Vishay Precision Group VPG On-Board Weighing SI Onboard TruckWeigh, Installation, Setup And Calibration Manual

Page 1: ...TruckWeigh Installation Setup and Calibration Manual SI Onboard A Brand of VPG On Board Weighing Part Number 6190236 Revision 1 1 ...

Page 2: ...om any improper installation of the weighing equipment including but not limited to any misapplication or misinterpretation of the installation information contained herein Strict observance of these guidelines should help to ensure accurate weight measurement and enable safe operation of the vehicle Failure of our on board vehicle weighing equipment due to poor installation workmanship or incorre...

Page 3: ...eaf Springs 13 Positioning of Transducers on Rear Single Axle Leaf Springs 14 Positioning of Transducers on Rear Steel Spring Bogie Tandem Axle 15 Positioning of Transducers on Rear Hendrickson Rubber Bogie 15 Axle Transducer Mounting 16 Points to consider 16 Connect the Transducers to the Junction Box 17 Install the Chassis and Cab Cabling 18 Securing Excess Cable 18 Optional Jumper Settings 19 P...

Page 4: ... Time and Date 29 Set the Overload Alarm Set Points 29 Set the Slope Compensation 30 Configure Tandem Axle Bogie Mode 31 Tag Axle Overview 32 Configure Tag Axle if Required 34 Configure Optional 511 Transmitter 34 Configure Optional Printer 35 Record the Firmware Versions and Other Details 35 Set the Manager and User PINs 35 Calibration 37 TruckWeigh Calibration Process 38 Prerequisites 38 Weighin...

Page 5: ...5 Installation SI Onboard Installation SI Onboard TruckWeigh Manual Installation ...

Page 6: ... can be configured using either of the above transducers or certain combinations of the two Any display screenshots used in this document are intended as an illustration of the menu function being described as such any specific detail or settings shown will differ from one installation to another Attention The TruckWeigh indicator has a certain amount of legacy functionality available through its ...

Page 7: ...he power cable is used to connect the meter to the truck power There is one per meter Power Cable Fig 1 07 The signal cable connects the meter to one or more junction boxes There is one signal cable per junction box Signal Cable Fig 1 08 Each steel suspension axle uses a pair of TruckWeigh axle transducers For example 4x2 all steel suspension would require 4 axle transducers 6x4 all steel suspensi...

Page 8: ...ter for example on an 8x4 where two 4way junction boxes are used Signal Y Splitter Fig 1 10 This is used only on articulated vehicles one per system Truck to Trailer Cable Truck Part Fig 1 11 This is used only on articulated vehicles one per system Truck to Trailer Cable Trailer Part Fig 1 12 7 16 wrench 7 16 socket and ratchet wrench 1 4 wrench if installing a truck to trailer cable 1 4 socket an...

Page 9: ... TruckWeigh Truck Air System Truck Air System Leaf Spring Air Spring Air Spring Air Spring Leaf Spring Leaf Spring TruckWeigh Indicator CAN Air Pressure Junction Box and Transducers Suspension Air Bags CAN Junction Box and Axle Transducers TruckWeigh Truck Air System Truck Air System TruckWeigh Kit Number WKTW10005 Leaf Spring Leaf Spring TruckWeigh Kit Number WKTW10005 CAN Junction Box and Axle T...

Page 10: ...ransducers should point downwards Installation of Junction Box for TruckWeigh Axle Transducers For trucks with mechanical suspension install one or more junction boxes Identify a suitable location for the junction box Each junction box needs to be located close enough to the transducers so the cables reach it Each junction box must be mounted on a vertical surface of the chassis or sub frame with ...

Page 11: ...g 1 19 Circuit prior to installing the air transducer Installation of Air Pressure Transducer Decide on where to position the air transducer in the suspension air circuit The air transducer must be between the self leveling valve and the air bellows as shown below in figures 1 17 and 1 18 Circuit with air transducer installed Find a location where the air pipe is well supported and there is space ...

