Hofmann Megaplan GmbH

3D Wheel Aligner megaline SSENCE

Service manual

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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
Last revision:29.06.2018
Hofmann Megaplan Service Manual megaline SSENCE

Directory
1 Maintenance .................................................................................................................................. 4
1.1 Regular maintenance of Aligner .............................................................................................. 4
1.2 Regular maintenance of Computer ......................................................................................... 4
1.3 Maintenance of screen targets, and cameras ......................................................................... 4
1.4 Site selection and distances.................................................................................................... 4
2 Repair of the aligner....................................................................................................................... 6
2.1 Targets ................................................................................................................................... 6
2.1.1 Exchange of Targets - mechanical part (all models) ........................................................ 6
2.1.2 Exchange of targets - electronically data (all models) ...................................................... 6
2.1.3 Loose of the target files:................................................................................................... 7
2.1.4 Target calibration ............................................................................................................. 7
2.2 Camera bar............................................................................................................................. 8
2.2.1 Components of power supply for camera and motor ........................................................ 8
2.2.2 Exchange of motor controller (400M and 600) ................................................................. 9
2.2.3 Adjustment of motor controller (400M and 600) ............................................................. 10
2.2.4 Exchange of the steel rope of camera bar...................................................................... 11
2.2.5 Camera bar runs over the limiter switch (400M and 600): .............................................. 12
2.2.6 Exchange of limiter switch (400M and 600).................................................................... 13
2.2.7 Failure/wrong signals of the position LED rings.............................................................. 13
2.2.8 LED Ring not working - check the power support........................................................... 17
2.3 Check and exchange of camera and camera chip ................................................................ 18
2.3.1 Check before change the camera .................................................................................. 18
2.3.2 Change camera module:................................................................................................ 18
2.3.3 Possible failure of camera module ................................................................................. 18
2.3.4 Possible failure of camera chip: ..................................................................................... 19
2.3.5 Adjustment of camera chip by software ......................................................................... 20
2.3.6 Correct camera? Right camera shows left picture? ........................................................ 21
2.3.7 Different versions of camera modules ............................................................................ 22
2.3.8 Test and exchange IR-LEDs .......................................................................................... 22
3 Possible problems and failures .................................................................................................... 23
3.1 Increase of accuracy ............................................................................................................. 23
3.2 Scattered light and reflection................................................................................................. 23
3.3 Jumping values ..................................................................................................................... 24
3.4 USB Interface for cameras .................................................................................................... 25
3.5 Bad reflection of targets (car icon in the middle) ................................................................... 25
3.6 Wrong CAMBER values - restore factory data ...................................................................... 26
3.7 Correction of CAMBER values in the configuration file.......................................................... 26
3.8 Machine is very slow and freezes at some positions ............................................................. 27
3.9 Earthing of the aligner ........................................................................................................... 28
4 Handling of machines and software ............................................................................................. 29
4.1 Request of Activation Code................................................................................................... 29
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4.1.1 Activation code not accepted after restart system. ......................................................... 30

4.2 Data base handling and Hardware lock (Dongle) .................................................................. 31
4.3 Calibration data..................................................................................................................... 33
4.4 Backup of collected alignments, customized cars and user data ........................................... 33
4.5 Garage data.......................................................................................................................... 34
4.6 Faulty power supply - no SILABS board - no USB device ..................................................... 34
4.7 Printer Installation ................................................................................................................. 35
4.8 Screen resolution .................................................................................................................. 35
4.9 Hardware of aligner in device manager ................................................................................. 35
4.10 Camera picture is grey, blurring or complete white (F11) ...................................................... 35
4.11 ERROR USB CONNECTION while starting .......................................................................... 36
4.12 Numbers close to car ICON in the middle of the screen. ....................................................... 36
4.13 Camera view [F11] ................................................................................................................ 37
4.14 Values for exposure of the camera ....................................................................................... 37
4.15 Databases availabe in the program....................................................................................... 38
4.16 Install ANDROID® remote control ......................................................................................... 39
4.16.1 First step: copy files to the ANDROID® device .............................................................. 40
4.16.2 Connect by an existing wireless LAN ............................................................................. 41
4.16.3 Direct Connection by Soft Access Point with WLAN adapter.......................................... 42
5 Troubleshooting ........................................................................................................................... 47
5.1 Error messages .................................................................................................................... 47
5.2 Information for service technicians ........................................................................................ 50
5.3 Explanation of serial number................................................................................................. 50
5.4 Software and database updates. .......................................................................................... 51
5.5 Team Viewer Support ........................................................................................................... 54
5.6 Clamps - Size and technical drawing .................................................................................... 55
5.7 Switch from Automatic to Manual (Camera bar - only 600) ................................................... 56
5.8 Install shielded USB cables................................................................................................... 57
5.9 Exchange of personal computer ........................................................................................... 59
5.10 No targets visible – problems with the IR LED rings .............................................................. 63
5.11 Baseplate of the column ....................................................................................................... 66
5.12 Entries in the 33configuration file .......................................................................................... 67
6 Counter of alignments. ................................................................................................................. 68
7 Adding cars to the database ........................................................................................................ 69
7.1 Adding complete new cars to database. ( Version: 15.09.2501 and newer) .......................... 69
7.2 Copy an existing car, change values and save it as new. ..................................................... 74
8 Custom data transfer program (outside of SSENCE program) ..................................................... 78
8.1 Preparation of source data base ........................................................................................... 78
8.2 Preparation of data carrier .................................................................................................... 79
8.3 Where to find the transfer program ....................................................................................... 79
8.4 Transfer custom data to another SSENCE machine ............................................................. 79
9 Troubles with database H3D ........................................................................................................ 82
9.1 Build a new H3D.mdb ........................................................................................................... 82
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10 Autodata Copyright Notice ........................................................................................................ 83

