LoadMan LM200 Reference Guide...SETUP & CALIBRATION MODE 25 ... DUMP LOAD Weighing is complete and load is ready to dump. WEIGHING TARE Measuring the empty container weight while arms

LoadMan® LM200 Reference Guide

For

Fork Based Weigh-In-Motion Refuse Trucks

Revision 05.2013-3

Creative Microsystems, Inc. 15224 SE Renton Issaquah Road

Renton, WA 98059

Phone: 1.888.LOADMAN 1.888.562.3626 1.425.235.4335 Email: [email protected] [email protected]

LoadMan is a registered trademark® of Creative Microsystems Inc.

Copyright ©2009 Creative Microsystems

All Rights Reserved

mailto:[email protected]

mailto:[email protected]

ii

Safety Warning

iii

SAFETY WARNING

Using this system while operating a motor vehicle may be distracting, dangerous, or prohibited. Operator remains responsible for safe travel, should obey laws and regulations, and should exercise good judgment at all times. Failure to pay full attention to the operation of the vehicle may cause an accident resulting in serious consequences. You assume sole responsibility and risk for using this system.

iv

Table of Contents

v

TABLE OF CONTENTS

OPERATIONAL BASICS 3

Power On / Off .................................................................................................. 3

LoadMan Operating Modes ............................................................................... 5

Measurement Units – English / Metric .............................................................. 7

Introduction to the PROGRAM FUNCTION Display ............................................ 8

Connectivity & Communications ....................................................................... 9

Introduction to LoadMan Load Manager Software .......................................... 11

NORMAL OPERATING MODE 13

Weight and Information Displays .................................................................... 14

Route Information Displays ............................................................................. 17

PROGRAM FUNCTION Displays ........................................................................ 20

SETUP & CALIBRATION MODE 25

Basic Navigation .............................................................................................. 26

Setup & Calibration Commands ....................................................................... 27

1. Verify Wiring .............................................................................................. 49

2. Power On ............................................................................................... 49

3. Verify Angle Sensors ................................................................................... 50

4. Verify Fork Load Cells Respond Correctly .................................................... 51

5. Calibrate Arm Angle .................................................................................... 51

6. Calibrate Fork Angle ................................................................................... 52

7. Verify Angle Measurements Respond Correctly .......................................... 53

8. Determine Fork Angle Lag ........................................................................... 54

9. Verify Weigh-In-Motion Response .............................................................. 56

10. Calibrate System for ZERO FORK Load ...................................................... 57

11. Calibrate System Under Load .................................................................... 59

12. Fine Tune Span Adjust .............................................................................. 60

Table of Content

vi

TROUBLESHOOTING GUIDE 63

COLLECTING LOAD DATA 69

WIRING DIAGRAM 73

APPENDIX A – ERROR MESSAGES 74

APPENDIX B – SETUP & CONFIGURATION COMMAND TREE 75

APPENDIX C – DOWNLOADING LOADMAN METER SOFTWARE 75

INDEX 79

Introduction

1

INTRODUCTION The LoadMan® LM200 is a precision instrument capable of running and controlling many different vehicle weight measurement applications. The application documented in this manual is programmed for front load, fork based vehicles that weigh commercial containers in motion – as they are picked up, dumped, and lowered to the ground. The LoadMan system is completely automatic and the driver/operator does not have to press any buttons or take any actions to obtain a weight reading. The 16 character display provides all the information needed to understand the status of the weighing system. For example, the meter automatically provides the following instruction displays during the weigh-in-motion process: READY TO WEIGH The forks are below the start of the weighing window

and ready to weigh. WEIGHING LOAD Message while container is lifted through the weighing

window. GROSS WEIGHT Displays weight of the container and its load.

DUMP LOAD Weighing is complete and load is ready to dump.

WEIGHING TARE Measuring the empty container weight while arms are

going down. NET WEIGHT Displays the computed net weight of the dumped

material. TRUCK Displays the accumulated load net weight. The container load weights are measured and reported to the operator as a net load weight. Also, the dumped load weights are accumulated with the weight of the existing material in the vehicle – providing the driver/operator a running total of the net vehicle weight or the gross vehicle weight. This application not

Introduction

2

only supports in-motion weighing of the net contents dumped into the truck, but also records the measured load data with optional route, account and GPS data. The LoadMan Fork Based Weigh-In-Motion system consists of three digital electronic components: An onboard In-Cab Meter for displaying weight, route and system

information. A computer based Arm Weigh-In-Motion Assembly that is mounted in a

steel protective enclosure on the lift arm. A Fork Weigh-In-Motion Assembly mounted in a steel protective enclosure

on the fork assembly.

