Hofmann Megaplan GmbH 3D Wheel Aligner megaline...

Hofmann Megaplan GmbH

3D Wheel Aligner megaline SSENCEmegaline SSENCEmegaline SSENCEmegaline SSENCE

Service manual

Due to intellectual property rights. some features are not available in some countries. Some items shown in this manual are options.

Hofmann Megaplan GmbH

Hauptstraße 67

5302 Henndorf am Wallersee

Austria

Tel: +43 6214 - 64 66 12 • Fax: +43 6214 - 64 66 22

[email protected] • www. hofmann-megaplan.com

25.02.2015

Hofmann Megaplan Service Manual megaline SSENCE

SSENCE 400/600 Page 1 of 52

1.0 Maintenance

1.1 Regular maintenance of Aligner 4

1.2 Regular maintenance of computer 4

1.3 Maintenance of screen, system cameras and targets 4

1.4 Site selection 4

2.0 Repair of the aligner

2.1 Targets

2.1.1 Exchange of targets - mechanical part (all models) 5

2.1.2 Exchange of targets - electronically data (all models) 6

2.1.3 Loose of target files 6

2.2 Camera bar

2.2.1 Components of power supply for camera and motor 7

2.2.2 Exchange of motor controller (400M and 600) 8

2.2.3 Adjustment of motor controller (400M and 600) 9

2.2 4 Exchange of the steel rope of the camera bar (400 u. 600) 10

2.2.5 Camera bar runs over limiter switch 11

2.2.6 Exchange of limiter switch 12

2.2.7 Failure / wrong signals of the LED ring 12

2.3 Exchange of camera and camera chips

2.3.1 Check before changing the camera module 14

2.3.2 Change camera module 14

2.3.3 Possible failure of camera module 15

2.3.4 Possible failure of camera chips 16

2.3.5 Adjustment of camera chip by software 16

2.4 Different camera modules and LED IR panel

2.4.1 Different versions 18

2.4.1 Test and exchange IR-LEDs 18



3.0 Possible problems and failures

3.1 Increase of accuracy 19

3.2 Flare and reflections 19

3.3 Light influence from outside 20

3.4 Jumping values 20

3.5 USB interfaces for camera 21

3.6 Bad reflections of the targets (Car icon) 21

3.7 Prepare CAMBER corrections 22

3.8 Correction of CAMBER values in the configuration file 22

3.9 Machine is very slow and freezes in some positions. 23

3.10 Earth of the machine. 24

4.0 Handling of machines and software

4.1 Activation code required. 25

4.1.1 Activation code not accepted after system restart 26

4.2 Data base handling and Hardware lock (Dongle) 27

4.3 Calibration data 29

4.4 Backup of collected alignments, customized cars and user data 29

4.5 Garage data 30

4.6 Faulty power supply of the USB-ports 30

4.7 Printer installation 31

4.8 Resolution of the screen 31

4.9 Hardware of aligner in Device Manager 31

4.10 Camera picture is grey, blurring or complete white (F11) 31

4.11 ERROR USB CONNECTION while starting 32

4.12 Numbers close to the car icon in the bottom of the screen 32

4.23 Camera View [F11] 33

4.14 Values for exposure of the camera 33

5.0 Error Messages

5.1 Error messages 35

5.2 Internet connection 35



6.0 Miscellaneous

6.1 Information for service technicians 39

6.2 Explanation of serial number 39

6.3 Software updates 40

6.4 Team Viewer Support (Remote session) 41

6.5 Clamps - Size and technical drawing 42

6.6 Switch from Automatic to Manual (Camera bar) 43

6.7 Install shielded USB cables. 44

6.8 Install ANDROID remote control 46

6.9 Exchange of personal computer 49

Autodata Copyrights 51

Windows®, Android®, AutoData® and SSENCE® are registered trademarks- ©©©© Hofmann Megaplan GmbH 2014 HP



1.0 Maintenance 1.1 Regular maintenance of Aligner

Like every precise machine the aligner should have a continuous maintenance. For this reason at least once a year a service is recommended. The following tasks must be performed: - Check the rope on the horizontal bar for damage and tight fit - Check the pulleys (fixing, wear, lubrication) - Check treads of the camera bar, add some silicone grease if necessary - Check targets and brackets for damage and cleanliness. - Check the fastening of the camera bar (4 nuts) - Check operation of limiter switches - - Check the grounding of the device. - Check the IR-LEDs close to the cameras - Check the rotation plates. - Clean if necessary - If necessary computer maintenance (see below)

1.2 Regular maintenance of Computer

The computer itself usually do not need any special maintenance. But there is a lot of dust and dirt in the garage, so please take care, that the ventilation slots of the housing and the fan of the power supply are free of dust. If necessary, switch off the computer clean the ventilation slots with a vacuum cleaner. While using the aligner please take care that the ventilation slots are not covered.

1.3 Maintenance of screen targets, and cameras

Also the screen can have dusty ventilation slots, so please clean with smooth air pressure from time to time. Clear screen, targets and with a mild detergent. If camera is dusty clean with smooth air pressure or take a brush. To clean camera lens take pure water and a microfiber cloth. Targets are very sensitive against pollution, for this reason it is recommended to clean them every week.

1.4 Site selection and distances

- Be careful during selection of the location, that as little extraneous light from behind the targets is entering the camera (no open doors, large windows, etc). - Installation or storage of the targets not next to strong heat sources. - Distances from the aligner:

• From Camera to front target 2.05m up to 2,85m • From camera to rear target: max. 7,5m • Distance between columns of the lift :2,70m



2.0 Repair of the aligner

2.1 Targets

2.1.1 Exchange of Targets - mechanical part (all models)

After the damage of a target is is necessary to exchange the part. New target will be delvered complete, so the exchange is very simple. All important parts are fixed by seeger rings To exchange target it is necessary to build out one rod of the clamp. Dismount like this: - Unscrew fixing crew (1) on one side. If there is a Allen screw on the other side remove this also. - Remove Seeger rings of one side of the rods - Move rod until the nut is to reach with the wrench(2). - Exchange targets. - mount in opposite direction.