Page 12: ... transducer must be mounted with the groove around the transducer on top as shown below in figure 1 21 Each transducer must always be mounted inline with the chassis unless they are on struts in such a way as to ensure the face adjacent to each groove is facing up see figure 1 21 The cable from the transducer must always point from the transducer in the direction of the pivot point of the suspensi...

Page 13: ...entation into the Installation Calibration Record for entry into the meter during its setup Remember to leave only enough loose cable to allow the transducer to move with the spring without pulling the cable tight Excessive loose cable may result in the cable being snagged see figure 1 25 Front of Truck Front of Truck Positioning of Transducers on Front Strut Type Suspension With strut type front ...

Page 14: ...see figure 1 26 they are referred to as leading Record the transducer orientation into the Installation Calibration Record for entry into the meter during its setup The TruckWeigh axle transducer may also be mounted at the front of the leaf spring as shown above When the transducers are installed on the front of single axle leaf springs as shown above see figure 1 27 they are referred to as traili...

Page 15: ...as leading The rear transducers are referred to as trailing With Hendrickson rubber type rear suspension mount the transducers on the torque arms The torque arms may be round or square The transducers are mounted with the cables all facing the center of the bogie see figure 1 33 You may mount the transducers under or on the sides of the torque arms see figure 1 32 providing you observe that the gr...

Page 16: ... i e 1 Left front 2 Right front and so on This could be done using an indelible marker or even a corresponding number of cable ties 3 Consider the temperature The ideal temperature for application is 70ºF It is not recommended to fit the VHB tape at temperatures below 60ºF Preferably fit the transducer to the springs in a workshop Where necessary warm the spring with a hot air gun prior to bonding...

Page 17: ... Connect each cable to its corresponding junction box and port number Where a second junction box is used the port numbers are offset by 4 So Transducer 5 connects to port 1 Transducer 6 connects to port 2 Transducer 7 connects to port 3 Transducer 8 connects to port 4 As shown in the diagram below figure 1 46 Mark each end of the interlink cable with the position of the transducer it connects to ...

Page 18: ...ger than they need to be you will need to loop them and retain them using cable ties Note If you are installing a system on a semi truck you will need to refer to the sections for installing the truck to trailer cable Fig 1 48 Step 1 If possible have the cable in a clear section of chassis Fig 1 49 Step 2 Loop the excess cable back on itself to form a bundle and cable tie Fig 1 50 Step 3 Add extra...

Page 19: ... of approximately 150mA Follow the previous instructions to open the meter The location of power on jumper JP1 is shown by the red box IN FIGURE 1 53 Move the jumper so it will short the 2 pins of the header Figure 1 56 shows the location of jumpers JP2 top center on the PCB Re fit the PCB into the housing re fit the rear screws and re fit the front display panel Header pins are open meter power u...

Page 20: ...he notches over the fascia While pressing removal tools downwards pull the display free from the DIN slot 2 Bracket Mounted This method uses a U shaped mounting bracket to hold the meter to the dashboard or other suitable surface Smaller brackets are also required to be installed to either side of the meter The meter can be rotated to achieve the best viewing angle To Remove Disconnect the connect...

Page 21: ...Fuse 12V 0V Black White Brown Blue Blue Positive Positive Negative Negative Rear view of optional alarm Note The blue and white wires will be required if you are connecting the optional alarm see below If they are not used to feed an external alarm they must be terminated in such a way as to insulate them Install External Alarm Optional Fit the alarm in a location that provides some protection fro...

Page 22: ... along the trailers chassis rails Use 4 x 3 16 x 1 screws or longer if need be with 3 16 Nyloc nuts to mount the connector Install 511 Transmitter Optional The 511 is an optional hand held display that works using a radio link The transmitter is normally located near the meter The associated 511 receiver and its charge cable are also shown below Install Printer Optional Fig 1 67 Fig 1 66 The trans...

Page 23: ...23 Setup Setup SI Onboard TruckWeigh Manual ...

Page 24: ...edure that are of particular importance to ensure a reliable and properly functioning system and these are covered in detail in the manual TruckWeigh axle transducer installation and configuration suitable location and orientation for the transducer should be carefully identified and that location should then be prepared for the transducer to be attached Slope compensation should also be set accor...

