0 INTRODUCTION This manual contains the complete instruction for the connections and the calibration, relating the RAV wheel aligner equipment “RAVTD5040WD / 5060WD / 5080WD RAVTD5080WS - RAVTD1760WS/1780WS RAVTD1850WS - RAVTD2200WS” series. Instructions relating to use and maintenance (skilled the final users) are indicated in the specific manual equipped with the equipment. N.B. The RAVTD5040WD model is equipped with the previous SW (version 7.xx), so use this manual to refer only to the connections (Chapter 2). Regarding the installation, calibration and test procedures, refer to the previous instruction.
IMPORTANT! The procedure of “CALIBRATION” is reserved to personnel of technical services centres licensed RAVAGLIOLI S.p.A. s.r.l. for this reason the access is linked by a password. Such password, that must be NOT communicate to other person, is the sequences of keys “F8; F7; F6; F8”.
1 INSTALLATION AND UPDATING OF THE RAV PROGRAM................................................... 2 1.1 Installation.......................................................................................................................................... 2 1.2 Update ................................................................................................................................................ 6 1.3 Setting the logo of the dealer ............................................................................................................. 7
2 CONNECTIONS ................................................................................................................................... 8 2.1 Connecting to the power line ............................................................................................................. 8 2.2 Connecting the measuring heads to the console................................................................................. 8
2.2.1 Combining of the “Bluetooth” heads with the cabinet.................................................................. 10 2.2.2 Linking of the “Wired” heads with the cabinet ............................................................................. 12
2.3 R.M.S. device connection ................................................................................................................ 13 2.4 Electronic Turntables STDA43K connection .................................................................................. 13 2.5 Connection of sensors and internal measuring head devices ........................................................... 14
4 TEST PROCEDURES ........................................................................................................................ 20 4.1 Reading FW release (test for communication)................................................................................. 20 4.2 Reading all angles horizontal/vertical .............................................................................................. 20 4.3 Encoder on turntables Test............................................................................................................... 21 4.4 Encoder on Measuring heads Test ................................................................................................... 21 4.5 Keyboard Test .................................................................................................................................. 22 4.6 Counter of the performed aligner test .............................................................................................. 22
This procedure it takes averagely almost 35 minutes, could requires also some reboot, and also authorization on Win7. It will install: Windows Power Shell; SQL2008 sp1; SW for Smart Card reader; XVid Codec; .NET framework 3.5. and finally the ALIGNER AS9 SW. IMPORTANT: On O.S. Windows 7, it is necessary, before start the SW installation, to set the User Account Control (U.A.C) it must be set as “NEVER NOTIFY”.
Note: The PC not provided from factory (customer supplying) must have the minimum features below indicated: • CPU clock 1,5 GHz; RAM 1 GB;
• HD 80GB
• 4 USB 2.0;
• 2 serial COM port RS232 (or 2 additional USB 2.0 used as RS232 to USB adaptors in case of WD series - see par. 2.2.2)
• Operating System Windows XP or Seven 32 or 64 bit
• Video output 1366x768 Pixels
The Smart card reader is supplied from the factory, must be connected on a USB port
Switch-on the PC and insert the USB key supplied with the aligner kit.
The USB key contains a SETUP Folder, where inside there is a file: SETUP.exe
To run the NORMAL (Not DEMO) Aligner program it is also necessary to copy manually the system configuration and the Smart Card certificate: - Copy manually the “config” file Config_S9RAV001000011.enc from the folder \AS9 to
C:\TMLAB\ALIGNERS9\System\
- Copy also the “security” files Token_S9RAV001000011_975e932f39184095922af79ec1c1ed6b.enc and X509_S9RAV001000011.cer
from the folder \AS9 to C:\TMLAB\ALIGNERS9\Security\
Note: the above filenames are for examples, S9RAV001000011 is the serial number of the smart card where the file is linked. This files are unique and is not possible to copy in another PC for unlock the SW or the Data Bank.
Figure 8
Attention: Before run the Aligner Program it is necessary to reboot again the PC. Then will be necessary in the Aligner program, to set the configuration options and set the Bluetooth or Serial connections. See for details next chapters.
DEMO MODE: In a standard installation, in order to pass from NORMAL mode to DEMO mode (and vice versa), press contemporaneously the keys Ctrl+D. In a Demo installation it is possible to choose any model between all the range, initially appears the above indicated page, select the model and press F4 to continue
Figure 9
1.2 Update
The update software of the RAV Wheel Aligners AS9 series, consists of some files including a SETUP.EXE file. To update the AS9 SW simply made a double click on SETUP.exe If also DATA BANK updating is required, follow the procedure described in the User manual, copying first the Database file from the USB flash disk to the PC and then unlock it using the “Token import” procedure.