2.1.2 Exchange of targets - electronically data ( all models) With each new target (spare part or basic delivery) a file with basic calibration data is delivered from the factory. (see also 2.1.3) If you replace the target the new file must be saved assigned to the position on the car. Each Target has a unique position on the car. There are four files assigned to the targets in this position: Target_Data_0.yml = Target front left Target_Data_1.yml = Target front right Target_Data_2.yml = Target rear left Target_Data_3.yml = Target rear right This files must be in folder D:/SSENCE. The data are ready to use, just rename the target file to the target name on the car's place. (see table)

Save the files assigning to the position on the car . It is not necessary to make a calibration, because targets are calibrated in the factory with standard clamps.

2.1.3 Loose of the target files: Please send target ID number to Hofmann Megaplan GmbH.

Target ID Number. Distance value (necessary in the factory- part of the target calibration file) We send you the associated file.

If there is a suspicion that the clamps are deforme d, please perform a target calibration. (no camera calibration required)



2.2 Camera bar

2.2.1 Components of power supply for camera and m otor

old version

new version

According to the location of the installation: 1. Motor controller (controller of step motor.) 2. Switch pad (connector between modules- switches the contacts of connection to bridge board) 3. Bridge board ( connector for automatic/manual motor operation ) 4. Power supply 60V 6,6A for motor 5. Power supply 5V/12V for camera, LEDs and camera control board



2.2.2 Exchange of motor controller (400M and 600) This part controls the speed of the motor on top of vertical bar.

- The motor controller is below the iron cover inside of the cabinet (if you look from behind). - If in your machine is a motor controller with a red DIP block is installed, please exchange that

controller to one with the blue block. The red one sometimes did not catch the correct place between two steps so the motor was buzzing.

- While camera bar is not moving, and motor is buzzing. You can quit that by starting SSENCE, press [F11] (Camera view) and move bar by cursor. Exchange motor controller after this temporary fixing.

- If there are one or two red LEDs lighting up during operation. Exchange motor controller.

Please take care of the right position of the DIP switches. (see next chapter)

In normal operation, only one green LED lights up ( L1). If you see red LEDs while operating, exchange the controller. Newer ver sion got a blue DIP switch block.



2.2.3 Adjustment of motor controller (400M and 60 0) - Camera bar is to fast or too slow: on the backside of the controller is a table that shows all

positions of the DIP switches. If the motor (and within the camera bar) is too fast or too slow please check the DIP switches on the motor controller DIP switch must be like this: 1 1 0 0 1 0 1 SW1 OFF regular mode SW2 ON SW3 ON SW4 OFF SW5 OFF 16 Microsteps SW6 ON SW7 OFF SW8 ON amperage 3 Amp.

If the motor is very loud and rough check the adjus tments of the DIP switches.



2.2.4 Exchange of the steel rope of camera bar (400 and 600)

The camera bar of the SSENCE 400/600 is moved by a stepper motor (600 and 400M) or manually (400) in height. In the status column, a heavy counterweight (ca. 28kg), representing the compensation for the weight of the camera bar. In all devices the same steel cable is built in to move the bar.

The steel cable must be checked at every service of the machine. Please also appeal to the end user to call the service if the c able is damaged. A tear rope can cause significant damage and / or injury.

There are two variations of the rope: -Connection with threat bolt - Material regular steel ATTENTION!!! URGENTLY EXCHANGE THIS CABLE !!! -Connection with adapters - Material stainless steel

2x Adapter

(Ab 01/2013 in all maschines.)

Exchange of the rope - unscrew and lay down the vertical bar. (Be sure that it will not slip away) - Dismount cover of the motor (400M and 600) or of the deflection roller (400) - Move camera bar in upper position - dismount rope - Dismount motor or deflection roller - pull out the counterweight with the rope- dismount old rope. - screw the adapter pieces into counterweight and horizontal bar. (at least 8 rotations and fix it

with the counter nut). - connect rope and adapters with delivered screws. - Build in motor or deflection roller, push camera bar to the bottom of vertical bar. - Take care that the rope is correct on the pulley. - Please lift the horizontal bar slowly (because of the counterweight). - Fix it on the floor again



2.2.5 Camera bar runs over the limiter switch (40 0M and 600): The way of the camera bar is restricted by two metal sensors on top and bottom.

These are triggered by an attached piece of metal on the side of the camera bar.

The function can be tested easily if you hold a wrench in front of the sensors. The camera bar must stop immediately. (Red LED burning) If this is not the case, check connector of the switch. If this is OK change the part. If something was changed in the machine or after new installation it can be, that the cables are mixed up or not connected.

Normally the upper switch interrupts the upward

movement, the lower switch breaks the downward

motion of the camera bar. If the cables are mixed

up, the upward movement is reacting to the lower

switch and vice versa.

Check if connectors are OK and exchange the

plugs from 10 and 20

The movement of camera bar is also wrong if the cab le between bridge- and connect board is connected wrong. If all the limite r switches seem OK, please try this.. (see also page 7)



2.2.6 Exchange of limiter switch (400M and 600) Both cables for the limiter switch are inside the vertical column. To exchange one of the switches the column must be dismounted: - Lay down column and remove the support on bottom side. Now you can see the three plugs

of the motor connect cable. - Unscrew defective limiter switch and remove the silicone cap. - Unplug the connector of the defective limiter switch. (must be a three pin connector) - When the upper switch is defective, install a cord to the plug, and pull out the cable with cord .