The fork weigh-in-motion assembly converts the sensitive analog data signals from the two fork loadcells to digital, using a precision digital to analog encoder called a LoadCoder®. It also measures the fork angular position and acceleration, converts the information to digital, and transmits the data to the arm weigh-in-motion assembly. The arm weigh-in-motion assembly also contains an angle sensor; so the weighing system not only knows the position and acceleration of the forks, but also the angular position and acceleration of the lift arm at all times. The arm weigh-in-motion module gathers the weight measurement from the two fork loadcells, the fork angular position and acceleration, and the arm position and acceleration. It then processes this information to determine the weight of the containers plus its contents while going up. Then, in the same manner, measures the tare weight of the container going down. The difference between these two weights determines the weight of the material that was dumped into the truck. All of this information is transmitted to the in-cab meter and displayed to the driver/operator. LoadMan's Load Management Software (operating on an office PC) allows remote tracking of trucks, drivers, customers, routes and products by account or job. Route lists are created with the software and downloaded to the LoadMan meter. Any recorded load data and/or GPS position data in LoadMan’s data collection memory will be automatically transferred to the Load Management Software - without any prompting or intervention from the driver – whenever a wireless modem connection is established.

Operational Basics

3

OPERATIONAL BASICS This section will introduce the operational basics of the LoadMan Meter. Anyone new to the use of the LoadMan Meter should first read this section to become familiar with: Front panel display Keypad definitions and use Basic navigation Programming basics Connectivity & Communications LoadMan Load Manager Software

Power Connecting power at the rear panel causes LoadMan to power on, displaying the message “LOADMAN”, followed by “PROG VERSION X.X”. The Program Version number X.X represents the application software version and aids in tracking software updates. With power on, and when in any operating mode, momentarily pressing the POWER button causes LoadMan to briefly display the “GOODBYE!“ message, followed by a repeat of the “LOADMAN” “PROG VERSION X.X” sequence. The LoadMan meter cannot be powered off with this button. Note: When power is applied, the message “CYCLE ARMS” may appear if the arms and/or forks are substantially out of their zero positions. Repositioning the arms and/or forks as close as possible to zero turns off this message.

Operational Basics

4

LoadMan Front Panel and Display As shown in Figure 1, the LoadMan LCD display has a 16 character alphanumeric field for displaying operational messages as well as setup and calibration instructions. There are 6 push-buttons used for power, programming and display selection.

Figure 1. LoadMan Meter Front View

PROGRAM Keys

These PROGRAM keys are used to enter a command (like ZERO TRUCK), print a load record (PRINT LAST LOAD), change a programmable number (like setting the TRUCK tare weight in Setup & Calibration), or set the Date and Time. If a selected display is programmable, pressing the PROGRAM key will

initiate a flashing cursor in the display, signifying that LoadMan has entered the Program Mode.

For programmable displays, use the PROGRAM key to move the flashing cursor left to the next programmable digit/item in the display.

Once the flashing cursor is positioned over the item to be changed, use the PROGRAM key to increase/bump the digit/item to its next value.

Continue to use the /PROGRAM keys until the display has been programmed.

The PROGRAM key will execute the command and save any changes SET

made to the display.

Note: LoadMan will take NO action on selections and/or changes until the

PROGRAM key is pressed. And, if a selected display is not programmable, SET

pressing any of the PROGRAM group of keys will have no effect.

Operational Basics

5

SELECT Keys

The SELECT keys are used to manually scroll through any of the currently available vehicle weight displays and route information. These keys are also for scrolling through setup & calibration command options. The SELECT key will sequence forward through a group of displays. The SELECT key will sequence in reverse through a group of displays.

Weight and Message Display

Any weight information, route information or status message information shown on the 16 character display will depend on the overall setup and configuration of the LoadMan Meter (discussed in later sections).

LoadMan Operating Modes LoadMan has two distinct operating modes: the Normal Operating Mode and Setup & Calibration Mode. Introduction to Normal Operating Mode At power on, LoadMan enters the Normal Operating Mode which provides the main operational, messaging and status information for the LoadMan weight and route applications. Table 1 contains a list of display messages that can be manually accessed using the /SELECT keys, or automatically cycle displayed. Introduction to Setup & Calibration Mode LoadMan’s Setup & Calibration Mode provides the operator the capability to program advanced functionality, choose optional information displays, enable communications, and to setup and calibrate a truck’s configuration. The top level command options are summarized in Table 2, and detailed programming of these options will be discussed in the section titled Setup & Calibration Mode later in this guide. Also, a detailed command tree is located in the Appendix. Activating – Setup & Calibration Mode w/SECURITY OFF

Continually depress the POWER button, through the “GOODBYE!“ message, and until the “LOADMAN SETUP“ message is displayed.

The first setup & calibration category displayed is “SET ZERO?---->NO”.

Operational Basics

6

Activating – Setup & Calibration Mode w/SECURITY ON

Continually depress the POWER button. The messages “GOODBYE!“ and “ENTER PASS CODE!“ will display.

At the prompt, “PASS CODE 0”, use the /PROGRAM keys to program

the security code TO “123”and save the code with the PROGRAM key. SET

If correct, LoadMan displays the message, “LOADMAN SETUP”. And the first setup & calibration category displayed is “SET ZERO?---->NO”. If the security code is NOT correct, the error message, “SECURITY FAILED” is

displayed, and the Setup & Calibration mode cannot be accessed.

When finished with any of the setup categories and to return LoadMan to the normal operating mode: Press the SELECT key until “EXIT SETUP?-->NO “ is displayed. Then press PROGRAM key to display “EXIT SETUP?-->YES“.

Finally, press the PROGRAM key. SET

LoadMan will now return to the normal operating mode – Information Display.

