VPG TruckWeigh, Installation, Setup And Calibration Manual

Page 1: ...vpgonboard com TruckWeigh Installation Setup and Calibration Manual...

Page 2: ...2 TruckWeigh...

Page 3: ...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 en...

Page 4: ...ansducer 35 How to install the display unit 37 Additional device options 40 Configuration 41 Overview 42 Display unit operation 43 Action buttons 43 Gross display mode 44 Net display mode 45 Axle disp...

Page 5: ...B 113 Appendix A 115 System configuration table 116 Zero and span weights tables 117 Zero weights 117 Span weights 118 Appendix B 119 1160 Back Panel D Type Connector Pinouts 120 9 Way Male D Connecto...

Page 6: ...These measure changes to air pressure on air suspension systems Different system configurations can be used to support different chassis types The system can be configured to use either type of trans...

Page 7: ...ducer to be attached See How to install a steel axle transducer on page 35 TruckWeigh axle transducer orientation Axle transducers must be mounted to the vehicle with the correct orientation See How t...

Page 8: ...8 TruckWeigh...

Page 9: ...9 Installation TruckWeigh...

Page 10: ...isplay unit is supplied for the vehicle Display Cage A single display mounting cage is supplied for the display unit Axle Transducer A single cable with a connector at one end and the axle transducer...

Page 11: ...r are supplied in a bag A single air transducer is made up from a T connector a brass sensor fitting and two plastic air pipe fittings This is supplied for air suspension systems A single transducer a...

Page 12: ...nction boxes are supplied for each trailer unit Internal Domain Junction Box Cable The cable is identified by the grey junction box connectors Internal Domain Junction Box Cable 2 way The cable is ide...

Page 13: ...y splitter is supplied for each transducer The cable is identified by a single female internal domain cable connector and two male internal domain cable connectors External Domain Junction Box Cable A...

Page 14: ...ternal domain cable connectors at the other one for input and one for output External domain cable A single external domain cable is supplied for the system The cable is identified by the external dom...

Page 15: ...15 Tractor Suzi Trailer Suzi Rigid Suzi TruckWeigh...

Page 16: ...16 Double Ended Suzi Cable Protector and Cable Ties Cable protector is supplied and can be cut as required Cable ties are also supplied Surface Cleaning Wipes Double Sided Bonding Tape TruckWeigh...

Page 17: ...the following tools before starting an installation Tool Check Screwdriver set Hex driver set Torx driver set Socket set Multimeter Side cutters Drill set G Clamp Spanner set including 18 mm and 24 mm...

Page 18: ...xternal domain cable The external domain is a series of junction boxes connected together One junction box is installed on the chassis of the vehicle One junction box is also installed on the chassis...

Page 19: ...re installed on air suspension systems Axle transducers are installed on steel axle suspension systems The sensors must be installed in an appropriate position on the suspension system and linked to t...

Page 20: ...junction box is required for a single chassis Rigid vehicles will only require one junction box Articulated vehicles will require a junction box for the tractor and a junction box for every trailer Ar...

Page 21: ...ir Spring Truck Air System Truck Air System TruckWeigh Display unit Junction Box and Axle Transducers Suspension Air Bags Air Transducers Leaf Spring Leaf Spring Leaf Spring TruckWeigh Display unit Ju...

Page 22: ...cable sockets must point to the rear of the vehicle The TruckWeigh system will not provide the correct measurements if the junction box is not mounted with the cable sockets pointing to the rear of t...

Page 23: ...forms a single multi drop connection to each sensor on the vehicle 1 Connect the grey plug on the sensor input cable to the grey port on the junction box 2 Route the cable to the first sensor at the...

Page 24: ...h sensor Avoid running cables on or near sharp objects Keep cables away from hot components such as exhausts and engines Use cable protector to protect the cable at positions where it may be exposed t...

Page 25: ...o types of sensor Air pressure transducer This type of sensor can be mounted on air suspension systems Axle transducer This type of sensor can be mounted on steel axle suspension systems This includes...

Page 26: ...n number and where it is installed on the vehicle It is recommended that you use the system configuration table to record this information and refer to it when you are configuring the system See Syste...

Page 27: ...self levelling valve and the air bellows The air transducer can be supported without risk of damage from any moving parts The internal domain cable can be routed and connected without risk of damage f...

Page 28: ...g with the internal domain cable running away from the axle The transducer is not at risk of damage from any part on the vehicle throughout the full range of movement of the spring The internal domain...