With the cord you can install the new switch more easily. - After exchange and connect the switch, switch on machine (without computer) and test

function of the switch with a wrench or a screwdriver or another piece of iron. (red LED must flash)

- If this is OK please mount back the support and test function with software.

2.2.7 Failure/wrong signals of the LED rings The function of the LED ring is pending on: - IR-LED board - Cable - LED ring Please check cable no. 8 (or 7 for left side) for break. (Flat cable). Plug and unplug the connectors of the cable a few times in order to avoid poor contact to the LED rings or to the control board The LEDs located on the ring can be tested for function using a diode tester (or also a buzzer). Please note that the LED (as a purebred diode) passes electricity flow only in one direction. So please check in both directions. If there is no result and everything seems fine, it may be that the control board (Art.No.650 220) is defect.



Old and new version of LED-ring: On the left side there is the old version of the LED ring. The new one on right side. Both are exchangeable, cable is fitting on both. If connecting the new ring please take care that the red marked wire is placed to pin no. 1. (see marked item)



2.3 Exchange of camera and camera chip

2.3.1 Check before change the camera The replacement of a system camera is a deeper engagement with the inner workings of the aligner, and is performed only when the camera is actually defective and must be replaced. The complete camera consists of two main components: - Camera module with housing - Camera chip on backside of the camera (screwed and glued (lock))

Before exchanging the camera urgently check if the camera chip is the reason for the fault. 95% of all failures of the camera ar e due to a defective camera chip..

2.3.2 Change camera module: - Be sure that there is no static electricity. - Earth yourself - Before exchanging the camera module, unplug the old camera and plug the new, already not mounted camera, start aligner and check with [F11] the function of the new camera.

- Camera modules are screwed and fixed with glue. Be sure that the new camera module is placed in exact the same position.

- Together with the camera it is urgently necessary to exchange the camera file . This is usually delivered with the camera. If there is no camera file, please contact Hofmann Megaplan.

- After change of camera module in any case a calibration must be done. (See separate manual for calibration)(Not if only the camera chip was changed. !!!!) - Be sure to place the camera in right direction. - Check how many coated surfaces are in front of the lens. (please see also page 18)

2.3.3 Possible failure of camera module - Windows does not recognize the camera although it is mounted correct. (device manager) Seriously, up to now this is the only reason to diagnose a broken camera. All other problems with the camera are pending on the camera chip. But also this can be caused by the camera chip, because the only connector of the camera is on the chip. So please change the camera chip first in any case and check again. If only the chip is changed there is no calibration necessary. If you unscrew the camera for any reason a calibration must be performed.



2.3.4 Possible failure of camera chip: It seems that we had broken camera modules, in this condition the modules showed incorrect values in the configuration file CONFIG.INI laying in D:\SSENCE In the file are values for the cameras:

< This files shows correct values: This file has abnormal high values. >

If these values are shown camera is black. The came ra-chips are not configured well. Please adjust chips ID left to 0 and ID right to 2. Restart complete machine. (not only computer) (see 2.3.5) If this is not working try 1 for left and 2 for right and leave the machine switched off for 5 Minutes. (to decrease po ssible static electricity.)

- There is a black picture on the screen (F11) Adjusting exposure without result. - Picture is "foggy", or worse resolution as on the other side- - Bluring lines on screen (please clean camera lens before to check) - Different colour (sepia) - Windows does not recognize the camera although it is mounted correct. (device manager)

The camera housing with support . On the back of the camera, the control chip is mounted (on the board). On the front side of the camera is a sticker which-reflects the programming of the camera chip, "L" is the camera is set to the left side of the camera. ("R" for right) This default setting can be changed by a program tool.



2.3.5 Adjustment of camera chip by software

This software is used to adjust the respective side of the camera chip. The program tool for setting the camera chip can be fou nd on the homepage of Hofmann Megaplan.

Installation of the software:

- Create a folder with a meaningful name. - Download the software: "Camera chip Installation" from the Homepage - Extract the ZIP-file into the new folder

- change into that folder - you see:

Usage of the software - Double click at program "Cameraupdate.exe" to execute.

What you see now is: ◄ selected camera ◄ Firmware update (Don't use it.

This program is used also for other aligners, but this is not necessary for SSENCE)

◄ Select side on left and

modify the selected camera

◄ Erase firmware! Attention! Do not use it !!!



Selection of the camera - The software can manage more cameras. The details of the cameras in the Windows

Device Manager are not unique, so it can not be determined which camera is on which side. To be sure that you get the correct camera please follow that steps:

- Start SSENCE software; press [F11] to get the camera view. The USB-plugs 2 and 3 on the

backside of the computer are linked to the left and right camera. While camera view is running unplug one camera and see which picture is switched off. Test with your hand in front of the left camera which of both cameras is switched off. If the hand is to see, the left camera is active. Maybe the left hand is to see on the right side camera.

- Now the configuration of camera can begin.

In camera select now there is only one camera visible.

Select camera side by "Modify Serial": 1 = left side (in front of aligner, looking at the monitor) Press "Modify" to change initialisation of camera. Unplug first camera, plug the second camera and define it in the same way. 2 = right side (in front of aligner, looking at the monitor) Press "Modify" to change initialisation of camera. Plug both cameras, there should be at the right place in the camera view. [F11] If only chip was changed, no calibration is necessary. If a camera was changed do the camera calibration. (See own manual - SSENCE calibrations)



2.4 Cameras and IR-LED Panel

2.4.1 Different versions In the course of product development since 01.07.2013 is a modified camera, in which the reflection filter is applied directly to the camera lens. Both types of cameras are shown here. .