Page 25: ...tton is not currently active B ON OFF BUTTON Located to the far left of the display with a circular symbol broken at the top by a vertical line it is used to switch the display on and off If the Power On jumper option is enabled this button will have no function C LEFT ARROW BUTTON Located to the upper left hand side of the LCD display with a left facing arrow symbol it is generally the alarm sele...

Page 26: ...explained on the previous page Do not give the PIN to truck drivers You can change the PIN if needed This will be explained later 1 To change this press button edit This will clear the long bar and highlight the first changeable value as shown in figure 2 03 2 Use buttons to alter the original value to the required value 3 To move to the next value in line press and repeat as for line 2 4 Once the...

Page 27: ...re a group of axles share a common air suspension circuit only one CAN Air junction box is required and TruckWeigh will treat these as one axle referred to as an Axle Group Obtain the Truck s GVWR and Axle Ratings Locate the truck s rating plate and record the maximum gross axle weights and the truck s maximum Gross Vehicle Weight Rating GVWR and record these figures on the TruckWeigh Installation...

Page 28: ... the cursor down to JBox Config and select it You will see the screen shown below Plug in the first CAN junction box or air transducer interface box you wish to configure Scroll the cursor down to the mode you wish to configure the item to Press the Select button You will be prompted Are you sure Yes No Press Yes You should see the following screen to confirm it has configured OK Un plug that CAN ...

Page 29: ...edit keys to edit the values as previously described At the top of the Alarm menu there is a setting Alarms that can be set to Manual or Auto In the event of any active alarm being silenced by the user this setting dictates the method for resetting that alarm Manual alarm will need to be manually reset by the user before it becomes active again Auto alarm will automatically reset when the weight i...

Page 30: ...ant axle in turn and using the select button cycle through the options Leading Trailing None until the desired value is displayed Press Exit four times to return to the main user weighing screen NOTE 1 Any axles with Air transducers installed will default to None and are not configurable NOTE 2 Although uncommon a setting of None may be applied to an axle when the transducers are mounted perpendic...

Page 31: ... 3 and 4 1 2 3 4 5 6 7 8 Fig 2 17 By axle number this means the axles that have TruckWeigh axle sensors installed counted from the front of the truck Example 1 The truck in figure 2 18 has all 4 axles weighed using TruckWeigh axle transducers Example 2 The truck in figure 2 19 has the drive and trailer axles weighed using TruckWeigh axle transducers no weighing on the steer axle It has Hendrikson ...

Page 32: ...up axle Note that one air junction box is used for both rear axles This is what forms the air group One air junction box connected to more than one axle one of which is also a tag axle FRONT STEEL AXLE AIR GROUP MID LIFT TAG AXLE AXLE 1 AXLE 2 AIR GROUP Bag Bag Air Tanks Lift PRV PRV Bag Bag Bag Bag Fig 2 20 The air group manager should only be used in situations where a tag axle is a part of an a...

Page 33: ...this is the case by looking in the diagnostics menu Press Up until you see Menu on the top left Select Menu then select Diagnostics Now press the down button 3 times You should see the External inputs screen Make the tag axle raise and fall and you should see Input 1 change Record which axle position relates to what signal for example axle lowered signal low 0V or axle lowered signal high 12V The ...

Page 34: ... its default setting The Tag axle rated wgt Is figure taken from the trucks rating plate for the tag axle The Total group weight is the rating of all the axles in the air group added together In diagram fig 2 22 in the previous section this would be the figure of both axles in the dotted area Axle group 2 added together Now press Exit 4 times to return to the main user screen Configure Optional 51...

Page 35: ...er s management or maintenance staff Scroll the cursor down to the Set User PIN item Select it Change this to a number agreed with or to be given to the customer s management or maintenance staff Make sure they are clear that the user one may be given to the driver if they are allowed to change alarm set points If the owner of the truck does not want the driver to be able to change anything they s...

Page 36: ...36 Installation SI Onboard SI Onboard TruckWeigh Manual Setup ...