Table 1. Normal Operating Mode Display

Information Display

Information Display READY TO WEIGH WEIGHING LOAD GROSS LOAD / DUMP LOWER ARMS NET RECORDING LOAD

Use the SELECT key to sequence forward through available displays Use the SELECT key to sequence in reverse through available displays

Weight Displays

LAST

TRUCK

TARGET

Route Information Displays

LOAD NAME

LOAD ACCOUNT #

STOP #

PRODUCT NAME

PROBLEM NAME

Date & Time DATE & TIME

Operational Basics

7

Table 2. Setup & Calibration Commands

SET ZERO Calibrates the Fork and Arm sensors to zero. Also calibrates the fork load sensors to a net weight of zero.

SELECT Sequence forward through available displays /PROGRAM Keys for programming values and command entry

PROGRAM SET

To enter/activate command or value SELECT Sequence in reverse through available displays

SET SPAN Calibrates the truck’s load of material to readings taken from another scale.

SET TARE

Sets the empty weight of the vehicle.

INSTALL Provides the capability to setup and/or change the operating configuration of LoadMan.

SET DEFAULTS

Returns all settings to factory default settings.

ERASE DATA Permanently erases all data in LoadMan’s data collection memory.

TROUBLESHOOT

Provides detailed angle sensor, loadcell, communications and other LoadMan information that can be useful for isolating issues.

Measurement Units – English / Metric The LoadMan meter comes preconfigured at the factory to display weight measurements in English units. Throughout this manual, English units will be used when explaining commands and presenting examples, but everything presented in this manual is valid for both English and metric configured meters. Metric Units – Setting Kilograms/KG To configure LoadMan to display weights in metric units, kilograms/KG: First enter the Setup & Calibration Mode as just described above.

Operational Basics

8

Use the SELECT key to locate “INSTALL?----->NO”.

Press PROGRAM to choose “YES ”; then . SET

Use the /SELECT keys to locate “SET DISPLAYS->NO”.

Press PROGRAM to choose “YES ”; then . SET

Now use the PROGRAM and PROGRAM keys to choose and set SET

“DISPLAY UNITS=KG”.

This exercise introduced the programming and configuration process. More programming and configuration will be covered later in this manual. But for now, when finished programming and to return to the normal operating mode, press SELECT to locate “EXIT SETUP?”; choose “YES” with the PROGRAM key;

and save/exit by pressing the PROGRAM key. SET

Introduction to the PROGRAM FUNCTION Display

Use the PROGRAM FUNCTION display to access and activate one of the command options listed in Table 22.

Table 2. PROGRAM FUNCTION Commands

SHOW NET

SHOW GROSS

Set display for NET weight operation.

Set display for GROSS weight operation.

Use the /SELECT keys to locate the PROGRAM FUNCTION display. Use the /PROGRAM keys to sequence through available program options. = forward = reverse

Use the PROGRAM SET

key to activate command.

PRINT LAST LOAD Prints the most recent load data to a pre-configured printer

ZERO FORK LOAD Resets the fork’s load cells to zero

CYCLE DISPLAY Initiates the automatic display cycle of weight information and status messages

ZERO TRUCK Zeros the accumulated truck load TOTAL

Operational Basics

9

Either of the /PROGRAM keys will sequence through the available

PROGRAM FUNCTION displays, and once an item is selected, the PROGRAM SET

key will activate and save the selection. LoadMan will then return to the normal operating mode. Note: While within any of the PROGRAM FUNCTION options, the /SELECT keys will abort programming and return LoadMan to manual display.

Connectivity & Communications RS232 Ports LoadMan comes standard with one 9-pin RS232 port that is a dedicated for connecting the meter to the motion sensors and loadcells. During setup and configuration, this is referred to as RS232 Port #2. RS232 Port #1, as referenced in Setup and Configuration, is a 9-pin connector for use by peripherals like printers (for printing load and route information) or by large scoreboard displays mounted on the truck exterior. Also, RS232 Port #1 can connect to input devices like barcode readers for reading account and route information from Route Sheets. Communications The LoadMan meter may come equipped with an optional Bluetooth wireless modem, or a GSM cellular modem. The modem is used to connect and communicate with LoadMan’s Load Manager Software. The Load Manager Software allows remote tracking of trucks & drivers, plus customer accounts and route location; and exchanges the route and location information through one of these modems. GPS The LoadMan meter may also come equipped with an optional onboard GPS chip and antenna. When recorded GPS coordinates are uploaded into LoadMan’s Load Manager Software, office management can use the coordinates to track truck routes and aid with several other advanced location based functions from the office. Refer to Figure 3. LoadMan Connectivity Example.

Operational Basics

10

Figure 2. LoadMan Meter Rear View

GPS The LoadMan meter may also come equipped with an optional onboard GPS chip and antenna. When recorded GPS coordinates are uploaded into LoadMan’s Load Manager Software, office management can use the coordinates to track truck routes and aid with several other advanced location based functions from the office. Refer to Figure Error! Reference source not found..