Windows®, Android®, AutoData® and SSENCE® are registered trademarks

 Hofmann Megaplan GmbH 2014

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1 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 camera bar for damage and correct fit in the roller
- 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.
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- Distances from the aligner:

• From Camera to front target 2.05m up to 2,85m
• From camera to rear target: max. 7,0m
• Distance between columns of the lift : min. 2,70m

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2 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.

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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.

2.1.4 Target calibration

The target calibration shows the system the direction of middle axle. Together with target files
a precise point can be calculated as basis for the next measurements.
Target calibration must be done if:
- clamps were exchanged
- targets were exchanged
- targets with clamps were falling down

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

For information how to do please refer the calibration manual.

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2.2 Camera bar

2.2.1 Components of power supply for camera and motor

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

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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 version got a blue DIP switch
block.

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2.2.3 Adjustment of motor controller (400M and 600)

- 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:

SW1 OFF regular mode
SW2 ON
SW3 ON
SW4 OFF
SW5 OFF 16 Microsteps 01100101
SW6 ON
SW7 OFF
SW8 ON amperage 3 Amp.

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

NEW HD Motorcontroller:

11000110

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2.2.4 Exchange of the steel rope of camera bar

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 cable 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.

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- 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 (400M 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 cable between bridge- and
connect board is connected wrong. If all the limiter switches seem OK, please
try this.. (see also page 7)
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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 position 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.

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Old version of the LED Rings

there are two different rings

SX12060139 is for the left side of the aligner

SX12060140 is for the right side of the aligner
(Both if you are in front of the aligner)
On each ring there are the connectors for the flat cable.

Usually pin1 must be connected to the red line of the cable.

Normally pin 1 is always connected to the red line of the flat cable. Here it
must be in the opposite direction. The red line must be away from the pin
one.

If the pin one is connected to the red line the LED ring
shows wrong signals in direction. Please plug in opposite
direction. Take care that both rows of pins are plugged
correctly.

Connectors on the board are self explaining

and can't be plugged in a wrong way.
Board ID for old LED rings:

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These are the parts for the old version of LED-rings:

Blue plastic material

New version of the LED Rings

The new LED rings can not be connected wrong. There is also no left and right side.
The connector is with a slot so that the flat cable can not be connected wrong.

All connectors remain, no changes.

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This is the equipment of the new LED-rings.

Black plastic material.

To find out which LED is on top (for installing the ring into the housing)
just start alignment software and start alignment. If you are at push-pull,
check the direction and mark the shining LED. This is top.

Test sequence of the LEDs if you switch on aligner software. On both sides this sequence is
shown.

If this is shown, all connections are fine.

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2.2.8 LED Ring not working - check the power support

You can check the voltage of the LEDs from power supply to the plug on the LED rings.
If there is a problem with the rings (IR or Red-Green-ring)

Dismount camera housing and cover of the camera control board on the back side of the bar.

Voltage check on the connector.

- unplug the power connector of the RedGreen-ring (brown-black cable)
- connect the aligner to the power and switch on the main (not the computer)
- check with a multimeter the brown-black cable. There must be from 11,6 to 12V.
(if this is OK go on with the signal check)
- if there is no power,
• check the plugs connected to the camera control board on the back of camera bar.

Black and brown

pins.

Signal cable

• check connections of the bridge board

• check voltage from power supply. (if it is under 11Volt, change or adjust power supply)

Signal cable check (flat cable)

- check connections of the RedGreen-Ring (see also page 13)
- check connection on the camera control board
- If possible, check flatcable with a multimeter. If all wires are OK, exchange the camera board.

We had the case that the flat cable was damaged by squeezing while
mounting the housing.

Repair of the cable

Flat cable can be repaired if the damage is not too far

away from plug. please check length before shortening.
Remove cable from plug (3) cut cable on the defective
place and lay the cable in the plug like shown. Place
number 2 on number 3 and press together with pincer.