Old camera New camera also the disc with the LEDs was changed. old style with filter new style without filter Both types of the camera can be mixed, they are compatible. The only thing you have to take care is that never two filters are used together. If you change to a camera with included filter please remove the filter on the ID LED disk. (fixed with hot glue)

2.4.2 Test and exchange IR-LEDs The Infrared LEDs simply can be checked with a digital camera. Through camera the LED shines in white. Here in the picture you can see broken LED's, but the quantity of broken LEDs does not have an influence to the function of the aligner. If it is nearly dark the aligner can work with one (!) LED. That means, that a 50% fail of the LEDs still always brings a good result, if there is not much sunlight around the aligner. If more than 50% of the LEDs are broken, please exchange the LED-ring.



3.0 Possible problems and failures

3.1 Increase of accuracy Aligners are calibrated at the factory on special equipment. In some cases, performing the camera calibration brings an improvement in the measured values. Reason for that can be during the transport of the unit. If there are bad or implausible values, a camera calibration should be done. The camera calibration can be carried out on the ground or on a straight lift. If you are not sure please contact Hofmann Megaplan..

Urgently take care that the calibrations bar is mou nted like shown in the manual for this device. According to the calibration urgen tly take care that there are no reflections come inside the camera during calibrati on. (check with [F11])

3.2 Scattered light and reflection Scattered light and reflections can significantly impair or even prevent the functionality of the aligner. Reflections occur when intense solar radiation meets the camera during the measurement. . - The working speed of the aligner decreases and the computer needs more time to filter the bad

values coming from the camera. - There can be jumping values. - Faults while measurement can happen or values do no make sense. Reflections occur at unfavorable shiny surfaces. Mostly the coatings of the vehicles are the reason for that. If the aligner does not respond correctly or work very slowly, always make a test with F11 (camera control).

In this case the target is reflecting in the surface of the vehicle. The result of this measurement is sure wrong. Jumping values and a very slow working speed is the result because the software must filter all the signals

-

What can you do? Cover the car with a blanket or stick some newspaper on the sides of the car. Check results with [F11] on the screen.

There should be no light irritations otherwise the aligner has problems with calculation. You can: Darken room, workshop doors s hoot, cover reflective



surface of vehicle.

3.3 Light influence from outside Another reason for not reliable measuring results can be strong light sources close to the camera. Common error is an open door or light from outside. This light directly hits the cameras from the aligner. To avoid this, please close the door while measurement or darken the room. The software automatically controls the exposure of the cameras as needed for front and rear targets. When the ambient light that hits the front and rear view mirror, is the same, the software needed to make only one image to the complete evaluation. The evaluation is faster. When the ambient light that hits the front and rear-view mirror is different, the camera must take more pictures on the front and back with different exposures. (This is the reason for the "flicker", which sometimes happens in the camera view.) This process takes more time, the evaluation is slower. That is the reason why different lights on front and rear targets should be avoided.

3.4 Jumping values The values are not static, It is normal that they jump on the display, if they stand between two numbers, so don't care about 2 or 3 minutes. A bigger change of values also can be the influence of extraneous light. Check the following points: - the following entry in the config.ini in the directory D:\ ssence:

- if targets are clean targets (check with small car icon in the middle of the screen) - No lights from outside - No reflection light from blank chassis of the vehicle (Check with [F11])) - Be sure to have a good earth on the machine (especially camera bar)



3.5 USB Interface for cameras If cameras fail, the first check is to look in the device manager of Windows system control center. For the aligner there must be:

3.6 Bad reflection of targets (car icon in the mid dle) The software shows a little car icon in the middle of the screen (bottom). If you cross the icon with the mouse, values for target reflection are shown.

Red tire - Connection to this tire is broken. Please remove blocking obstacles or lift camera bar that all targets are full visible in the camera view [F11]. - There are more than two targets visible in the camera view. (Reflection on the surface on the car!)

Blue tire, number shows more than 100

- Bad Reflection, Clean targets, Eliminate turbidity of the targets

Blue tire, number below 100 - Values OK, software can work without problems.

Both cameras (CatchBEST) and the Camera

control board (Silabs) must be visible in the device

manager. If this is not the case, check the USB

ports on backside of the computer and on the

camera control board under the horizontal bar. Be

sure that the cables are OK. Plug and unplug the

USB ports and check what happens in the device

manager.

Check also output voltage of both (or the single

(400)) power supply. (see also 4.6)



3.7 CAMBER corrections In some cases it is necessary to make a CAMBER correction after the calibration. This fine adjustment will be done in the factory. Only camber need to be adjusted.

For any case save the calibration data of the machine to a new folder Target data

Camera data

Stored on the harddisk on drive D: are also the factory settings of the calibration data. They are stored in the folder with the serial numbers name.

Before you make corrections in the CONFIG.INI file please first copy these data in the folder D:/SSENCE. Do a test alignment before .

3.8 Correction of CAMBER values in the configurat ion file If at a wheel alignment the camber values are displayed consistently wrong, there is the possibility to set an advance correction in the file d:\ssence\config.ini. In this file you will find these entries.

Front Left camber

Fron Right camber

Back Left camber

Back Right camber

Values are specified in 1/100 decimal units . The value of 20 corrects the pre setting of the tyre to 20/100 units positive. It is also possible to add negative values. After change and save restart the alignment software.



3.9 Machine is very slow and freezes at some posit ions

Data transfer between target and camera If the machine is very slow and freezing especially when doing the push-pull or the caster swing, one reason can be the data transfer between camera and targets.