Operational Basics

11

Figure 3. LoadMan Connectivity Example

Introduction to LoadMan Load Manager Software

Figure 4. LoadMan Load Managment Software

Operational Basics

12

LoadMan's Load Management Software allows remote tracking of trucks, drivers, customers, routes and products by account or job. LoadMan offers two versions of Load Manager Software: 1) LoadMan Load Manager for Waste & Recycling and 2) LoadMan Load Manager for Mining & Steel. These two products are very similar, and each offer a User Interface and features that are customized for the specific industry served. Each fleet truck’s data collection memory can be accessed by the software to gather:

Routes, vehicle ID, driver ID, and customer accounts Products hauled or delivered - by account or job Load weights, load sites and commodity Truck and load locations by GPS coordinates Problems encountered (Waste & Recycling) Commodity and mix Recipes (Mining and Steel) Time & date stamp on all loads

This load data is uploaded to a back office management database, where load data can be further studied by date, customer, account, driver, etc., and even exported to popular accounting and spreadsheet programs. Visit our LoadMan website for more information about LoadMan Load Manager and to view a video demonstration:

http://www.loadman.com/products_solutions/software

http://www.loadman.com/products_solutions/software

Normal Operating Mode

13

NORMAL OPERATING MODE At power on, LoadMan enters the Normal Operating Mode, which provides the main operational, messaging, and status information for the LoadMan weight and route applications. The first display is the Information display that shows detailed load and process information about the in-motion weighing cycle. This initial information display and other weight, route and programming displays are discussed in this chapter. Refer to Table 4.

Table 4. Normal Operating Mode Display

Information Display

Information Display READY TO WEIGH WEIGHING LOAD GROSS LOAD / DUMP LOWER ARMS NET RECORDING LOAD

Use the SELECT key to sequence forward through available displays Use the SELECT key to sequence in reverse through available displays

Weight Displays

LAST

TRUCK

TARGET


LOAD NAME

LOAD ACCOUNT #

STOP #

PRODUCT NAME

PROBLEM NAME

Date & Time DATE & TIME


14

Weight and Information Displays INFORMATION DISPLAY – This display is where the weigh-in-motion system

normally operates. It has been set up to automatically provide the operator all the instructions and information needed to run the in-motion weighing system.

CYCLE ARMS Infrequently, (if the arms and/or forks are initially positioned substantially away from zero degrees), this message informs the operator to position the arms and forks as close to zero degrees as possible. READY TO WEIGH appears after this correction has been made.

READY TO WEIGH

Informs the operator that the weigh-in-motion system is ready to weigh.

WEIGHING LOAD

This message is displayed once the arms have reached the start of the weighing window. There is no need to stop the arms during the weighing sequence as LoadMan computes the weight while the forks and arms are in-motion.

GROSS xxxxxx The gross weight of the loaded container – once the arms have been raised above the weighing window. xxxxxx represents the gross weight of the container and its contents.


15

DUMP xxxxxx LOAD xxxxxx These two messages display alternately to inform the operator to complete the lifting process by completely dumping the load. xxxxxx represents the gross weight of the container and contents. Note: If the arms are lowered before reaching the programmed DUMP set point, LoadMan ignores the weight and display the message, “IGNORING LOAD!”.

LOWER ARMS LoadMan displays this message once the load has been dumped and the arms are being lowered.

WEIGHING TARE Message displayed as the emptied container is being weighed – while the arms continue to be lowered below the weighing window.

NET xxxxxx

Displays the net weight where xxxxxx represents the weight of the material just dumped into the truck.

RECORDING LOAD The message indicates that the weigh-in-motion process has successfully completed and the net weight has been entered into the load record. Additionally, the recorded net weight is added to the accumulated total weight of the TRUCK.


16

WEIGHT DISPLAYS – While in the Normal Operating Mode, LoadMan presents various weight displays, some of which can be configured in the INSTALL/SET DISPLAYS group of the Setup & Calibration commands (see the section on Setup & Configuration Mode for instructions on choosing optional weight displays). LAST xxxxxx LB – Displays the net weight of the contents dumped from

the last container picked up and weighed. TRUCK xxxxxx LB – Displays the total net weight of the contents

dumped into the truck for all containers since the last ZERO TRUCK command was executed. (See PROGRAM FUNCTION below for executing the ZERO TRUCK command.)

TARGET xxxxxx LB – This is a programmable display that shows the current target net weight set point. When turned on, this display allows the operator to set a target net truck weight that will activate an alarm when exceeded. (To enable the TARGET display, use the INSTALL/SET DISPLAYS/ TARGET SETPT->ON command in Setup & Calibration.) To program the TARGET weight: o In the Normal Operating Mode locate the TARGET display using the

SELECT key. o Now use the /PROGRAM keys to program the target load

weight.

o Press PROGRAM to set and activate the target weight. SET

Software Alarm – To enable an overload display message when the TARGET net truck weight is exceeded, use the INSTALL/SET DISPLAYS/FLASH OVERLD command in the Setup & Calibration mode. So in the normal operating mode, the message “GROSS >>> TARGET” displays anytime a net truck weight exceeds the target weight.


17

Hardware Alarm – To activate a hardware alarm, an overload hardware signal will short to ground whenever the net truck weight exceeds the TARGET set point value.


While in the Normal Operating Mode, LoadMan presents various optional displays that can be configured in the INSTALL/SET DISPLAYS group of the Setup & Calibration commands (see the section on Setup & Configuration Mode for instructions on choosing optional status displays).