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Cut the side with the defect. With number 1 you can
change the way of the cable.

2.3 Check and 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 are 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.

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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 camera-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 0 for left and 2 for right and
leave the machine switched off for 5 Minutes. (to decrease possible 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.

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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 found 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:

See if camera side is correct

Both chips on the backside of the camera are assigned to a side. (left-right)
After changing a chip or a camera it can be that both camera views are swapped.
So the number of the chips must be updated. (0 for left, 2 for right)
The low value is for the left camera, the high for the right.
Usage of the software
- Double click at program "Cameraupdate.exe" to execute.
Select camera side by "Select device":

◄ selected camera (lets say

that this is the left side)

◄ 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 to 0 (left)
◄ Erase firmware! Attention!
Do not use it !!!
After pressing Modify there is no need to save, it will be stored in the camera chip at once.

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0 = for left side (in front of aligner, looking at the monitor)

Press "Modify" to change initialisation of camera.

2 = for right side (in front of aligner, looking at the monitor)

Press "Modify" to change initialisation of camera.

At last start SSENCE software; press [F11] to get the camera view. Test with your hand in
front of the left camera if the left picture shows the hand. If yes, everything is OK, If not,
swap both numbers (0 and 2)

If only chip was changed, no calibration is necessary.

If a camera was changed do the camera calibration. (See own manual - SSENCE
calibrations)

2.3.6 Correct camera? Right camera shows left picture?

- 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. Cable 2 is for left, cable 3 is for right.

- If your hand in front of the left camera is shown in the right field of the camera view, swap
the camera assignments as shown above.

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2.3.7 Different versions of camera modules

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)

2.3.8 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.
See also Chapter 6.11 page 51

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3 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 mounted like shown in the
manual for this device. According to the calibration urgently take care that
there are no reflections come inside the camera during calibration. (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
-

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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 shoot, cover reflective
surface of vehicle.

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.

3.3 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)

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3.4 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:

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)

3.5 Bad reflection of targets (car icon in the middle)

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 - Bad Reflection, Clean targets, Eliminate
100 turbidity of the targets
Blue tire, number below 100 - Values OK, software can work without
problems.

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3.6 Wrong CAMBER values - restore factory data

In some cases camber seems to be not correct. Before performing a complete calibration, try to
correct this by restoring original calibration data of the factory.
Stored on the harddisk (drive D:) are the factory settings of the calibration data. They are
stored in the folder with the serial numbers name.

Target data

Camera data

For the first correction of the values copy this original data to D:\SSENCE and
make an alignment (with the same car) again.

If the problem is not solved please do a camber value correction. Only camber values can be
corrected "by hand". This fine adjustment will also be done in the factory

3.7 Correction of CAMBER values in the configuration 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

Front Right camber

Back Left camber

Back Right camber

Values are specified in 1/60 ARC minutes . The value of 20 corrects the pre setting of the tyre
to 20' minutes in positive. It is also possible to add negative values.
(FL_Camber = 30 or FL_Camber = -30 means: Inclination will be corrected half of a degree
in positive or negative direction.)

After change and save restart the alignment software. Values will be read while starting
SSENCE.

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A calibration of the cameras changes also the basic values for camber, so this is only a
temporary help until the next calibration will be performed. After calibration delete the correction
values in the config.ini file.

3.8 Machine is very slow and freezes at some positions

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 cable

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)

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3.9 Earthing of the 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.
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4 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 requested, mark the text and save it in a notepad file. Send this file together
with the serial number of the machine 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.

If the aligner is new installed from the box, urgently take care, that all boxes of
the aligner have the same serial number. If there is a wrong box, the machine
requires a new code 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:

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The User ID is changing if a camera fails or a chip is not working anymore. The software
requests a new code then. If you have a code like this: xxxxxxxxxxxNOCAMERA

The program tells you to that one or both cameras are missing. If you have a code like this
please check if the cameras are working correct.
- Entry in the control panel
- Connection (cable, plugs)
- Drivers for cameras are correct
- Assignment of the camera chips is OK.

4.1.1 Activation code not accepted after restart system.

(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 you make a Team Viewer session with us to
register software, you have to take the basic code before the remote network
card is installed.

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4.2 Data base handling and Hardware lock (Dongle)

The SSENCE base program will be delivered with a sample database (sample.mdb). This is a
not 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
Database for Mexico Mexico, 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:

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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

Error Message:
This means that a Dongle for SSENCE is present,
but a not fitting program version is running. Check
the feature like mentioned above and install the
fitting program version or make an official update of
the database. (With that you receive a correct dongle
for the software version)

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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 camera- and target files here,
so we can send you the original files coming from the factory.
After restoring of the data it is not necessary to make a calibration of the
machine.

4.4 Backup of collected alignments, customized cars 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 every month.

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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 - no SILABS board - no USB device

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.