- First switch on the camera view [F11] and check the targets on the screen are clear and complete visible. - Check surface of the targets - also check numbers of the dummy Icon (see chapter 3.6) Check earth of the machine and build in earth cabl e

Take a multimeter with a buzzer. Switch on multimeter and unplug the power chord from the wall. Check connection from the earth pin of the power plug to every metal part of the machine. There must be connection everywhere. (see chapter 3.10)

Check USB cable shield Open the black box on the backside of the machine. There you see the camera control board. Please check the connection of the USB cable on Camera Control-Board. (silabs) If USB port for Silabs board (cable no. 1) is not plugged on the shielded connector do the following: - Check camera chip if it has the same shielded USB connector. If not, change both camera chips.

(see chapter 3.11) - Change USB.camera cable to the PC - Change USB cable to both camera chips (see chapter 6.7)



3.10 Earth of aligner The SSENCE aligner urgently need a correct earth to work perfect. All the new models coming after January 2015 do have a better and correct connected earth included in the cabinet. If there are problems with the older machines (black cameras, freezing of screen or extensive slow working operations), one reason for this can be a bad earth connection. The machine urgently needs an update of the earth connection. If it is not sure if there is a good earth over the 220v power chord: - use the delivered earth pin and connect on the earth screw on outside the housing, or - connect earth to a heater or water tube. If it is sure that the 220V power chord is earthed: - the connection between earth connector and power chord must be done inside the machine: How to install the earth connector. The easiest way to mount the system-earth is to connect the DMI-filter that is included in the system. Test if internal earth connection is OK Please open the filter. Prepare a earth cable with two ring connectors,(1) and connect it on the screw where filter is fixed in the black housing. (2). Then cut al little slot in both sides of the housing (3, 4) close cover again and connect the cable to the earth screw of the housing. (5)

1 2 3 4 5

Close cover of the filter and connect it again on the power and the earth screw in the machine. Check earth connection again.



4.0 Handling of machines and software

4.1 Request of Activation Code The Activation Code is on one side a security of the software on the other side it makes sure that the correct components are together in one machine. Also if some basic components are changed, the machine requires a new code.

Activation code is associated to: - 2 Camera IDs - ID of the main board If the code is reqested, mark the text and save it in a notepad file. Send this file to:

[email protected] We are looking for fastest return of the USER ID. As soon as you got it please open the text file mark the text, copy and paste it ot the screen.

After software restart the aligner is working normal.

Urgently take care, that all boxes of the aligner h ave the same serial number. If there is a wrong box, the machine requires a new co de because of different cameras in the software registration. To open the window with the licence key during normal work, go to the SETUP-menu and then:



4.1.1 Activation code not accepted after restart s ystem.

(This is probably if you use a software before 14.02.0701, if you use a later version this chapter can be ignored) If you use a USB network adapter to make a remote session, it can be that the SSENCE software recognizes two network adapters in the device manager. (here Vodafon)

If you use this remote session to give the system a new activation code it can be that the aligner software does not accept this code after restarting system. The code of the older software was pending on the network adapter. If there are two of them it can be that the software is linking the activation code with the wrong adapter. Only solution for this: Make an update to the latest version that is valid for your dongle. See homepage www.hofmann-megaplan.com

If you use the old software and a Team Viewer sessi on with us to register software , you have to take the basic code before t he remote session is started.



4.2 Data base handling and Hardware lock (Dongle) The SSENCE base program will be delivered with a sample database (sample.mdb). This is not an encrypted database. After that the database packages can be installed: Database for Europe: Autodata ® and special cars (Italian sports cars) Database for Russia Russian DB und Autodata ® and special cars Database for South Africa SA Database, Japan, Autodata® and special cars Database for USA and Arabia USA , Autodata ® and special cars Database for Japan Japan, Autodata ® and special cars These data bases are encrypted and can only be used together with the dongle and SSENCE aligner software. It is also not possible to open databases with a special program outside SSENCE. Driver for Dongle The hardware lock (Dongle) urgently requires a driver that usually is installed in the factory. If, for any reason, the driver is missing, it can be downloaded from the Hofmann Megaplan homepage.

If the driver is not present or not correct installed, the following error message appears:

Please install driver and plug the dongle on a USB-port. For testing if the dongle is working correct and driver is installed properly please run the following test program:



If the dongle lost the sticker to identify the number of database do the following: Sentinel controll function: - Open your browser on the machine. - Tye in address: http://localhost:1947 - it appears

A click on Sentinel Keys shows the current status.

A click on Features shows information of the dongle

Here you can see : - If dongle is present - which year of database will be supported * Feature 3 is Database 2013 * Feature 4 is Database 2014



4.3 Calibration data Calibration data of the machine are the following: Target data:

Camera data

These data are stored in D:/SSENCE and are urgently necessary to execute the program. Each machine is pre calibrated in manufacturers company. A backup of these important files is stored in D:/ in a folder names with serial number. Please do not erase this folder.

If calibration data are lost for any reason, please send us the serial number of the complete system. We have a backup of all the ca mera- and target files here, so we can send you the original files coming from t he factory. After restoring of the data it is not necessary to make a calibration of the machine.

4.4 Backup of collected alignments, customized car s and user data

There is no particular data backup included in the program. Basic alignment program and database can be installed again within a few minutes over the internet. There is only one file in the system where all the user data are included: - customized cars (added by user) - all saved alignments - all data of the users customer. All these data are stored in one database. This is stored in: D:/SSENCE/DB/H3D.MDB We recommend to make a regular backup on a USB-stick.



4.5 Garage data

Garage data can be entered under setup Workshop data

Here only text can be added. This appears in the print out as table or graph. If the text is not shown in the printout check if there are special letters included. If so select another name.

4.6 Faulty power supply of the USB ports

In the device manager you can check if all necessary parts are available. For the aligner this is:

If the devices are not shown correct in the device

manager, next possibility for a fault can be the

power supplies. Please check that with a

multimeter Please check the smaller power

supply to the specified voltages under load. If

nothing found, try a new power supply because

power supplies generally sometimes tend to

provide the correct values without load, but drop

in power loss in the power output.