In the RAV wheel aligner program there is the possibility to put in the final printout (on the top right side) a picture with the logo of the dealer; the procedure to set it is as follow:
- Create a file representing the logo of the dealer, called “DEALER.PNG” in PNG format (300 x 192 pixel)
- Copy this file in the below indicated folder: C:\TMLAB\ALIGNERS9\PrintTemplate\images
The wheel aligner console must be connected to a 100/240Vac 50/60Hz power line; max power used is 500W. Use the power socket provided, positioned on the rear of the unit. IMPORTANT: The power line is best not disconnected during the night as the measuring heads have to be recharged. For this reason, when the appliance is switched off, the system interrupts power to the PC, to the monitor and to the dedicated electronics, but not to the media or recharge cables.
2.2 Connecting the measuring heads to the console
The console of the wheel aligner “WS” series communicates with the measuring heads
through a Bluetooth device fitted into a USB port of the PC, and the correspondent
Bluetooth modules fitted inside the front heads. These must be combined together as later described. The heads charging are done while the heads are hold on some supports on the console. The supports have DC power 7.4V. See Figure 11. Attention: the + and – poles must be right, check this when put the heads on charging. If the +/- poles are right the battery charge (green led on), if reversed it doesn’t charge. Attention: never charge the battery with AC current (old model had AC current), with AC it seem the battery is correctly charging (green led on), but after some hours it could be damaged.
NOTE: Model TD5080WS it isn’t equipped of charging support but has 4 charging cables as the rear ones of the model “WD” series, see Figure 12.
The console of the wheel aligner series WD communicates with the front measuring heads directly through the cables provided; these must be connected to Serial Ports (or standard RS232 serial to USB adaptors) and linked as later described. Front measuring heads do not feature batteries and consequently these cables also provide power. The charging of rear heads are done while the heads hare connected to the charging cables. See Figure 12. Attention: the + and – poles must be right, check this when put the heads on charging. If the +/- poles are right the battery charge (green led on), if reversed it doesn’t charge. Attention: never charge the battery with AC current (old model had AC current), with AC it seem the battery is correctly charging (green led on), but after some hours it could be damaged.
2.2.1 Combining of the “Bluetooth” heads with the cabinet
If the PC isn’t provided from factory (customer supplying) the front heads must be combined with the PC as below indicated.
The console of wheel aligner series TD5080WS, TD1760/80WS, TD1850WS, TD2200WS,
communicates with the measuring heads through a Bluetooth device fitted into a USB
port of the PC, and the correspondent Bluetooth modules fitted inside the front heads.
The Bluetooth transmission allow to “combine” in a univocal way only a single couple of front heads, leaving protected by the external interferences, and also leaving the
possibility to use many Bluetooth aligners in the same place.
The procedure of “Combining” described in the following pages, is already done in the factory. It is necessary only if the customer provide himself to acquire the PC, or is necessary in case of heads replacing as spare part.
ATTENTION: The Bluetooth USB device (DONGLE) provided from factory DOESN’T NEED any drivers installation! It is enough to insert it in a USB port free; the O.S. Windows automatically will set it.
Starting from the initial page press F2 to enter in the System Menu, then using the keys F2/F3 select the "System configuration" option and confirm by key F4.
Using the keys F2/F3 select the "Bluetooth Search" option and confirm by key F4.
Figure 14
Turn on the front heads, then press the key F5, the Bluetooth searching will start.
Figure 15
On the two windows appears the MAC address of all heads provided with Bluetooth devices founded. The heads set as LEFT are indicated in the left window, the heads set as RIGHT in the right window. If more than 2 heads where founded, select the correct by the F2/F3 keys than press F4 to confirm.
Figure 16
Once the Bluetooth combining is completed, the two Bluetooth icons located in down at right, becomes BLUE. Instead, if the combining isn’t made, (or the front heads are turned off) those icons are GREY. Important: To check the true connections with the measuring heads use the communication test (release FW) described in par. 4.1
2.2.2 Linking of the “Wired” heads with the cabinet
The front heads of the “WD” Aligner (Wired) are linked to the console through two serial cables on two serial COM of the PC. This linking is already done in the factory. If the PC isn’t provided from factory (customer supplying) the front heads wired must be linked with the PC through serial connections as below indicated:
Starting from "System configuration"
option (see Figure 13), press F4, then
using keys F2/F3 select the "Serial Ports Configuration" option and confirm by the key F4.
Figure 18
On the two windows appears the COM available on the PC It is necessary to set the COM Ports where will be linked the LEFT head in the left window, the RIGHT head in the right window. Use the F2/F3 keys than press F4 to confirm.
Figure 19
Once the linking is completed, the two “serial” icons located down at right side, becomes OK. Instead, if the linking isn’t made, those icons are with a “cross” over it.
