandising message to proceed Perform keypad test from main menu Diagnostic The balancer must be displaying information to proceed D
56. o planes In this case the rigid body is an automobile wheel and tire assembly which is mounted precisely on center and rotated to measure the imbalance forces in two planes As the wheel rotates any imbalance in the wheel results in radial outward forces on the wheel and the distances from the voltages produced by the piezo sensors With the forces known at the planes of the piezos the imbalance forces at the wheel planes can be calculated by using the distance from the force transducer planes to the wheel correction planes These wheel imbalance forces are displayed for the wheel planes selected dur ing the setup procedure so the correction weights can be added A check spin is recommended to assure that the wheel is in fact balanced For the measurement to be accurate 1 the wheel must be mounted precisely on center 2 the wheel plane parameters must be entered accu rately 3 the distance and diameter arm and the balancer must be calibrated carefully The Model IBS 2000 Balancer uses several modules to control the balancing sequence The COATS Direct Drive system includes the following primary elements e Direct Drive Motor and Shaft Assembly Motor Controller Printed Circuit Board e CPU Printed Circuit Board Assembly e Touch Panel Display Printed Circuit Board e LCD Display The balancing operation is started by mounting the wheel and then selecting the planes for the desired placement of wheel weights from the touc
57. oes this indicate a problem Cycle the power again Does this correct the problem Was keypad locked up at power up Check keypad connections Does this correct the problemt No Replace Keypad No Yes Troubleshooting complete NOTE When a key is shorted or locked down at power up 1 the LCD may be lighted but blank 2 the Press Any Key to Continue message may be displayed 3 the LCD may be in another mode such as ADJUST LCD CONTRAST BALANCER DISPLAY DIAGNOSTICS Service Manual COATS Model IBS 2000 15 No LCD Display Perform pre diagnostic check balancer must be displaying merchandising message to proceed Adjust contrast Is LCD display blank Is display completely dark No No Adjust contrast Turn Power Off Hold down the first rim key while turning the power back on or use the potentiometer on the top of the display board Are LED s displaying the merchandise message Is display illedgible No Yes Replace display board Check LCD cable amp LCD Does display show LCD ERR Yes No Does it beep 5 seconds after power on Adjust contrast No See KEYPAD Ho SHODU paws problems Does Replace the supply and AC voltages Are all AC amp DC voltages correct this correct the display board problem 16 Service Manual
58. ontrol on the Is it Plugged in main CPU Check control Does the wheel start to spin Yes i Check Interlock No Yes No Plug it in switch cable on P7of MC board Is in Does it It plugged in complete the Yes spin Disconnect Interlock switch from P7 on the MC No board Check continuity with the hood down between pins 1 amp 2 Do you have continuity Replace Interlock switch Yes Troubleshooting Complete calibrate Troubleshoot AC Ne 12 e Service Manual COATS Model IBS 2000 s the voltage correct on T1of he MC board 45v when spin is Yes Replace motor controller Replace the motor controller Unplug P3 on motor controller Check for 5v on pin 3 of CPU No Do you have 5v on pin 3 P10 power on The main CPU Yes Check Replace control cable Replace motor controller Does voltage on P12 1 drop to ressed Replace the CPU Wheel Does Not Stop Perform pre diagnostic check balancer must be displaying merchandising message to proceed Does an error message appear Does wheel attempt to stop Replace the motor controller Yes Yes Cross reference error message to Unplug P3 on motor controller Check for 5v on pin 3 CPU table and troubleshoot from the given location N
59. orm this procedure for more than Two 2 seconds spin amp Stop Diagram Electronic Stop Switch Electronic Spin Switch Circuit Ground Modapt adaptor Contact East 118 785 1 800 225 5334 Motor Controller NOTE Outside numbers are for a 6 pin connector 3 13 98 Service Manual COATS Model IBS 2000 21 Motor Controller Diagram Tas 243 CI TERT 320360 Op Goa 8p ALL PESTO ON dQ TWUJON SON AP papori Ea Uo DON CONDAAS yop das Ag PAO 23019 a x IEA 022 ue 4201002 Adda exa moqo L WE JBAQZZ I E EE 324 022 uouoraci Aog Fr ze O rodumyesey ge ical SHO ADEZ 22 e Service Manual COATS Model IBS 2000 Optical Encoder Checking Procedure This procedure allows you to check the optical encoder to determine if it is operating properly A defective encoder can result in spin or braking prob lems 1 When reading the voltages on the white and green wires turn the faceplate slowly by hand The low volt age must be less than 7VDC The high voltages must be greater than 4 0VDC 2 Voltage readings are taken with all optical encoder wires connected Lead Color X Voltage GREEN to PURPLE 2 4 5VDC YELLOW to PURPLE Less than 7VDC greater than 4VDC BLUE to PURPLE Less than 7VDC greater