LOAD NAME & ACCOUNT # – Configuring these two optional displays allows the operator to display, select, and record a Load Name and its associated Account Number for every load in a pickup route. This display function can be turned on or off by using the INSTALL/SET DISPLAYS/FLASH LDNAME and the INSTALL/SET DISPLAYS/FLASH ACCT# commands in the Setup & Calibration Mode. When these options are turned on, the Load Name and Account Number flash on the LoadMan display.

When enabled, up to 1000 sixteen character alphanumeric load names along with their associated seven digit account numbers can be downloaded from LoadMan’s Load Manager Software. The LoadMan Load Manager Software uses various communication methods (such as wireless Bluetooth or cellular modem) to connect and download route and account information. When the Load Manager software downloads route information to the LoadMan meter, the number of Load Names and Account Numbers is set automatically.

The load name and account number combination is tied to each load to be picked up on the operator’s route. When a load is recorded – confirmed by the RECORDING LOAD information display message – the currently displayed load name and account number are recorded into LoadMan’s data collection memory. After all of the load and route information is recorded, LoadMan automatically sequences to the next load name/account number in the route list.


18

Unexpected departures from the planned sequence in the route list can be managed using the PROGRAM group of keys to select an out of sequence stop and load. Refer to the section Collecting Load Data for details.

STOP # xxx – In addition to the optional Load Name and Account Number, every load has a Stop Number (#) that is recorded in LoadMan’s data collection memory whenever a load is recorded. The Stop Number represents the sequence in the route list of Load Names and Account Numbers that have been downloaded by the LoadMan Load Management Software. The Stop Number is programmable and aids in identifying accounts. Each time a load is recorded, LoadMan automatically increments the stop number (if enabled with the INSTALL/SET RECORD/INCR STOP# command). This optional display function can be setup to flash during a weight display using the INSTALL/SET DISPLAYS/FLASH STOP# command in the Setup & Calibration Mode. Note: The stop number is reset to one (1) whenever LoadMan’s Load Manager Software downloads route information.

The operator can override the current stop number by using the PROGRAM group of keys to program a desired stop number. Refer to the section Collecting Load Data for the out of sequence instructions.

PRODUCT NAME – LoadMan allows up to 250 different Product Names to be captured whenever a load is recorded into the data collection memory. (These product names can be downloaded with LoadMan’s Load Manager Software.) This optional display function can be setup to flash a PRODUCT NAME during a weight display by using the INSTALL/SET DISPLAYS/FLASH PRODUCT command in the Setup & Calibration Mode. When the Load Manager Software downloads route information to the LoadMan meter, the number of Product Names is set automatically.

When enabled, and before a load is recorded, the operator can select a product name (e.g., RECYCLE, CARBOARD, etc.) that will be recorded in LoadMan’s data collection memory. To choose a product name: Locate the current PRODUCT display using the /SELECT keys. Locate the particular product name using the /PROGRAM keys.


19

Activate the product name with the PROGRAM key. SET

When a load is recorded – confirmed by the RECORDING LOAD information display – the product name is recorded into LoadMan’s data collection memory along with the account name, account number, and any other enabled route options. Note: Once a product name has been selected, it remains in effect for all subsequent load recordings. The product name should be re-programmed whenever the product condition changes.

PROBLEM – LoadMan provides up to 50 different Problem conditions that can be recorded whenever a load is recorded into the data collection memory. (These problem conditions can be downloaded with LoadMan’s Load Manager Software.) This optional display function can be setup to flash a PROBLEM condition during a weight display by enabling the function with the INSTALL/SET DISPLAYS/FLASH PROBLEM command in the Setup & Calibration Mode. When the Load Manager software downloads route information to the LoadMan meter, the number of Problem conditions is set automatically.

When enabled, and before a load is recorded, the operator can select a problem condition (e.g., ROAD CLOSED, CONTAINER LOCKED, etc.) that will be recorded in LoadMan’s data collection memory. To choose a problem condition: Locate the current PROBLEM display using the /SELECT keys. Then locate the particular problem condition using the /PROGRAM

keys.

Activate the problem condition with the PROGRAM key. SET

When a load is recorded – confirmed by the RECORDING LOAD information display – the Problem condition is recorded into LoadMan’s data collection memory along with the account name, account number and any other enabled route options.


20

Note: Once a problem condition has been selected and recorded, it reverts back to the NO PROBLEM condition for all subsequent load recordings. New problem conditions should be re-programmed anytime a problem is encountered and before a load is recorded.

DATE and TIME – The currently displayed Date and Time is recorded in LoadMan’s data collection memory whenever a load is recorded into the data collection memory. This display function is not optional. Programming DATE and TIME – Using the programming basics discussed in the previous section, the date and time can be changed with the PROGRAM keys: Locate the Date and Time display with the SELECT key. Now use the /PROGRAM keys to program the time (hours, minutes,

AM/PM) and date (month, day, year).

Press PROGRAM to set and activate the new time. SET

PROGRAM FUNCTION Displays Use the PROGRAM FUNCTION display to access and activate any of the command options listed below in Table 3.

Table 3. PROGRAM FUNCTION Commands

SHOW NET

SHOW GROSS

Set display for NET weight operation.

Set display for GROSS weight operation.