L N 220V Input

Ground

Measuring result

between COM and V2: 11.5Volt

between COM and V1: 5Volt

If these values are too low, camera and control

board will fail because the power for this devices

is coming from this power supply.



4.7 Printer Installation SSENCE is a normal windows program and basically works with every printer that is recognized by the system. It can be that special printer drivers from the printers manufacturer not always work with SSENCE. If there are problems to print the form of the alignment please try another printer driver or a compatible windows PDF printing device. The PDF printer generates a file that can be printed by the PDF reader. In this case it is also necessary to install a PDF reader. If the aligner has LAN connection, also a network printing device can be used.

If there is only a white paper while printing pleas e check the entry of the workshop data. Aviod symbols and special letters.

4.8 Screen resolution

The standard resolution of the SSENCE aligner is 1366x768 (small HD) If it is not possible to install this resolution , please run special software delivered with VGA device to add customized resolution.

4.9 Hardware of aligner in device manager Additional to the standard Windows devices the aligner places three additional devices inthe system: Both cameras

and the camera controll board

These devices are urgently necessary, if they are missing, the aligner can not work. If there are unknown devices after plug in the camera, load driver of the parts from D:\SSENCE\DRIVERS. If there are problems with installing the drivers, unplug all USB ports from camera and control board and restart Windows. After the start plug one device after the other and see what happens.

4.10 Camera picture is grey, blurring or complete white (F11)

The camera view can be activated with [F11]. Usually picture is shown black-white, a target in the camera will be shown in a high contrast to the background. If the picture is grey or showing bad contrast, try to adust values of the camera. If this is not possible or has no influence to the picture you see, the camera chip or camera itself is damaged. In 95% of all cases the camera chip on the backside of the camera module is broken. If so, please go on with -- 2.3 Exchange of a camera module



4.11 ERROR USB CONNECTION while starting - Check all connections on the backside of PC., - Check connections on the camera conroll board

- Check power supply (chapter 4.6) - Check entries in the device manager and check for correct driver (chapter 4.9) - Change camera control board.

4.12 Numbers close to car ICON in the middle of th e screen. The little icon shows values for reflection (See also Point 3.6)

- The smaller the value the better - If values are over 100 the reflection of the targets is too bad.

• Clean targets. • Remove foreign bodies. • User smooth cleaner for targets. Take care that cleaning fluid will no come between glass

and measuring dots. Due to the increased reflectance values occur sometimes substantial delays in the processing time of the machine. Is a red wheel as shown here, the contact between the target and the camera is faulty.



4.13 Camera view [F11] The picture that comes through the camera is responsible for accuracy, speed and function of the aligner. So please urgently take care for:

• No strange lights from the backside of the machine should come in the camera. If necessary use a curtain behind the car.

• Targets must be clean. • No reflection in the surface of the car (please cover if necessary) • There is no clouding of the lens

• Lift must be big enough (Difference of posts more than 2,70m -- !! not smaller) • No obstacles between the target and cameras. • Car is centred on the lift. • Targets are mounted correct and do not cover. This all can be checked with [F11]. Any disturbance slows or hinders the measurement.

4.14 Values for exposure of the camera

Strange lights, reflection and direct sunlight can have influence to the speed of the aligner. The cameras are very sensitive, so the exposure can be set to a lover value. There are two ways to set values for exposure:

- Camera view [F11]

Press "adjust" to go to next screen:

Please only change "exposure".

Pending on your software version it can be that "exposure" is higher, so please set following parameters in d:\ssence\config.ini

Minimal value of exposure can be 1, Maximal is 25, but you can experiment with the values between that. The more light comes into the camera from sun light or anything else, the smaller is the exposure . Don't forget to save....



5.0 Troubleshooting (Messages)

5.1 Error messages

Fault Camera does not work, no IR-LEDs active, no LED of the board is shining.

Possible Reason

Soldering pin on camera contross board broken(see mark left)

Fixing Replace the board with the one with SMD capacitors. Exchange is necessary only if there is a really fault. Function of both boards is the same.

Fault Camera calibration was interrupted with unplausible values.

Possible Reason

Calibration was not successful but was stored anyhow. Values of the car differ with 1 degree or more.

Fixing Check the calibration bar if it is assembled correct. (Compare with sketch in the box) Repeat calibration..

Fault Camber values are always wrong on the same tyre position. Machine is calibrated but values for camber are always shown with the same offset

Possible. reason

Calibration can not be done better.

Fixing It can happen that the values for camber must be corrected. This has nothing to do with calibration, it can happen that there must be a camber correction after a successful calibration. We have the possibility to make pre corrections for the camber values. These are experienced data and can be done if you have more aligners to compare values. One unit is 1/100 of a degree. That means if you add -15 on the BL (back left) camber all values are shifted at -15 1/100 degrees Usually this "shifting" will be done in the factory right after calibration. They have tools to measure and check calibration. The values for camber can be changed in the CONFIG.INI that is placed in D:/SSENCE. FL_Camber= 0 FR_Camber= 0 BL_Camber= 0 BR_Camber= 0



Values can be positive or negative Example FL_Camber=10 = Front Left = positiv 10 units BR_Camber= -23 = Back Right = negativ 23 units.

Fault Humming noise from the motor

Possible Reason

The motor of the SSENCE aligner is a step motor. If there are noises coming from motor the rotor inside stopped in a place between the steps.

Fixing Just move the motor a little by switch or cursor keys during camera view. If this occurs more often, exchange the motor controller. Not to damage the motor, please avoid to leave it in a "humming" condition.

