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6

Introduction and scope

Please read this installation guide completely to ensure that all instructions are fully understood

before you install TruckWeigh®

Introduction

TruckWeigh® is a vehicle payload optimisation, overload monitoring and load distribution system for use

on vehicles with steel spring or air suspension or a combination of the two.

Scope

This document is intended as a guide to the installation and commissioning of TruckWeigh®.
It covers two transducer types currently supported in a TruckWeigh® system:
• TruckWeigh® axle transducers. These measure suspension deflection on mechanical spring

suspension systems

• Air pressure transducers. 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 transducer and any combination of the two.

About this document

Any display screenshots used in this document are intended as an illustration of the function being

described. As such, any specific detail or settings shown will differ from one installation to another.
The documentation uses the following conventions:

Important. These are important notes and appear inside a green border

Caution. These notes warn of an operation which may cause damage to the TruckWeigh® system.

These notes appear inside an orange border

Warning. These notes warn of an operation which may cause injury to the installer. The note is

highlighted in a yellow banner

TruckWeigh

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Содержание TruckWeigh

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

Страница 2: ...2 TruckWeigh...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 8: ...8 TruckWeigh...

Страница 9: ...9 Installation TruckWeigh...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 41: ...41 Configuration TruckWeigh...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 87: ...87 Calibration TruckWeigh...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 98: ...98 TruckWeigh...

Страница 99: ...99 System options TruckWeigh...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 114: ...114 TruckWeigh...

Страница 115: ...115 Appendix A TruckWeigh...

Страница 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...

Страница 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...

Страница 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...

Страница 119: ...119 Appendix B TruckWeigh...

Страница 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...

Страница 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...

Страница 122: ...122 TruckWeigh...

Страница 123: ...123 Appendix C TruckWeigh...

Страница 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...

Страница 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...

Страница 126: ...126 TruckWeigh...

Страница 127: ...127 Appendix D TruckWeigh...

Страница 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...

Страница 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...

Страница 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...

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