Use the /SELECT keys to locate the PROGRAM FUNCTION display. Use the /PROGRAM keys to sequence through available program options. = forward = reverse

Use the PROGRAM SET

key to activate command.

PRINT LAST LOAD Prints the most recent load data to a configured printer.

ZERO FORK LOAD Resets the fork load cells to zero

CYCLE DISPLAY Initiates the automatic display cycle of weight information and status messages

ZERO TRUCK Zeros the accumulated load TOTAL


21

Either of the /PROGRAM keys will sequence through the available

PROGRAM FUNCTIONs, and once an item is selected, the PROGRAM key will SET

activate and save the selection. LoadMan will then return to the Information Display. Note: While in the PROGRAM FUNCTION displays, LoadMan will take no action

until the PROGRAM key is depressed. SET

Note: While within any of the PROGRAM FUNCTION options, the /SELECT keys will abort programming and return LoadMan to manual display.

SHOW GROSS – Set the display for GROSS weight mode, enabling LoadMan to display the gross TRUCK weight – which is the payload weight plus the tare weight. When in the GROSS display mode, the truck’s weight (TRUCK xxxxxx gLB) will be displayed in gross weight. Choosing the GROSS weight display will terminate the NET display operation.

SHOW NET – Set the display for NET weight mode, enabling LoadMan to display the net TRUCK weight (or the payload weight). When in the NET display mode the truck’s weight (TRUCK xxxxxx nLB) will be displayed as net weight. Choosing the NET weight mode display will terminate the GROSS mode display operation.

PRINT TICKET – Prints the most recent load information to an output device connected to RS232 Port #1; such as a printer or scoreboard. Load data includes the current weight data, date and time, GPS coordinates, and any other optional route display information that has been enabled with the INSTALL/SETUP RS232/PRINT commands (i.e., Account Name, Account Number, Stop Number, Product Name, Problem, etc.). Figure 5. Print Ticket Example shows a sample printout from an in-cab printer (the diamonds () represent optional fields that may be setup with the INSTALL/RS232/PRINT commands in Setup & Configuration Mode).


22

DATE: 02-12-10

TIME: 12:34:56 PM

** LOAD NAME ***

ACCOUNT # 31560

STOP # 194

* PRODUCT NAME *

TARGET 9600 LB

LOAD 560 LB TOTAL 14445 LB

Figure 5. Print Ticket Example

If you would like to take advantage of custom print heading capabilities, contact LoadMan directly to obtain related technical specifications and documentation.

ZERO FORK LOAD – Zeros the fork’s weight. This command is useful whenever there is nothing loaded on the forks but LoadMan weighs something other than zero when an empty fork is going up. If this is the case, executing this command will direct LoadMan to lead the operator through a process to zero the fork’s weight reading. REMOVE FORK LOAD

Make certain there is no load on the forks. LOWER ARMS! and SET FORK ANGLE = 0

Lower the arms to the start of the weighing window and position the forks until they are perfectly horizontal. LoadMan will provide instant feedback on the current fork ± angle. When the fork angle is ±1 degree of zero, LoadMan will move to the next step of the ZERO FORK process.

TO ZERO FORKS followed by RAISE ARMS SLOW! Now raise the arms until LoadMan indicates that the ZERO FORK process has completed successfully.

ZERO COMPLETE and LOWER ARMS! The forks have been successfully calibrated to zero and the system is ready to weigh.

CYCLE DISPLAY – Directs LoadMan to automatically cycle through all of the available displays (order listed in Table4). The duration of each item displayed is configurable using the INSTALL/SET DISPLAYS/CYCLE command in the Setup & Calibration Mode (default is 2 seconds).


23

Note: Pressing either the /SELECT keys will terminate the automatic cycle display and allows manual selection of the display by using either of the /SELECT keys.

ZERO TRUCK – Zeros the accumulated TRUCK load total. Thereafter, TRUCK xxxxxx nLB will display the accumulated net weight of any recorded loads. Or, TRUCK xxxxxx gLB will display the truck’s accumulated gross weight - total of the truck’s tare weight and the accumulated weight of any recorded loads.


24

Setup and Calibration

25

SETUP & CALIBRATION MODE LoadMan’s Setup & Calibration Mode provides the operator the capability to program advanced functionality, setup and calibrate a truck’s configuration, choose optional information displays, enable communications, and troubleshoot issues. Refer to Table 4.

Table 4. Setup & Calibration Commands

SET ZERO Used for setup and calibration of the fork & arm load sensors and angle sensors

SELECT Sequence forward through available displays /PROGRAM Keys to change “NO” to “YES”

PROGRAM SET

To activate command SELECT Sequence in reverse through available displays

SET SPAN Calibrates LoadMan to readings taken from another truck scale

SET TARE

Sets the empty weight of the vehicle

INSTALL Provides the capability to setup and/or change the operating configuration of LoadMan

SET DEFAULTS

Returns all settings to the original factory default settings

ERASE DATA Permanently erases all data in LoadMan’s data collection memory

TROUBLESHOOT

Provides detailed sensor, loadcell, communications and other system information that can be useful for isolating issues


26

Basic Navigation Activating – Setup & Calibration Mode w/SECURITY OFF

Continually depress the POWER button, through the “GOODBYE!“ message, and until the “LOADMAN SETUP“ message is displayed.