Note: With the new camera control cable (shielded USB) the camera chips are directly connected to
computer. Power supply has no effect to the cameras.

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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 please 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. Full HD (1929x1080) is also possible but this is slower.

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

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4.11 ERROR USB CONNECTION while starting

- Check all connections on the backside of PC.,
- Check connections on the camera control 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 the 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 sometimes substantial delays occur in the
processing time of the machine.
Is a red wheel as shown here, the contact between the target and the camera is faulty.

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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....

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4.15 Databases availabe in the program

Basically several databases can be installed in the system. After installing the new database
usually it is visible in the "SETUP - PARAMETER - DATABASE" selection.
If you had more databases installed before, the "old" database disappeared. Although it is
stored in: D:/SSENCE/DB it is not visible.

In the text file "SPECDB.INI" (D:/SSENCE) all necessary databases must be included,
otherwise it will not be recognized by the software.
SPECDB.INI looks like this:

This are the regular entries of the Autodata© database.

On this

the Japanese and South African Database are included.

Each Database Package has its own SPECDB.INI. This file will be installed
with the database itself. If you have more that one additional databases you
must add the names of the databases manually in the SPECDB.ini.

How to include the databases.

The specdb.ini is a text file. Please change content with a text editor (just like notepad).
The following syntax must be present.

NAME OF DATABASE = Visible Name in PArameter

The name of the database is without extension, it can be only a *.MDB file.
(see example above)

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4.16 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)

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

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

The computer in the aligner is meant to be used for the aligner software only. Do not install additional
software that is not necessary to work with SSENCE

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Please prepare:
- SSENCE Software must be installed to aligner
- SSENCE app (included in Software) must be installed on the Android device.
This file is delivered with the SSENCE software and is stored in D:/SSENCE:

4.16.1 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.

There are two ways to connect the devices.

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4.16.2 Connect by an existing wireless LAN

An existing WLAN can be used to connect the aligner and the Android device.
- First of all connect the aligner to the WLAN (a WLAN stick must be installed- Install only drivers for
the adapter - no special software)

If you connect a WLAN device to a existing LAN, the DHCP-server (included in the
server software) gives the new device a new IP-address.(within a particular range of
IP-addresses. This happens with both devices, if connected to WLAN)

- Now start the aligner software on the computer.

Be sure to have the software version that supports the remote control. You can see that on
this icon left bottom side close to the Hofmann logo.

This means SSENCE is not connected to remote control.

- Now start the SSENCE APP on tablet.

You see the range of IP addresses got from the server (192.168.0.XXX):

Press to start the search for the valid IP address. (it takes some time to connect)

If a corresponding IP-Address is found you see:

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Tablet is connected now. The Hofmann icon on the aligner is showing the
connect icon. The tablet mode will be started if you go on working with the
aligner and come to the selection of 4 and 2-wheels.

If you have two or more aligners in your network it will not work in this way, tablet is
always connecting to the first IP address found. If this is necessary, the IP addresses
must be given by hand. Please contact Hofmann Megaplan.

4.16.3 Direct Connection by Soft Access Point with WLAN adapter.

Preparation is the same as before:

- SSENCE Software must be installed to aligner
- SSENCE app (included in Software) must be installed on the tablet.(see service manual)

Difference here is that there is no network available; we must direct connect both devices.

- Install a WLAN adapter (can be the TP-LINK or some other device. Please only install drivers that
windows can handle the device. Do not install additional programs. After installation it can be
necessary to restart the computer one time for recognizing the new hardware correctly.)

- Install the software program which is simulating the access point. Advantage is that all WLAN stick
have the same program to make the access point. We have a unique solution.
The program is called

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You will find it on our homepage in the support area 1 -- aligners ready for download.
The program is freeware and can be used without licence fee.

MyPublicWiFi

After downloading the program start installation and follow the instruction of the setup
program. You have to restart the computer. Now you see a new icon:
With this you can start the program.

Configuration of MyPublic Wifi

It can be that the hotspot is running.

click on: Stop hotspot first.
click on: Automatic Hotspot Configuration

SETTING
here you are able to change parameters.
Network Name (SSID): this name will be shown as
WiFi net name later.

Network Key (at least 8 char) this is your password

Enable Internet Sharing: please enable

click on : Set up and start Hotspot

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CLIENTS

Not important you can ignore this.

MANAGEMENT

Language: select your language

Block file sharing:

Not important you can ignore this

URL log
Not important you can ignore this

Autostart
Leave this active..

Now connect the tablet to the new defined Hotspot. Search for the LAN with the given name in the
WIFI software. In our case here "SSENCE"

If you define the "local" WLAN device as a "software access point" the software defines for the new
created LAN a range of IP-addresses. If you connect the tablet to that WLAN the tablet takes this
range of IP-addresses as default.)

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Now start the SSENCE software (first) and then the app on the tablet.