See example beside.
Figure 20
NOTE: Once the two COM ports are assigned, always use the LEFT cable to LEFT head and RIGHT cable to RIGHT head, reversing such cables, the communication will not possible. Important: To check the true connections with the measuring heads use the communication test (release FW) described in par. 4.1
NOTE 2: If the PC isn’t provided of serial ports, it is possible to use standard RS232 to USB adaptors.
The R.M.S. (REMOTE MEASURING SYSTEM) device can be fitted to all RAV wheel aligner models on PC serial port. If the PC isn’t provided of serial ports, it is possible to use standard RS232 to USB adaptors. The number of serial port used have to be entered in the "System Configuration” settings.
To make the connection, see the installation manual R0075.
2.4 Electronic Turntables STDA43K connection
These turntables communicates with the console through the front Bluetooth measuring heads series “WS”. The connector of the electronic turntable (see Figure 21) must be fitted in the socket on the measuring head. The option "Electronic Turntables" must be entered in the “equipment configuration” setting of the "System Configuration" menu.
Figure 21
Removing the encoder: If the turntable with encoder has to be opened, for instance to replace
the plate balls, the encoder device will have to be removed:
Perform the following operations: - Loosen cable gland “A” - Remove the 3 screws “B” that secure the cover - Remove the 2 screws “C” that secure the board with the angular reader - Remove disc “D” , handling this carefully and trying not to touch its surface; use a 0.9 mm or
0.035 inch socket-head wrench. - The plate can be opened by removing pin “F”, using a 19 mm wrench
2.5 Connection of sensors and internal measuring head devices
The connections inside the measuring heads are already factory made, so the measuring head itself need not be opened, except to replace component parts. It is best however not to remove the measuring head cover; in the event of malfunctions, always contact the manufacturer. If simple maintenance jobs have to be performed however, e.g., changing the battery, care must be taken to return any moved parts to their original position. Below is a short description of the connections of the different boards fitted on the measuring heads, depending on the model.
CPU board Code 18253 - fitted on the following FRONT heads: RAVTD5080WS - RAVTD1760WS - RAVTD1780WS - RAVTD1850WS - RAVTD2200WS
CPU board Code 18293 - fitted on ALL REAR heads and the following FRONT heads: RAVTD5040WD – RAVTD5060WD – RAVTD5080WD (This CPU isn’t equipped with the Bluetooth devices JP310 and Encoder for turntable connector JP305)
Figure 23
JP100A Battery charge or power supply from console lead (from Serial cable connected also on JP301)
JP100 Battery charge or power supply from console lead (from Serial cable connected also on JP301)
JP101 Battery lead (where provided)
JP305 Electronic Turntable encoder lead (only on board 18253 where provided)
JP301 Data connection to console lead
JP401 Alignment CCD signal cable
JP402 Toe CCD signal cable
JP310 Bluetooth device (only on board 18253 where provided)
JP203 Led indicators for tolerance and level cable (where provided)
JP309 Electronic encoder for shaft (where provided)
The measuring heads of the RAV wheel aligner are already factory set; moreover, the calibration settings are stored in the CPU memory of the measuring head itself. At the time of installation or changing a measuring head, the appliance does not therefore require data calibration or configuration. Calibration is only required if the transducers are changed or following ascertained repeated errors due to transducer movement (as a result of falls, knocks, etc.). Use the following calibration systems depending on the models provided:
1) STA14 calibration system
Figure 24
2) STA14T transportable calibration system
Figure 25
Key Figure 24, Figure 25
A) Knobs for fastening the measuring heads B) Level C) Standard calibration stand D) 3° thickness for standard calibration stand E) Transportable calibration stand F) 3° thickness for transportable calibration stand
Starting from the initial page of the program, using the key F2/F3 select the "Additional features" option and confirm by key F4.
Figure 26
Using the key F2/F3 select the "Calibration" option and confirm by key F4. Enter the required password to access the calibration phase: “F8; F7; F6; F8”
Figure 27
Using the key F2/F3, select the "Measuring Head" calibration option and confirm by means of key F4.
Figure 28
If required press F3 to enter the serial number for the sensor heads so the report eventually printed out will report such numbers. Enter eventually also the serial number of tool and operator name. Proceed confirming by key F4.
The angles calibrated are pointed out by the following marks, (see Figure 30)
Figure 30
All models except TD5040WD Calibration of the measuring heads is split into 8 stages, described in detail, including graphically, in the calibration program.