Page 29: ...rear of the spring with the internal domain cable running away from the axle The transducer is not at risk of damage from any part on the vehicle throughout the full range of movement of the spring T...

Page 30: ...e axle with the internal domain cable running away from the axle The transducer is not at risk of damage from any part on the vehicle throughout the full range of movement of the arm The internal doma...

Page 31: ...at risk of damage from any part on the vehicle throughout the full range of movement of the strut The internal domain cable can be routed and connected without risk of damage from any moving parts and...

Page 32: ...left side of the truck and one on the right Ensure that you select the appropriate position for the sensor Please see Sensor installation positions on page 26 for guidance on selecting a position for...

Page 33: ...tape is wrapped around the air transducer connector and a little way up the cable to provide protection 4 Cut the air pipe at the appropriate position 5 Cut 1 of pipe off the cut end of the air pipe 6...

Page 34: ...es Use cable protector to protect the cable at positions where it may be exposed to damage Use cable ties to secure any excess cable to the chassis of the vehicle Ensure that you make a note of the se...

Page 35: ...2 Ensure the mounting surface is at an appropriate temperature The ideal temperature of the mounting surface is 70 F 21 C If required warm the spring with a hot air gun before bonding the transducer...

Page 36: ...ke a note of the serial number of the sensor and the location on the vehicle where it is installed 6 Make a note of the serial number of the sensor the position it is located on the vehicle and the di...

Page 37: ...e external domain cable starts at the junction box and routed to the cab of the vehicle 1 Connect the black plug on the external domain cable to the black port on the junction box 2 Route the external...

Page 38: ...n The black wire allows you to connect the monitor to an alarm if required 5 Mount the display unit Use mounting cage to mount the display unit to the DIN mount in the cab of the vehicle Use the cage...

Page 39: ...ain cable into the display unit Plug in any cables for the optional features See Additional device options on page 40 for further information 8 Test the power connection 9 Mount the display unit into...

Page 40: ...This allows you to retrieve transaction data backup your parameters and install firmware updates See USB functions on page 112 The 25 PIN female D type connector port provides digital I O and RS232 c...

Page 41: ...41 Configuration TruckWeigh...

Page 42: ...hicle configuration on page 74 Calibrated to accurately show the weight measurements Once the configuration is complete see Calibration on page 87 The display unit will show a message to indicate the...

Page 43: ...tapped to activate the corresponding action on the screen next to it Action buttons There are several action buttons on the display Each button will only be displayed if there is an option on the scr...

Page 44: ...the toggle mode button to toggle between the display modes Tap the cycle button to cycle through the menu options A border is displayed around an option as you cycle through the menu Tap the select bu...

Page 45: ...the load on the vehicle This provides access to the same menu options as the gross display mode Axle display mode The axle display mode displays the current gross or net weight of the vehicle and the...

Page 46: ...ght readings of each trailer Axles are grouped into trailer groups for the purposes of measuring the weight applied to a trailer See Trailer axle groups on page 50 Tap the toggle mode button to toggle...

Page 47: ...o view the data on your system and update the user settings including the user password This does not provide access to the configuration menus Level 3 Engineer This allows you to view and access any...

Page 48: ...you want to apply any relevant changes to 4 Tap the scroll up or scroll down buttons until the weighing config option is highlighted 5 Tap the select button to open the weighing config menu Power on...

Page 49: ...e scroll up or scroll down button until the correct option is displayed 4 Tap the select button to select the power on screen option 5 Tap the go back button to save the setting and go back to the sys...

Page 50: ...n a vehicle are fitted with a bogie the weight measurements for these axles can be combined and displayed as a single value 1 Tap the scroll up or scroll down buttons until the trailer axle groups opt...

Page 51: ...buttons to set the last axle Refer to your installation notes to determine which axles need to be grouped 8 Tap the select button to save the group If there are ungrouped axles on the vehicle another...

Page 52: ...its setting 3 Tap the select button to access the weighing units setting 4 Tap the scroll up or scroll down buttons to select the appropriate unit to display weight measurements in 5 Tap the select bu...

Page 53: ...setting and go back to the system weighing menu Net weighing Net weighing allows you to change the display to show the net weight The net weight represents the weight of the load applied to the vehic...

Page 54: ...to go back to the system weighing menu Reading stability The weight measurement taken by the system can continually fluctuate as the vehicle moves Reading stability is the acceptable level of change...