The first setup & calibration category displayed is “SET ZERO?---->NO”.

Activating – Setup & Calibration Mode w/SECURITY ON

Continually depress the POWER button. The messages “GOODBYE!“ and “ENTER PASS CODE!“ will display.

At the prompt, “PASS CODE 0”, use the /PROGRAM keys to program

the security code TO “123”and save the code with the PROGRAM key. SET

If correct, LoadMan displays the message, “LOADMAN SETUP”. And the first setup & calibration category displayed is “SET ZERO?---->NO”. If the security code is NOT correct, the error message, “SECURITY FAILED” is

displayed, and the Setup & Calibration mode cannot be accessed. Navigating and Programming – Setup & Calibration Mode The SELECT keys are used to manually scroll through the seven setup, calibration and troubleshooting categories. The SELECT key will sequence forward through a group of displays. The SELECT key will sequence in reverse through a group of displays.

Once the desired setup category is displayed, use either of the /PROGRAM

keys to toggle “NO” to “YES”; and then press the PROGRAM to select and SET

activate the setup category. For programmable displays (like setting a tare weight): Use the PROGRAM key to move the flashing cursor left to the next

programmable digit/item in the display. Once the flashing cursor is positioned over the item to be changed, use the

PROGRAM key to increase/bump the digit/item to its next value. Continue to use the /PROGRAM keys until the display has been

programmed.

The PROGRAM key will execute the command and save any changes SET

made to the display.

Note: LoadMan will abort the process of programming displays if either of the /SELECT keys are pressed.


27

Exiting – Setup & Calibration Mode When finished with any of the setup categories and to exit setup & calibration: Press the SELECT key until “EXIT SETUP?-->NO “ is displayed. Then press PROGRAM key to display “EXIT SETUP?-->YES“.

Finally, press the PROGRAM key to exit. SET

LoadMan will now return to the normal operating mode and will reinitiate the information displays of weight and status messages.

Setup & Calibration Commands

SET ZERO – Used for setup and calibration of the fork loadcells and the fork & arm angle sensors.

ZERO ARM ANGLE procedure: o Use the PROGRAM key to select “ZERO ARM ANGLE?” and activate

with the PROGRAM key. SET

o LoadMan responds with the message, “THIS IMPACTS YOUR CALIBRATION” followed by “ PROCEED?---->NO”.

o When ready to proceed, use the PROGRAM key to choose “YES”,

followed with the PROGRAM key. SET

o When the message, “POSITION ARMS TO ZERO ARM ANG!” is displayed, position the arm to the desired zero angle position.

o And choose “YES” when” READY”. o LoadMan confirms the procedure with:

“ZEROING ARM ANG!” and “SAVING CHANGES!“

ZERO FORK ANGLE procedure: o Use the PROGRAM key to select “ZERO FORK ANGLE?” and activate

with the PROGRAM key. SET

o LoadMan responds with the message, “THIS IMPACTS YOUR CALIBRATION” followed by “PROCEED?---->NO”.

o When ready to proceed, use the PROGRAM key to choose “YES”,

followed with the PROGRAM key. SET

o When the message “POSITION FRKS TO HORIZONTAL ANGLE!” is displayed, position the fork to the desired zero angle position.

o And choose “YES” when “READY”. o LoadMan confirms the procedure with:

“ZEROING FORK ANG!” and “SAVING CHANGES!“


28

ZERO FORK LOAD procedure: Use the PROGRAM key to select “ZERO FORK LOAD?” and activate with

the PROGRAM key. SET

LoadMan responds with the message, “REMOVE FORK LOAD” and “LOWER ARMS!”

Make certain there is no load on the forks. Position the arms to the start of the weighing window (display will

direct the operator to either RAISE or LOWER ARMS until within ±1 degree of zero).

“SET FORK ANGLE = 0“ – Position the forks until they are perfectly horizontal. LoadMan will provide instant feedback on the current fork ± angle. When the fork angle is zero, LoadMan will move to the next step of the ZERO FORK process.

“TO ZERO FORKS RAISE ARMS SLOW!” – Now slowly raise the arms until LoadMan indicates that the ZERO FORK process has completed.

“ ZERO COMPLETE!” and “LOWER ARMS!” – The forks have been successfully calibrated to zero and the system is ready to weigh.

SET SPAN – Used to calibrate LoadMan to the readings taken from another truck scale. Use this setup command to calibrate a truck load of material that has been weighed on another scale; or alternately, calibrate LoadMan to the weight of a loaded container weighed on another calibrated scale.

Important Note: Prior to performing SET SPAN setup on a truck load of material, LoadMan must display a zero TRUCK net weight when the vehicle is empty. If not, then perform a PROGRAM FUNCTION/ZERO TRUCK command when the vehicle is empty. Otherwise an inaccurate calibration will result. Also Note: Prior to performing the SET SPAN setup command with a calibrated container, an empty fork load should measure zero. If not, then perform a PROGRAM FUNCTION/ZERO FORK LOAD command. Otherwise an inaccurate calibration will result. SET SPAN Calibration Procedure -- This procedure can be used for either calibrating a loaded truck (preferably with several loads to fill the truck at least 50% full) or for calibrating a single container: Use the PROGRAM key to select “SPAN TRUCK?” and activate with the


29

PROGRAM key. SET

LoadMan responds with directions to “ENTER METER LOAD”. Use the programming keys to enter the weight readings obtained from

the LoadMan meter. This would be the net (TRUCKn) or gross (TRUCKg) weight for the truck, or the net load weight (LAST) for a container. Press

the PROGRAM key to save. SET

Press the SELECT key and LoadMan will respond with the directions, “ENTER CAL LOAD”.