In stages 1 and 2, the front and rear left hand measuring heads are fitted and the Left Alignment and Level angles are calibrated (AFL, ARL, LFL, LRL)
In stages 3 and 4, the front and rear right hand measuring heads are fitted and the Right Alignment and Level angles are calibrated (AFR, ARR, LFR, LRR)
In stages 5 and 6 the front left hand and front right hand measuring heads are fitted and the Front Toe-in and Camber angles are calibrated (TFL, TFR, CFL, CFR)
In stages 7 and 8 the rear left hand and rear right hand measuring heads are fitted and the Rear Toe-in and Camber angles are calibrated (TRL, TRR, CRL, CRR)
When are calibrated the rear sensors for ALL models (step 7/8), it is necessary put Front sensors in correspondence, in order that the data transmission to the cabinet pass through these ones.
If the Aligner is a 6 CCD system (TD5060WD or TD1760WS), in step 7/8, it is necessary to press the key F2 in order to disable the TRL/TRR calibration (these sensors are unprovided of TRL/TRR). The related displays will disappears.
Figure 31
Legend of the Figure 31:
1 - Measuring heads on actual calibration step 2 - Actual calibration step 3 - Calibration steps already acquired 4 - Angles calibrated in this step with tolerance reading 5 - Value of the angle actually reading 6 - Graphic description of the measuring heads positioning on the calibration stand 7- Keys used to put into execution the calibration step (F5 or the central key on the
measuring head); It is displayed or blinks when it possible to press it
Press F5 to establish the new calibration and press F4 to proceed step by step. ATTENTION: The sensors of the WIRED models (WD) have to be connected only if front (the transmission of rear ones pass through the front ones). The sensors of the WIRELESS models (WS) have NOT never be connected.
The first option of the calibration menu (see Figure 28), is used in order to adjust the caster angles readings caused by eventual “out of level” of the vehicle in longitudinal direction. This could happens, for example, when the lift groove of the turntables, have a differently height than the turntables height. It is necessary set, simply by the key F2 and F3, the difference between the front wheel height and the rear wheel height (see Figure 33).
The system will automatically adjust the caster reading, considering this difference relating it with a standard wheel base of the vehicle.
Figure 33
3.3 Steering Self calibration procedure
If the measuring heads are not perfectly calibrated could happen that after the adjustment of the vehicle, on the road, it will result with the steering wheel not in the straight position. The second option of the calibration menu (see Figure 28), is used in order to adjust the position of the steering wheel. It is necessary set, simply by the key F2 and F3, the position how become actually the steering wheel (see Figure 34).
The system automatically adjust the reading values in order to obtain a position straight of the steering wheel.
4 TEST PROCEDURES By means of the TEST procedure program it is possible to verify the correct working of all the devices present in the wheel aligner system. It is necessary select the TEST procedure menu as follows: In the initial logo page press simultaneously the key CTRL - F2, will appear the display page of Figure 35.
Figure 35
4.1 Reading FW release (test for communication)
On the screen are displayed all the FW version from measuring heads; It is possible by this test verify the correct working of the communication between rear to front sensors and from front sensors to console Press the key F1 to exit
Figure 36
4.2 Reading all angles horizontal/vertical
This test consist of display all the angle angles readings from the measuring heads; they are divided into 5 groups as follows:
1- Alignment angles (see Figure 38); 2- Toe-in angles; 3- Level and camber of front heads 4- Level and camber of rear heads 5- All levels with tolerance indicators
By pressing the key F5 were displayed a picture that is a graphically representation of all the angles initials (see Figure 30). Press F1 to exit
Figure 38
4.3 Encoder on turntables Test
On the screen are displayed the readings of the angular transducer (encoder) mounted below the turntables (available only with models WS) It is possible by this test verify the correct working of the encoders simply turning the upper plate and check that the value displayed correspond to the real angle carried out (see Figure 39). The F5 key is used to set to zero the value displayed on the screen. Press the key F1 to exit
Figure 39
4.4 Encoder on Measuring heads Test
On the screen are displayed the readings of the angular transducer (encoder) mounted on the measuring heads (where provided). It is possible by this test verify the correct working of the encoders simply turning the shaft of the measuring head and check that the value displayed correspond to the real angle carried out (see Figure 40). The F5 key is used to set to zero the value displayed on the screen. Press the key F1 to exit
On the screen is displayed a representation of the measuring heads keyboards; if a key were pressed again and again, the one linked on the screen will become of the his real colour an will return uncoloured again; (see Figure 41). Press the key F1 on the PC keyboard to exit.
Figure 41
4.6 Counter of the performed aligner test
In the initial logo page, press simultaneously the key CTRL-F12, will appear the counter display page (see Figure 42). The meanings is as follow: DC = Vehicles where Diagnosed Counter RC = Vehicles where Regulated Counter SC = Vehicles where Saved Counter NOTE: The counter is still increased also after a SW update. NOTE 2: Pressing the F2 keys a “Log” file is saved into a USB key as filename#.log in a “AS9” folder.