Page 37: ...37 Calibration Calibration SI Onboard TruckWeigh Manual ...

Page 38: ...hod Ideally 1 pair of weigh pads per axle is required i e 2 axles 4 weigh pads 3 axles 6 weigh pads etc If only 1 pair of weigh pads is available leveling mats should be used under all other un weighed axles in order to maintain the overall level of all axles Very Important If using weigh pads the axle figure is calculated by adding together the readings from both weigh pads beneath that axle Note...

Page 39: ...t Yes to confirm Fig 3 07 Message shown for process complete c Zero Menu Setup Calibrate Zero Fig 3 09 Select Yes to confirm Fig 3 10 Message shown for process complete b Zero Inclinometers Note This step MUST be completed for mechanical springs with Axle transducers attached This step is NOT required for Air only systems Fig 3 05 Menu Setup Calibrate Zero Inclinometers a Axle Tares Menu Setup Veh...

Page 40: ...vehicle positioned on flat level ground on the meter select a Menu Setup Calibrate Axle Spans 6 Calculate Axle Spans a The axle span figures you need to enter into the meter are the axle net weights They are calculated as follows b Subtract each axle tare weight from the weight from the axle gross figure measured by weigh pads or weighbridge for each axle For example axle 1 tare weight 6000 lbs ax...

Page 41: ...tings are all saved correctly b Record diagnostics for vehicle Span on the Installation and Calibration Record record below 8 Where required enable any additional features such as Tag Axle Manager 9 Complete loaded checks for slope compensation and zero return as detailed on the TruckWeigh Calibration Zero Return Checks document Fig 3 19 Message shown for process complete Repeat for each axle Fig ...

Page 42: ...42 SI Onboard TruckWeigh Manual Calibration ...

Page 43: ...Appendices Appendices SI Onboard TruckWeigh Manual ...

Page 44: ...ion that the limitations of the system are not exceeded i e 8 sensors and or 4 junction boxes In the example above the junction box can be left with its default factory setting as the TruckWeigh axle transducers will be numbered 1 4 using all the available sockets on the junction box 4x2 Rigid Chassis Leaf Spring Leaf Spring CAN Junction Box and Axle Transducers TruckWeigh Indicator TruckWeigh SI ...

Page 45: ... the available sockets on the junction box Axles 2 and 3 are likely to be a tandem configuration If this is the case the Bogie Mode setting should be configured accordingly 1 2 3 4 5 6 7 8 6x4 Rigid Chassis Leaf Spring Leaf Spring Leaf Spring TruckWeigh TruckWeigh Indicator CAN Junction Box and Axle Transducers Appendix A SI Onboard TruckWeigh Manual ...

Page 46: ...ll mean it will need to be re configured to mode 5 As with the front junction box all available sockets are used Axles 3 and 4 are likely to be a tandem configuration If this is the case the Bogie Mode setting should be configured accordingly 1 2 3 4 5 6 7 8 8x4 Rigid Chassis Leaf Spring Leaf Spring Leaf Spring Leaf Spring TruckWeigh Indicator CAN Junction Box and Axle Transducers CAN Junction Box...

Page 47: ...1 The rear air transducer interface box will be acting as transducers 3 and 4 even if there is only 1 air transducer It will need to be re configured to mode 2 4x2 Rigid Chassis Leaf Spring Air Spring Truck Air System Truck Air System CAN Air Pressure Junction Box and Transducers Suspension Air Bags CAN Junction Box and Axle Transducers TruckWeigh Indicator TruckWeigh Appendix A SI Onboard TruckWe...

Page 48: ...ducer interface box will be acting as transducers 5 and 6 even if there is only 1 air transducer It will need to be re configured to mode 3 4x2 Tractor Trailer Leaf Spring Air Spring Air Spring Air Spring Leaf Spring Truck Air System Truck Air System TruckWeigh Indicator CAN Air Pressure Junction Box and Transducers Suspension Air Bags CAN Junction Box and Axle Transducers TruckWeigh Appendix A SI...