After start you see that there is a different range of the IP addresses
192.168.137.XXX.

Start searching correct IP address with . If the address is found the tablet shows you:

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Tablet is connected now. The Hofmann icon on the aligner is showing the
connect icon..The tablet mode will be started if you go on working with the
alinger and come to the selection of 4 and 2-wheels. Tablet is starting then.

If you have two or more aligners in your network it will not work in this way,
IP addresses must be given by hand. Please contact Hofmann Megaplan.

To make it more comfortable:

If the tablet is used every time it makes sense to let start that all in the "STARTUP" routine of
windows.
- make shortcuts of the hotspot program and of SSENCE icon.
- place them in "Startup"
- every time the aligner is starting, the WiFi program and SSENCE will be started automatically.

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.

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5 Troubleshooting
5.1 Error messages
Fault Camera does not work, no IR-LEDs active, no LED of the board is shining.

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

Reason
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 Calibration was not successful but was stored anyhow. Values of the car differ with 1
Reason 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. Calibration can not be done better.
reason
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
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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 The motor of the SSENCE aligner is a step motor. If there are noises coming from motor
Reason 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 - Earthing of the device is not OK.
Reason - 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 - Strange lights are falling in the camera.
Reason - Earth of the machine is not enough

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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 - The power supply is insufficient or brocken.

Reasons - 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 This occures during calibration. The calibration bar is not fixed correctly and has moved
Reasons 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 Appears while starting the aligner software. Camera is not present. Mostly if you need to
Reasons restart the system.
Fixing Power supply is not OK, restart the complete machine, not only computer. If the error
appears again check power supply.

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5.2 Information for service technicians

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 Megaplan homepage. If you do not
have access to that, order your passwort for Hofmann Megaplan homepage.

5.3 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

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5.4 Software and database updates.

Software update can be several times a year. (Usually this is for free)
Database update is two times a year and appears in March and
September. (To pay)

BEFORE DOWNLOAD

NEVER uninstall SSENCE software by hand

A complete update for the SSENCE aligner always consists 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 corresponding to your
USB hard lock (Dongle)
(here 09.2015 and 06.2014 - see red arrow in headline of table)
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This is dongle Version 08.12-003 (from Sept 2013)

This is dongle Version 06-2014 (from Sept. 2014)

This is dongle Version 09-2015 (from Sept 2015)

If your dongle is not fitting to the software release, you need an update to
latest version. Please contact Hofmann Megaplan.

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 contact 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)
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This message appears if the dongle is not present.

Insert dongle in a USB port. If this will not work try
another Port.

This message appears if the wrong dongle is

present. Please insert the new dongle with the
latest update date. (actual 09-2015)

There is a serious problem with the alignment

software. This happens if Software was deleted
not over control panel.

Probably the camera files were deleted. Usually there is a folder in the root of d: named with the serial
number of the machine. Here inside are camera – and target files. Copy these files into the D:\SSENCE
folder. Restart software, if the message comes again, contact Hofmann Megaplan.

If there are any other problems contact Hofmann Megaplan.

If possible prepare the machine for a remote session. _(see next capter)

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5.5 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 module of team viewer available. 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)

You will find the module:

- On the very first page if you enter the HM homepage.

- in support for registered customers - support aligners

- in 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 firewall is activated.again after
remote session.TeamViewer module also can be started over USB stick to
connect. Do not install other software on the machine, warranty will be lost!

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5.6 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)

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

On the machines from 2016 also the switch is working together with automatic.

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.

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5.8 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

Shielded plug (3)

Camera chips on the backside are only connected to the shielded connector.
(see picture 3) - The white plug is NOT connected anymore.

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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.

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5.9 Exchange of personal computer

If you have to install the software because of a computer crash urgently take
care to use the delivered 32-Bit version of Windows® 7 Ultimate. NEVER
install a 64-Bit version of Windows. Drivers for camera and camera control
board will fail because they work only with 32-Bit.

Minimum Hardware requirements:

-2.1 Ghz dual core CPU
- 2 GB memory
- 20 GB Harddisk
- 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)

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

If the personal computer must be exchanged, please follow these steps:

Before formating the PC Additional notes
If possible make a backup of camera- and target files. • stored in D:/"serial number folder"
• If not possible the data are also on a separate CD

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• If not available call Hofmann Megaplan for a copy

If possible make a backup of H3D.mdb • stored in D:/SSENCE/DB
• contains all data and measurements of the
customer