Page 55: ...select button to activate the stability limit setting 4 Tap the scroll up or scroll down buttons to set the stability limit value 5 Tap the back button to return to the vehicle config menu G A G A G P...

Page 56: ...menu If multiple junction boxes are connected to the system you are prompted to select a junction box Select the junction box you want to apply any relevant changes to 4 Tap the scroll up or scroll do...

Page 57: ...vated 1 Tap the scroll up or scroll down buttons until the serial output option is highlighted 2 Tap the select button to open the serial output menu 3 Tap the scroll up or scroll down buttons to sele...

Page 58: ...to a 3rd party device 6 Tap the select button to open the menu for the port 7 Use the scroll up or scroll down buttons to highlight a setting 8 Tap the select button to activate the setting 9 Use the...

Page 59: ...ckWeigh system Frequency This determines the frequency of the transmission Tx Retries This determines the number of times the transmission is resent if the initial transmission fails Ack Required Tick...

Page 60: ...port before it is activated 1 Tap the scroll up or scroll down buttons until the serial output option is highlighted 2 Tap the select button to open the serial output menu 3 Tap the scroll up or scro...

Page 61: ...7 Use the scroll up or scroll down buttons to highlight a setting 8 Tap the select button to activate the setting 9 Use the scroll up or scroll down buttons to adjust the setting 10 Tap the select bu...

Page 62: ...ppropriate rate Vehicle ID The vehicle ID is used when sending data via a serial port The ID can be set to the requirements of your organisation For example it can be a number plate or fleet number et...

Page 63: ...n to open the vehicle ID menu 7 Tap select to activate the vehicle ID setting 8 Use the cycle and scroll buttons to change each character of the vehicle ID 9 Tap the select button to save the change 1...

Page 64: ...al output menu 3 Tap the scroll up or scroll down buttons to select RS232 4 Tap the select button to open the RS232 menu 5 Tap the scroll up or scroll down buttons to highlight the printer option G A...

Page 65: ...evice and use the import print header to import a text file to define the print header used on a printout 9 Use the printout menu to define what information is printed on a printout You can select the...

Page 66: ...buttons until the outputs option is highlighted 2 Tap the select button to open the outputs menu 3 Tap the scroll up or scroll down buttons to select an output 4 Tap the select button to access the o...

Page 67: ...the level is high for the duration set in the associated parameter before returning to a low state Active low This is a constant high signal that drops to a constant low signal when it is triggered A...

Page 68: ...eight Axle Weight Select this to send a signal when the weight on an axle reaches a specific weight Axle Group Select this to send a signal when the weight on an axle group reaches a specific weight N...

Page 69: ...ighlighted 2 Tap the select button to open the change PIN menu 3 Tap the scroll up or scroll down buttons to highlight a PIN G A G A G Serial Output Outputs Change PIN Reset Defaults Time Date Auto Po...

Page 70: ...1 Tap the scroll up or scroll down buttons until the reset defaults option is highlighted 2 Tap the select button to open the reset defaults menu G A G A G Level 1 Level 2 Level 3 Change PIN PIN Conf...

Page 71: ...s System Config This will reset the settings in the system configuration to their default values Junction Box This will reset the vehicle and calibration settings for the junction box to the default v...

Page 72: ...se the scroll and select buttons to set the current time date and enable or disable the daylight saving setting 4 Tap the go back button to save the setting and go back to the system configuration men...

Page 73: ...off option is highlighted 2 Tap the select button to open the auto power off menu 3 Use the scroll and select buttons to activate the power off screen and set the number of minutes it will wait befor...

Page 74: ...oggle mode button to open the gross display mode 2 Tap the cycle button until the configuration option is highlighted 3 Tap the select button to open the configuration menu 4 Tap the scroll up or scro...

Page 75: ...ntation option is displayed 5 Tap the select button to select the orientation option The junction box orientation is determined by the direction the top face of the box is facing For example Up down l...

Page 76: ...oll up or scroll down buttons to input the number of axles on the chassis that the junction box is attached to 5 Tap the select button to set the number of axles 6 Tap the back button to open the axle...

Page 77: ...le configurations Axle This is used to indicate that axle transducers are located on a single leaf spring axle This type of configuration will usually have 2 sensors on each axle one for each side of...

Page 78: ...t and rear axle of the air group The number of sensors is always the same as the number of sensors on the Air group front axle Air group rear This is used to indicate the last axle in the air group Th...