Fault Measurement is very slow, aligner is freezing, camera picture disappears from time to time,

Possible Reason

- Earthing of the device is not OK. - EMS filter defect or not present - strange lights in the camera view - IR LEDs a not working or too many of them are faulty - The aligner is not fitted with the full shielded cable

Fixing - Urgently check if the machine is earthed correct. Check internal connections and outside.

- If there is no filter in the housing add one. The filter can not be checked. - Check with F11 the camera view. Darken the room and check if there are mirrors in the

chassis of the car. - Check the IR LEDs with a digital camera. (page 18) - Check the camera chips if the new shielded cables are used.

Fault Values are jumping during adjustment

Possible Reason

- Strange lights are falling in the camera. - Earth of the machine is not enough

Fixing - Check earthing of the machine - Close doors and avoid direct sunlight to the cameras or targets.

Fault There are no camera devices in the device manager, no Silabs board

Possible Reasons

- The power supply is insufficient or brocken. - Cable connection not OK.



- Cable broken - The power supply supports not only the cameras but also all LEDs

Fixing - Check voltage of the small power supply (see Sticker) - Unplug and plug all connections to avoid corrosion. - Check if the connectors are placed correct. - Check also other devices

Fault

Possible Reasons

This occures during calibration. The calibration bar is not fixed correctly and has moved during calibration. This fault appears mostly after step 3 if the bar must be moved on the other side.

Fixing

Check mounting of the calibration bar, take care that it is fixed correct. Check that the ground is not different when moving bar to the next position. Keep the ground clean. Do not lift the calibration bar during calibration.

Fault CAMERA SIZE ERROR

Possible Reasons

Appears while starting the aligner software. Camera is not present. Mostly if you need to restart the system.

Fixing Power supply is not OK, restart the complete machine, not only computer. If the error appears again check power supply.

5.2 Internet connection

basically it is possible to make a remote connection with this machine. Urgently needed is a internet connection with the aligner PC. This can be done by following: - join an existing network by cable - join an existing network by WLAN. - make a direct connection with SIM-card and SIM-USB router - make a connection by mobile phone (Tethering)

To install one of these possibilities please refer to the manuals of connection device, mobile or hotspot



6.0 Miscelanious

6.1 Information for the Service Technician

For support it is sometime necessary to connect to Internet, so it is recommended to have a USB router with a SIM card with you. Another possibility is to have the following software on a USB stick - Installation manual - Users manual - latest SSENCE software (basic) - tool to assign cameras to one side - Driver for Sentinel Dongle - TeamViewer 8 Modul from our homepage - PDF .Viewer installation program - Your login and password for Hofmann Megaplan homepage.

All Manuals are also available on the Hofmann Megap lan homepage. If you do not have access to that, order your passwort for Hofman n Megaplan homepage.

6.2 Explanation of serial number. The serial number is explaining like this.

13 06 600A -0041 | | | | | | | | | running Number | | | Version | | Type of machine | Month of manufacturing Year of manufacturing



6.3 Software and database updates.

Software can be several times a year. (Usually this is for free) Database updates are one time a year and appear in September. (This is not for free-to pay)

BEFORE DOWNLOAD

NEVER uninstall SSENCE software by hand A complete update for the SSENCE aligner always con sists of two files: - Basic Software update - Database update

Go to www.hofmann-megaplan.com

Enter Support area for registered customers. Enter you login and password for this area Go to Support for aligners Here you will find: (for example)

Please take care that the files you download are co rresponding to your USB hard lock (Dongle) (here 06.2014 - see red arrow in headline of table)

This is dongle Version 06-2014

Download Basic Software by clicking on the small icon on the right side Download Database by clicking on the small icon on the right side



AFTER DOWNLOAD:

Be sure that the dongle is plugged into a USB-port and the red LED is on. Otherwise contact Hofmann Megaplan. Installation of Basic Software

• Go to your download folder and start installation by double click SSENCE software (version number).exe

• Setup starts to install the Basic Software Follow the steps of the installation routine (always confirm)

• After complete installation the SSENCE program is starting.

• Close the SSENCE program to go on with database installation.

For the password to extract the database files cont act Hofmann Megaplan.

Installation of Database

• Start Database installation by double click.

• Type in password you got from Hofmann Megaplan.

• Always confirm - folder will be selected automatically.

• After Installation start SSENCE Software

• It can be that the software can not find the correct links to the database on first start.

• If that is the case please shut down and restart SSENCE Software.

• Check if databases are present and activate the database you need. (By Setup - please refer manual)



6.4 Team Viewer Support A very useful software is Teamviewer, that makes a remote control possible and within to repair problems in the computer of the aligner. Hofmann Megaplan use a licence for TeamViewer 8. -- Other versions are not supported. --

On the Hofmann Megaplan homepage is a runtime modul of team viewer available. ´This module is available in the support area for registered users and for endusers. Just download that program and start. No installation is required. If the module is started it shows you a ID and a password. (Password is covered with ******) If you need help urgently please send us a mail with this ID or call Hofmann Megaplan ([email protected] 0043 6214 646610)

Support for registered customers

Support for end customers - support aligners

It is recommended that the service technician has a USB SIM-Router to be able to connect every customers PC to the internet.

Before connecting to the internet check if the fire wall is activated.again after remote session.TeamViewer module also can be starte d over USB stick to connect.