Save the camera- and target data • example

contained in "D:\serialnumber" on a
USB-stick

download necessary drivers for the • Drivers for network card

DELL computer on the USB-stick • Drivers for graphic card
• Drivers for sound card
• save everything on a USB stick

http://www.dell.com/support/home/us/ Go on here with "auto detect" to find the correct drivers

en/04 for the system.
Download the necessary SSENCE To have the alignment programs if it is not possible to
files from Homepage make an internet connection.
• Driver for dongle
• Pdf viewer
• Basic software (unprotected)
• Database updates (protected)
Install new Windows system • BIOS must be set to "Boot from CD"
• Start with delivered Win 7 Ultimate 32-bit CD
• Must be 32 Bit version, cameras will not work on 64 bit OS
• Must be activated by telephone (after installation)
Install win7 Ultimate 32 bit on suitable
PC and define a partition of 40% of
disk space for drive C:
Make a partition of the rest space on SSENCE is always installed on drive D:
disk (drive D:) and format disk
Install the DELL drivers for the Try to get Internet connection. (Not urgently necessary if you
hardware components. have stored all alignment files on a USB stick)

Install an internet connection By cable, USB-stick or with mobile telephone.

Install the backup of camera- and Name of the folder is the same as serial number.
target data on drive D: (e.g.
D:/1307600A-0042)
Install necessary drivers and updates. You will find all programs on our homepage.
• Driver for dongle If there is no internet connection prepare a USB-stick with all files.
• Pdf viewer SSENCE will start during installation. Please don't mind
• Basic software (unprotected) about all the error messages, Camera and target data are missing.

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• Database updates (protected) This will be installed in the next step.

• Bugfix for Database (protected)
• Software for camera location

Disconnect from internet. If there is a internet connection, please disconnect the PC to avoid
problems with viruses and malware. After installation of firewall and anti
virus software you can connect again.
The aligner should be connected to internet only in case of
maintenance.
In folder D:/SSENCE
Restore the original camera- and
target files.

Restore original H3D.mdb In folder D:/SSENCE/DB

Go to the control panel Search for unknown hardware.
- device manager Install drivers for cameras and Silabs board.

Drivers are stored in D:/SSENCE/DRIVERS. (after installation of the

alignment software)
If you are successful there must be:

Now start software the first time with You should have the start screen.
all necessary drivers Software is sure not registered.
Please copy the USER ID - number to a file and send to
[email protected]

After you got the code insert it here:

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Restart the SSENCE software

Install correct database Go to setup, Parameter and select the correct database.
If there is only sample database available check the file:
D:\SSENCE\SPECDB.INI
(see also service manual chapter page:
Check if cameras are correct Press [F11] to check the correct camera sides.
Check with your hands in front of the camera if both sides are correct. If
this is not the case you must assign the cameras to one side.
(see also service manual chapter 2.3.5 page16

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5.10 No targets visible – problems with the IR LED rings

Check function of the IR LEDs:

It is very easy to check the function of the IR LEDs. Just take a digital camera or a mobile phone and
have a look trough the display. The LEDs must be shining while on the display.

The more LED are faulty, if there should be targets, but they are not
the shorter is the range of the aligner. visible, check the IR-LED.

Check connection of the IR LEDs:

There are 2 different LED connectors. The IR ring is connected to the position LED ring to get power.
(voltage 12V (~11.8V))

The power connector of the IR-LED ring

goes to the position LED-ring.

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goes on to the camera control board in the middle of the horizontal bar.

Check Voltage:
Black-brown 12V
Orange-red 5V

the old connector for camera chip is

not used anymore If this cable is
connected to camera chip, urgently
change complete cable and chips.

Connections of camera control board.

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The red LED on the camera control board must be on. That means the power supply inside the
cabinet should be OK.

Check voltage cable no 4

must be 12V and 5V

If the LED of the control board is not

red, check fat cable on the backside
of column and connectors inside the
cabinet.

Cable no 4 inside the cabinet must

be connected.

Cable no. 4 connected to bridge

board.

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5.11 Baseplate of the column

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5.12 Entries in the configuration file

After installing and calibrating the aligner the first time in manufacturers company, a
configuration file will be written. In this file are runtime parameters of the SSENCE main
program. If a absolute new installation must be done, backup the configuration file first, and
delete the original. If the file is not present, a new one will be created.
Please note! If an update was made, this file will NOT be erased or
overwritten.
[V3D]
target_data_file = .\target_data.yml
camera_data_file = .\camera_data.xml
same_corner_condition=100
inaccuracy_threshold=100 Threshold for the dummy car icon values limit
Caster_rock = 80
calib_r_err=20
calib_t_err=8
repeat=3 Accuracity of control measurements (repeats)
repeat2=1 Only HD, Fast push Pull, but maybe more shakes. Has nothing to do
with exact results.
exposure_max=25 older Software had 10 -- not valid anymore for newer machines.
print_chassis=1 printout of chassis data on the printing sheet. 0=not shown
FL_Camber= 0
FR_Camber= 0 Correction values of Camber (1/60) can be minus and plus. See also
BL_Camber= 0 page 26.
BR_Camber= 0
shutdown=0 1 = SSENCE software will shut down first if shut down computer.
AngleUnit=0 Selected angle unit in Setup of SSENCE
ToeUnit=0 Selected Toe unit in Setup of SSENCE
resolution=0 Selected resolution in Setup of SSENCE
print_format=1 Printout 0= Black-white 1 =color
[ParamSet]

language=en Installed language

Version=17.05.0101 Software Version
SPECDB=2 Active Database after start (Pending on installed database)
[channel1]
gain=70
exposure=11
gamma=-9
gamma_on=1
[channel0] camera parameter (channel 1 is right camera)
gain=70
exposure=11
gamma=-9
gamma_on=1

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6 Counter of alignments.