Page 79: ...f sensors is the total number of sensors for the rear axle of the bogie ASym bogie front This is used to indicate the first axle fitted to the bogie This is used if there is an uneven load distributio...

Page 80: ...a sensor Use the scroll up and down buttons to highlight the sensor field and tap the select button to open it Use the scroll up and down buttons to scroll through the sensors and tap the back button...

Page 81: ...or Use the scroll up and down buttons to highlight the direction field and tap the select button to open it Use the scroll up and down buttons to select a direction e g facing forward facing backward...

Page 82: ...t permitted for the chassis Net This represents the maximum load weight which can be placed on the chassis Axle This represents the maximum load which can be applied to an axle on the chassis Set Poin...

Page 83: ...p the select button to activate the alarm setting 5 Tap the yes button to activate the alarm 6 Tap the back button to return to the alarms on off menu 7 Repeat steps 3 to 6 to activate the individual...

Page 84: ...alarm weight 5 Use the cycle scroll and select buttons to input the weight limit that will trigger the alarm 6 Tap the back button to return to the alarm weights menu 7 Repeat steps 3 to 6 to set the...

Page 85: ...larms menu 7 Repeat steps 3 to 6 to set the weights for each set point alarm 8 Tap the back button to return to the alarms menu Axle underload alarm Axle underload can occur when a load over the rear...

Page 86: ...Tap the scroll up or scroll down buttons to highlight the axle underload option 7 Tap the select button to activate the setting 8 Tap the scroll up or scroll down buttons to set the axle underload per...

Page 87: ...87 Calibration TruckWeigh...

Page 88: ...weight measurement of each axle when the vehicle has an empty payload Span weights This is the weight measurements for each axle when the vehicle has a payload as close to GVW as possible The display...

Page 89: ...e pair of weigh pads per axle If possible weigh all axle at the same time If not use levelling mats to maintain the overall level of any axles which are not being weighed 2 Add together the weight mea...

Page 90: ...les on page 117 See below for an example of this calculation It is recommended that the same weighbridge is used to take all weight measurements for both the zero and span calibration processes Weighb...

Page 91: ...ntil the configuration option is highlighted 3 Tap the select button to open the configuration menu If multiple junction boxes are connected to the system you are prompted to select a junction box Sel...

Page 92: ...roll up or scroll down buttons to highlight the junction box which is linked to the sensors on the axle 4 Tap the scroll up or scroll down buttons until the axle weights option is highlighted G A G A...

Page 93: ...dit 7 Tap the select button to enable the weight entry field 8 Tap the scroll up or scroll down arrows to adjust the first number in the weight measurement 9 Tap enter to keep the number and move to t...

Page 94: ...ap the back button to return to the calibration menu The wheel weights option provides an alternative method for performing the zero calibration Use this option to input the weight values for each ind...

Page 95: ...lues need to reflect the weight measurements taken for each axle with a payload as close to GVW as possible See Weighing the vehicle on page 89 Tap the scroll up or scroll down arrows to highlight an...

Page 96: ...highlight the span all axles option It is recommended that vehicle is positioned back on the weighbridge before selecting the span all axles option 13 Tap the select button 14 Tap the yes button perfo...

Page 97: ...97 The junction boxes will show as System OK in the select junction box menus when the calibration is complete A G A G A G 1 System OK 2 System OK Select a Junction Box 1 2 TruckWeigh...

Page 98: ...98 TruckWeigh...

Page 99: ...99 System options TruckWeigh...

Page 100: ...isplay settings Language options Diagnostics System messages USB upgrades to system Exporting configuration and calibration settings Use the TruckWeigh display unit installed in the cab to access the...

Page 101: ...the display monitor is activated Tick this option to activate the key bleep Display Time Tick this option to display the current time on the home screen of the monitor 1 Tap the toggle mode button to...

Page 102: ...button to activate the option 8 Use the scroll tick and select buttons to adjust the setting 9 Tap the back button to return to the display settings 10 Tap the back button to return to the user setti...

Page 103: ...ighlighted 3 Tap the select button to open the user settings menu 4 Tap the scroll up or scroll down buttons until the language option is highlighted 5 Tap the select button to open the language menu...

Page 104: ...104 9 Tap the back button to return to the display settings 10 Tap the back button to return to the user settings menu TruckWeigh...