60. ow Displayed under similar conditions as 422 Check cables or SSR Press CONTINUE to proceed 24 The Motor Accelerated Forward During Breaking Displayed when there is a phase problem with the SSR very rare Check loose shutter wheel or loose faceplate Check encoder cable AC power motor and SSR Press CONTINUE to proceed 25 The Time Required To Stop The Motor Was Too Long Displayed if a phase is lost on the SSR Check AC power cables and SSR Press CONTINUE to proceed Troubleshooting Flow Charts Pre diagnostic Check Make sure the unit is plugged in Turn the power off unplug the unit and Turn the power on connect the fan Does the balancer display appear Is the fan connected Does the fan turn on No gt Yes Yes Yes Continue troubleshooting T AG roubleshoo e See induvidual troubleshooting chart power Service Manual COATS Model IBS 2000 11 Wheel Does Not Spin Perform pre diagnostic check balancer must be displaying merchandising message to proceed Enter the Did you enter Check set up to AIWID No wheel parameters verify auto spin is on Attempt to spin the wheel Yes Cross reference error message to table and Yes troubleshoot from the given location Does an error essage appear No Check for 5v on cable from main pin 1 of P12 No CPU to MC Board c
61. r at the preset number Subsequent messages will also appear at that interval Example A Cycles Since Last Calibration Message 10 The preset number of TAV cycles has been reached do you wish to per form TAV 20 The preset number of TAV cycles has been exceeded do you wish to per form TAV B If NO is selected the balancer will resume normal operation Note If the preset number is equal to or greater than 250 the first message will appear at the preset number and again every 250 cycles Example B Cycles Since Last Calibration Message 500 The preset number of cycles has been reached do you wish to per form TAV 750 The preset number of TAV cycles has been exceeded do you wish to per form TAV 7 If YES is selected the balancer will automatically enter the calibration mode Follow the instructions on the display Error Codes LED Error Codes When the balancer is powered up several communi cation checks are made If the data is incorrect or not received the balancer generates the following error codes in the weight amount LED s on the display LCD ERR unable to communicate with LCD Displayed when the Display board is unable to commu nicate with LCD board This halts the program Check the LCD ribbon and all connections Most likely the rib bon is not installed properly backwards or on wrong pins Possibly the LCD board EE ERR unable to communicate with the EE PROM Disp
62. ray and weight tray shield 12 Perform ARM CALIBRATION and BALANCER CALIBRATION 13 Perform FUNCTION CHECKS Caution The potentiometers in this machine unlike potentiometers in other machines are a three turn pot Do not attempt to turn past the built in stop or you will destroy the potentiometer Note A bad potentiometer can be detected by looking at the A D Arm Calibration screen where the voltages are displayed As the pot is turned the voltage should increase or decrease steadily If it skips a range s the potentiometer is defective and should be replaced A Gear Assembly Replacement Note The A Potentiometer Adjustment pro cedure is included in the section 1 Unplug the balancer 2 Remove the weight tray and weight tray shield 3 Unplug the arm cable from P7 Inner Arm of the CPU board 4 Loosen the clamp screw and remove the plastic arm housing 5 Disconnect the A pot from the Arm PCB Distance 6 Rotate the arm out so the A gear and set screw are positioned on top 7 Loosen the set screw with an Allen wrench and slide the gear off 8 Loosen the 1 2 retaining nut on the A pot shaft and slide the pot out 9 Reinstall in reverse order Do not completely tighten the set screw in the A gear until the pot is adjusted properly 10 Adjust the A pot with a screw driver or pot tool until it is with in the appropriate range Refer to the ARM CALIBRATION procedures 11 Perform ARM CALIBR

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