Click in the counter box

Type in 0 and confirm with

System asks for a Password.

It is 1357. Counter will reset to 0.
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7 Adding cars to the database

7.1 Adding complete new cars to database. ( Version: 15.09.2501 and

newer)

Solution:
Please note the following:
- You can not automatically transfer data from one database to the other. Databases are from
different sources and will be prepared different for SSENCE. (A possibility to share new database
entries is written in 8.0)
- You can add a new manufacturer and new models.
- You can copy existing models, duplicate and rename.
- All operations must be done in the setup/database menu.

First select the database you want to increase.

7.1.1 Add new manufacturer and new model

Go to Setup and start Database

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Add a new Manufacturer......

Add name, country and location of the company logo. (Usually the manufacturer's logos are stored in
D:\SSENCE\LOGOS. If you place the new logo here you can take it from the standard folder.

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Now the new manufacturer is present. You can add the cars. The same situation is if you want to add
a new car to an existing manufacturer. Go on with [+] to enter a new vehicle.

Add the new car's data and save them be confirm.

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After confirming here the next screen will appear, where the data can be entered.

Now ready to go to change the values. Data entry is in DMS (Sexagesimal numbers) degrees. Enter
values with a point, after storing values, close and open again you will have DMS or DEC like stored
in the setup.

DMS = Sexagesimal numbers = 1 circle is 360° (Degrees), each ° is divided in 60' (Minutes), each ' is
divided in 60" (Seconds)
DEC = Centesimal (Decimal) numbers = 1 circle is 100 grades, 1 grade is divided in 100 subunits
(minutes); each minute is divided by 100 (seconds)

See also http://www.math-only-math.com/systems-of-measuring-angles.html

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All other data remain and will be saved with the vehicle.

The data are converted to the selected kind of display. Here we have DMS. For example here see the
3.60 in the input page and the 4° in the real values.

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7.2 Copy an existing car, change values and save it as new.

(Software Version: 15.09.2501 and newer)

Enter the Database in the setup menu

In this example we want to copy a Citroen, so please enter the Citroen and double click the car you
want to make a copy from.

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Here are the values of the database for our selected car. Now press the copy button.

Citroen appears with a copy of the current car. (marked with the [C])

Now double click o the new vehicle and go back once more (sorry this is a batabase internal)

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Now you can change the description of the car.

Or change the values of the car by double clicking on the vehicle itself.

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Now ready to go to change the values. Data entry is in DMS (Sexagesimal numbers) degrees. Enter
values with a point, after storing values, close and open again you will have DMS or DEC like stored
in the setup.

DMS = Sexagesimal numbers = 1 circle is 360° (Degrees), each ° is divided in 60' (Minutes), each ' is
divided in 60" (Seconds)

DEC = Centesimal (Decimal) numbers = 1 circle is 100 grades, 1 grade is divided in 100 subunits
(minutes); each minute is divided by 100 (seconds)

See also http://www.math-only-math.com/systems-of-measuring-angles.html

All other data remain and will be saved with the vehicle.

Please note: In the database itself (for example AUTODATA) will be

changed nothing. Copyrights do not allow that and it would be a problem
with the next update where all changes disappear.
All changes and alignments will be stored in the D:\SSENCE\DB\H3D.mdb.
Please save this file recurring every month.

There is no warranty for lost user data.

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8 Custom data transfer program (outside of SSENCE program)

Description: This program allows sharing a customized database with other users. You can make your source
database (H3d.mdb) with a demo version or a full version of the SSENCE software. All special
marked manufacturers and cars will be transferred by USB stick to another computer.
No existing custom data will be lost.

8.1 Preparation of source data base

• First place a new, empty H3D.mdb in the DB folder of SSENCE on drive D: (see in 8.1 how to create a
empty H3D.mdb)
• Select your working data base in SSENCE. (in most cases Autodata)
• Make sure that all models and manufacturers you want to transfer start with a #.

- To differ from other entries, all manufacturers and models must beginn with a "#"

manufacturer #car No transfer to database

#manufacturer car Only a new (empty) manufacturer is created
existing manufacturer #car Cars are transferred to existing manufacturer
#manufacturer #car All cars are transferred to the new manufacturer
manufacturer car No transfer
existing manufacturer car No transfer

Insert all your custom data in SSENCE on this machine.