Page 105: ...nostics option is highlighted 3 Tap the select button to open the diagnostics menu Live view The live view shows the current information about each sensor on your vehicle Use the cycle button to cycle...

Page 106: ...gs The gross alarm shows the total gross weight value and the gross weight values for each junction box that will trigger the alarm The axle alarms show the weight values that will trigger the alarm f...

Page 107: ...for each set point which has been configured Configuration The configuration menu provides access to the configuration details for the system A G Set Point Alarms Set Point 1 Set Point 2 Set Point 3...

Page 108: ...stem The sensors are configured when they are installed See Sensor configuration on page 80 The diagnostic details include Firmware version numbers Sensor serial numbers Sensor type and orientation Fi...

Page 109: ...provides access to the voltage and temperature measurements for the junction boxes and display unit Each sub menu shows the values for the associated hardware Logs The logs menu allows you to access...

Page 110: ...110 There are three options View log Clear log Use this option to clear all data from the log Save log Use this option to save the log to a USB TruckWeigh...

Page 111: ...s display mode 2 Tap the cycle button until the system messages option is highlighted 3 Tap the select button to open the system messages menu 4 Tap the scroll up or scroll down buttons to scroll thro...

Page 112: ...date firmware option allows you to update the firmware installed on a junction box Open the menu and select a junction box to update The menu displays the firmware update available on the USB Select t...

Page 113: ...e the current configuration and calibration settings on a junction box Open the menu and select a junction box Tap the yes button to save its settings A confirmation message is displayed when it is co...

Page 114: ...114 TruckWeigh...

Page 115: ...115 Appendix A TruckWeigh...

Page 116: ...osition No Sensor Type Orientation Serial No 1 1 2 2 3 4 3 5 6 4 7 8 5 9 10 6 11 12 7 13 14 8 15 16 9 17 18 10 19 20 It is recommended that you photocopy this table and use it to record the details of...

Page 117: ...es Zero weights Weighbridge Measurements Weight Calculation Axle Weight G Gross Weight G a Axle 1 g a b Axle 2 a b c Axle 3 b c d Axle 4 c d e Axle 5 d e f Axle 6 e f g Axle 7 f g h Axle 8 g h i Axle...

Page 118: ...Weighbridge Measurements Weight Calculation Axle Weight G Gross Weight G a Axle 1 g a b Axle 2 a b c Axle 3 b c d Axle 4 c d e Axle 5 d e f Axle 6 e f g Axle 7 f g h Axle 8 g h i Axle 9 h i j Axle 10...

Page 119: ...119 Appendix B TruckWeigh...

Page 120: ...5 6 9 9 Way Male D Type Connector View From Front Pin Function Description 1 Not Connected 2 RX RS232 PORT 1 Receive IN 3 TX RS232 PORT 1 Transmit OUT 4 Not Connected 5 Gnd Signal Ground 6 Not Connect...

Page 121: ...7 Gnd Signal Ground 8 Not Connected 9 Supply Voltage 10 DOUT3 Digital Output 3 11 DOUT1 Digital Output 1 12 DIN3 Digital Input 3 13 DIN1 Digital Input 1 14 Not Connected 15 Not Connected 16 CAN Lo 2...

Page 122: ...122 TruckWeigh...

Page 123: ...123 Appendix C TruckWeigh...

Page 124: ...save logs or settings Wrong sensor type for axle The sensor type is wrong for the axle For example an axle sensor is installed on an air group axle Invalid weight An invalid weight was entered Messag...

Page 125: ...r An error occured during the zero operation Span error An error occured during the span operation Calibration error An error occured during calibration Calibration zero gain error The gain was calcul...

Page 126: ...126 TruckWeigh...

Page 127: ...127 Appendix D TruckWeigh...

Page 128: ...mA Current standby at 24V 10 mA Weighing modes Net Gross Axles INDICATOR Type OLED Size 137 65 x 35 89 mm 5 42 x 1 41 inches Operating temperature 30 to 70 C 22 to 158 F Environmental protection IP51...

Page 129: ...0 9600 19200 38400 57600 115200 CAN No of ports 2 Baud rate 125 250 500 Kbs DIGITAL I O Inputs No of inputs 4 Voltage 6 36 V Current 0 5 5 mA Outputs No of outputs 4 Voltage 12 24 VDC Current 1 A ACCE...

Page 130: ...al results in different applications and performance may vary over time Statements regarding the suitability of products for certain types of applications are based on VPG s knowledge of typical requi...