6.5 Clamps - Size and technical drawing Here a scetch of the latest extended clamps up to 25" used from June 2013 on Usage: maximum 25" (real 25,25") minimum 12" (real 9,68")

The difference in the minimum is that you cannot rotate the wheel on the lift anymore if smaller rims are used..

delivery: ssence600: from Sno: 1306400A-0050 ssence400: from Sno:1306600A-0041

With three finger positions : (ab 01.2014)



6.6 Switch from Automatic to Manual (Camera bar - only 600)

It is possible on the SSENCE 600 to switch from automatic movement by software to a manual movement by hand. If switched to manual the movements of the arm will be done by the switch on the right side of the chassis. Automatic installation : The power for movement of the arm is coming over cable no. 4 from camera control board. This is plugged on the little bridge board. Here are the two versions: Old Version: New Version

If the cable Nr. 4 from camera board is connected the Automatic adjustment is installed. Manual installation. there is a second cable nr. 4 installed in the machine.

Switch machine off. Unplug the cable shown on automatic installation and plug this onto that board instead of the old one. Switch machine on. Even without computer you can adjust the height of the camera bar by switch. This can be done for example if the software controller does not work anymore. Correct installed manual switch.



6.7 Install shielded USB cables.

to avoid problems with black cameras, freezing machines or static electricity in the camera chips, the manufacturer updated the camera cable from USB connector on the backside of the computer to the camera chips. What has to be done? - replace camera chips without USB connector (B) - replaced the unshielded cables from both camera chip to the cam control board. - replaced the unshielded cable from camera control board to the main computer. Replace the camera chip without USB connector On the old camera chip was a USB connector with an unshielded plastic plug. This made troubles with static electricity. If there is a machine that has problems with that, the exchange of the camera chip is the first step to do the update of the machine. Open the camera housing and check the camera chip which is installed. If you have a connector like shown in the right picture there is nothing to do. If you have the plastic connector change both camera chips.

Chip with plastic cable Chip with shielded USB

Update Kit USB cables for camera



Replace the camera chip cable -In the next step both cables from the camera chips to the connectors of the main cable on the back must be exchanged. To do this we recommend dismounting the horizontal bar from the machine. Take the two small USB-cables from the Update kit. Open both camera housings to have access to the camera chips on the backside of the camera.

Unplug old camera chip, and leave the cable in the housing. The cable that is connected to the chip (red orange here) is left not connected in the housing. Dismount the housing of camera control board and dismount camera control board itself. With the data cable we are dragging the new USB cable into the slot. Connect both cables with a tape and pull the new cable gently from outside to inside. Now the reason for the removal of the bar is visible, the plug on the new cable must be through a duct. Do the same with the second cable segment.

Replace the USB Main cable on the backside. Last step is to exchange the fat cable on the backside of the bar. Dismount the old cable from computer and from the vertical bar. Then replace the old main cable against the new one. If you plug the upper side you will find a new USB plug which is connected now to the USB port on the camera control board.



6.8 Install ANDROID® remote control With software version 14.09.0901 (or later) it is possible to install a remote control of the software with an ANDROID® device. This can be a mobile phone or a tablet. (No IPhone) This file is delivered with the SSENCE software and is stored in D:/SSENCE:

First step: copy files to the ANDROID® device plug your device with a USB cable on the SSENCE computer and transfer the SSENCE.APK file to the device. Start the SSENCE.APK file with a file manager.on the device. The software needs ADOBE AIR to run correct, if this is not installed, the SSENCE.APK will download the latest ADOBE AIR for your Android version from Google play center. To have the latest update allow this, please. A little icon should appear on the device.

Now is the right time to disable all firewalls work ing in the windows session. Usually there is no need of a firewall if you do no t enter the Internet. Do not forget to activate, if the aligner should be connec ted to Internet again.

Follow the steps in the panel to disable all the firewalls.



Next step is the connection between SSENCE PC and ANDROID device by WLAN. For this a Router or a hotspot must be installed on the SSENCE computer. For the installation of this router please refer the manual of routers manufacturer. For testing it is not necessary to encrypt the connection. It is necessary to define an access point on the aligner computer's that the tablet can connect as client. (usually this is Soft AP mode) Now connect the ANDROID device to the router by WLAN connection. I there is a good working connection start the SSENCE app on android. After searching the IP address the ANDROID device is showing the start screen.

If the system does not connect at once, press the IP search button and the OK button a few time. You also see on the aligner PC if there is a valid connection.

Offline Online Now start working with the aligner software. (Not all sequences will be shown also on the ANDROID device). After select the loading weights and fuel filling from the vehicle the tablet will start to work and is active now for the rest of the alignment. Print out the alignment form must be done on the alignment PC. You can not print out from remote control. If the ANDROID device is ready to connect and logged in, the application working automatically after next starting.



6.9 Exchange of personal computer If the personal computer must be exchanged, please follow these steps: Save data from old computer (if possible! - If not contact Hofmann Megaplan) To copy all files use a USB-stick with at least 4 GB memory. 1. copy all calibration files to a USB stick

2. There is a folder named in the same way than the serial number of the machine. this folder contains factory calibration data.

3. Go to Folder D:\SSENCE\DB and save the H3d.mdb on the stick. Also save personal brand logos. 4. Copy D:\SSENCE\SPECDB.INI to the stick Go to another computer and download from our homepa ge: - Driver for Sentinel Hardware Lock (Dongle) - PDF-Viewer - Team Viewer Support module - Current basic software version - Current database version Be sure that the personal computer has: - 6 USB ports (or more) - HDMI connection - Win7 Ultimate installed (use delivered CD to install) - Two Partitions C: and D: (SSENCE always is installed in D:) - Win7 is activated by telephone (manual and help in Windows control panel) After installation of Windows: - Install Dongle driver, PDF viewer, Team Viewer Module - Install SSENCE basic software - Install SSENCE database - Copy calibration files to D:\SSENCE - Copy H3D.mdb to D:\SSENCE\DB - Copy SPECDB.INI to D:\SSENCE

After first start of SSENCE - get licence code from Hofmann Megaplan for this machine - Select currant database in the setup menu.



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