EXAMPLE FOR CUSTOM M AKE ENTRY EXAMPLE FOR CUSTOMIZED CAR ENTRY

EXAMPLE FOR CUSTOM M ODEL IN AN EXISTING MANUFACTURER

Then fill up the cars with data.

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8.2 Preparation of data carrier

After entering all #manufactureres and #cars:
• Exit SSENCE.
• Connect the USB stick you want to use to transfer the custom data.
• Create a new folder on the USB stick.
• If you have not done, download the file

from our homepage www.hofmann-megaplan.com

• and copy this file to the new folder on USB stick.
• copy the modified D:\SSENCE\DB\H3D.MDB also on the USB stick together in the same folder
than
the transfer program.

8.3 Where to find the transfer program

You will find the program in SUPPORT / Support for registered customers / support for aligners

You now have everything you need to transfer the custom data to a different SSENCE aligner.
Content of your USB stick should look like this:

8.4 Transfer custom data to another SSENCE machine

Follow these steps to transfer custom data to another SSENCE aligner
• Connect the prepared USB stick to the aligner you want to transfer the custom data to.
• Exit SSENCE if it is running.
• Go to your USB stick and open the folder containing the H3D.mdb file and the
SSENCE Custom Data Transfer.exe.

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All alignments and customers are stored in the H3D.mdb. Make a copy in
any case. Don't use H3D_old.mdb because this is the name of software
backup that is created automatically.

Double click SSENCE Custom Data Transfer.exe to transfer the data.

You should see something similar to this:

• If a custom model that is to be transferred is found on the target aligner, you will be asked if you
want to keep the current data and specs or if you want to override this model with the data from the
source aligner.

If a custom model already exists on the target aligner:

• press "y" to update this model
• press "n" if you want to keep the current model data
• press "a" to update all models
• press "z" to keep the current data for all models

• After the data is transferred to the new aligner start SSENCE to verify if the data was transferred
correctly.
Limitations
It is not possible to transfer data between SSENCE aligners that have
different databases. Different databases do have different model IDs.
If source and target have the same database but different IDs, the program
asks you if you want to do the transfer to the new ID.
If database name and ID is the same on source and target, the program will
make the transfer at once.
We recommend to make the source entries with the same database than the
target.
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9 Troubles with database H3D

The H3d.mdb opened when starting SSENCE. It is a temporary working file where all data coming
from data base, alignment, customer. It is open during all the time you work with SSENCE. When
closing the program by end button the file will be stored.

If one day:
• cars disappear in the database,
• alignments are not present anymore
• not all values of a car will be present
• cars are mixed up
• entries can not be saved
or something similar happens, please delete the H3D.mdb in the D:/SSENCE/DB folder and
replace it by your monthly backup of the file.
If the PC was switched off or power failure forced a stop of the computer, there is no time for the
operating system to close H3D.mdb. In most cases the H3D.mdb is damaged.

9.1 Build a new H3D.mdb

If there is no backup you must build a new H3D.mdb.
• Close SSENCE software
• Go to D:/SSENCE/DB and delete the H3d.mdb
• Start SSENCE again
• The setup creates a new, empty H3D.mdb

• !! All entries of alignments cars and customers are lost.!!

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10 Autodata Copyright Notice

Autodata Limited (´Autodata´) is the owner or licensee of the intellectual property rights
(including but not limited to the trade marks, copyright and database rights) in the Autodata
Website at www.autodata-online.net and this Autodata Database.

No part of the Autodata Website or the Autodata Database may be copied, stored in a
retrieval system or transmitted in any form whatsoever, in whole or in part, without the written
consent of Autodata. This notice must remain an integral part of the Autodata Website and
the Autodata Database and of any permitted copy. The restriction on copying includes
translations into another language or format.

Any person who does any unauthorised act in relation to the Autodata Website, The
Autodata Database or the information contained in them may be liable to criminal prosecution
and civil claims for damages.
Portions of materials contained herein are sourced from Chrysler Group LLC.
This product contains material that is reproduced and distributed under licence from FIAT. No
further reproduction or distribution of the FIAT information is allowed without the express
written permission of FIAT.
This publication contains material that is reproduced and distributed under a licence from
Ford Motor Company Limited. No further reproduction or distribution of the Ford Motor
Company Limited material is allowed without the express written permission of Ford Motor
Company Limited.
Data provided by IVECO. Re-edited and republished by Autodata. Copyright Autodata.
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SSENCE 400/600 Page 83 of 85
Hofmann Megaplan Service Manual megaline SSENCE

Collection for extension:

Target calibration:
Why target calibration -- Search the middle axle of the clamp-Target combination.
When target calibration? Exchange of clamp or target. Exchange of parts of clamps or target.

Dell PC does not start shows yellow light...

Possible reason: a connected USB device is defect.

SSENCE 400/600 Page 84 of 85