Page 49: ... 1 air transducer It will need to be re configured to mode 4 Axles 2 and 3 are likely to be a tandem configuration If this is the case the Bogie Mode setting should be configured accordingly 1 2 3 4 5 6 7 8 6x4 Tractor Trailer Leaf Spring Air Spring Air Spring Air Spring Leaf Spring Leaf Spring TruckWeigh Indicator CAN Air Pressure Junction Box and Transducers Suspension Air Bags CAN Junction Box ...

Page 50: ...ox will be acting as transducers 3 and 4 even if there is only 1 air transducer It will need to be re configured to mode 2 4x2 Tractor Trailer Air Spring Air Spring Air Spring Air Spring TruckWeigh Indicator CAN Air Pressure Junction Box and Transducers Suspension Air Bags CAN Air Pressure Junction Box and Transducers Suspension Air Bags TruckWeigh Truck Air System Truck Air System Truck Air Syste...

Page 51: ...ckWeigh for tippers with load cells Off Axle 1 Alarm set point for the axle 1 gross alarm 25000 lbs Axle 2 Alarm set point for the axle 2 gross alarm 25000 lbs Axle 3 Alarm set point for the axle 3 gross alarm 25000 lbs Axle 4 Alarm set point for the axle 4 gross alarm 25000 lbs Alarm filter Filter to stop false alarm activation Weights must be above the set point for this period before they trigg...

Page 52: ...er with regard to the axle axle 4 None Tag axle group config Tag axle group manager On off this enables the tag axle function Off Tag axle group position Describes which axle group number the tag axle in it 3 Signal axle down Defines if the input signal is axle down 0 volts default or if axle down 12V Low Axle deployment delay This delay on acting upon seeing the axle down signal is to avoid false...

Page 53: ...r and should not be changed unless instructed to do so by a VPG engineer 16384 Note 1 Cell 8 This value is a calibration factor and should not be changed unless instructed to do so by a VPG engineer 16384 Note 1 Settings Count by This is the increments of weight the meter displays in 100 lbs Filter This is filtering that the sensors apply to the weight Low changes faster but may be less stable and...

Page 54: ...quest the barrier of a garbage truck moves forward when the rear axle weight s are close to maximum Off Barrier control Barrier This feature is intended for load cell systems It is used to request the barrier of a garbage truck moves forward when the rear axle weight s are close to maximum Off Maximum incline The operation of the barrier control feature is inhibited if the trucks pitch angle excee...

Page 55: ...elect from PIN Off PIN Manager and PIN User Manager Manager Reset Re learn This option makes the meter forget extra devices it has previously had connected that are no longer connected Reset defaults This re loads the meters factory default values for all the items that can be set configured Diagnostics System Shows battery and transducer excitation voltages and the firmware version JBox config Sh...

Page 56: ...ersion numbers are shown here JBox inclinometers This is for internal diagnostic use showing junction box angles and an asterisk showing the angle currently being used Note 1 This default is stored in the Transducers not the meter so defaulting the meter will not affect these figures Note 2 If you wish to decode the serial data from the scoreboard output you will need to sign an MNDA mutual non di...

Page 57: ...R TW 7100225 ADAPTER BLOCK FOR TW 8100024 CABLE IND JBOX 10 M 8100026 CABLE CAN BUS L C 5MTR 8100027 CABLE CAN BUS L C 10MTR 8100200 SIGNAL SPLITTER PM 1155 8100204 SUZI CABLE TRK 8100206 POWER CABLE PM1155 8100211 SUZI CABLE TRL 15M 8100305 J BOX CANBUS TW 4 WAY 8100310 J BOX CANBUS TW 6 WAY 8100320 SINGLE CAN AIR TRANSDUCER 8100325 DUAL CAN AIR TRANSDUCER 8302210 TRANSDUCER TRUCKWEIGH 8501155 TW...

Page 58: ...58 SI Onboard TruckWeigh Manual Notes ...

Page 59: ......

Page 60: ...SI Onboard Post Office Box 1484 Cumberland MD 21502 Ph 1 301 722 6000 Fax 1 301 722 7346 E Mail obw usa vishaypg com www obwvpg com For technical questions contact obw usa vishaypg com ...