Use the programming keys to enter the weight readings obtained from

the calibrated scale. Press the PROGRAM key to save. SET

Now press the SELECT key and LoadMan will respond with the directions, “DO AUTOCAL?-->NO”. This display is confirming that the weights have been entered properly.

If a mistake was made when entering the truck’s net (or gross) weight (TRUCKn or TRUCKg) or the calibrated load weight (LAST), simply use the SELECT key to back up and re-enter.

To confirm that the weight entries are correct, select “YES” and press

. SET

LoadMan will now complete the SPAN calibration and confirm with, “DOING SPAN ADJUST” and “SPAN COMPLETE!”.

SET TARE – Sets the empty weight of the vehicle – referred to as the tare weight. LoadMan uses the configured tare weight to display the gross weight of the vehicle when LoadMan is configured for gross weight operation (activated by the PROGRAM/SHOW GROSS command). The gross weight is the net weight (or payload weight) plus the tare weight; and it is the tare weight that is set by using this command. First obtain the tare weight by weighing the fully fueled empty truck at a calibrated truck scale, and write down the tare weight here: TRUCK TARE WEIGHT: ______________________________ When the SET TARE category is activated, the message “TRUCK xxxxxx LB” is displayed where xxxxx is the current tare setting for the truck. Use the

/PROGRAM and PROGRAM keys to change and set the truck’s tare SET

setting.


30

INSTALL – Provides the capability to setup and/or change the operating configuration of LoadMan. When activated with “YES”, then the first installation option is displayed; “SHOW NEG WTS>YES“. The INSTALL options shown in Table 5 are available. These categories are

selected and activated using the /SELECT, /PROGRAM and SET

PROGRAM keys.

Table 5. INSTALL - Installation Commands

SHOW NEG WTS Configures how LoadMan will display negative weights

SELECT Sequence forward through available displays /PROGRAM Programming keys

PROGRAM SET

To activate command SELECT Sequence in reverse through available displays

SET DISPLAYS Programs LoadMan’s display options

SETUP MODEM Configures the communications modem

SETUP GPS Programs the time period between logging of GPS coordinates

SET RECORD

Configures options to customize how load data is recorded and/or displayed

SETUP RS232 Configures LoadMan’s RS232 port(s)

SERIALnum Displays the serial number for the LoadMan meter

SECURITY Turns LoadMan meter security ON or OFF.

SHOW NEG WTS – Configures how LoadMan will display negative weights. o NO – LoadMan will not display any measured negative net weights;

but instead will display negative weights as zero. o YES – Directs LoadMan to display all negative weights.


31

o <75 – LoadMan will display a weight of zero for any negative weights between zero and negative 75 pounds. Any value less than negative 75 pounds will display as measured.

o <150 – LoadMan will display a weight of zero for any negative weights between zero and negative 150 pounds. Any value less than negative 150 pounds will display as measured.

SET DISPLAYS – This setup category programs LoadMan’s display options. Refer to Table 6.


32

Table 6. SET DISPLAY Commands

DISPLAY UNITS Selects the units for measuring and displaying weights

CYCLE Programs the viewing duration of each displayed weight COUNTBY Programs the resolution of the weight displays

ACCOUNTS Configures the number of route Account names and numbers that can be displayed

PRODUCTS Configures the number of route Product names that can be displayed

PROBLEMS Configures the number of route Problems that can be displayed

ASSETS Configures the number of route assets that can be displayed

TARGET SETPT Display TARGET weight so a target overload set point can be programmed

FLASH LDNAME Active Load Name will be flashed every few seconds on the meter display

FLASH ACCT# Active Account Number will be flashed every few seconds on the meter display

FLASH STOP# Active Stop # will be flashed every few seconds on the meter display

FLASH PRODUCT Currently active PRODUCT will be displayed

FLASH PROBLEM Currently active PROBLEM will be displayed

FLASH OVERLD LoadMan will place a message on the display anytime the TARGET weight has been exceeded

GEO ROUTE Route information will be downloaded from Load Manager software.


33

o DISPLAY UNITS – Selects the units for measuring and displaying weights. The LoadMan meter comes preconfigured at the factory to display weight measurements in English units. Use the

/PROGRAM and PROGRAM keys to program, select and set SET

either English or metric units. English units – select pounds (LB) Metric units – select kilograms (KG)

o CYCLE xxx SEC – Programs the viewing duration (xxx seconds) of

each weight, route or status message displayed during the

automatic cycle display. Use the /PROGRAM and SET

PROGRAM keys to program, select and set the display duration in seconds. The Cycle Display Function can be completely disabled by setting the xxx value to zero (0) (Default is 2 seconds and maximum is 10 seconds.)

o COUNT BY = xxx – Programs the resolution of the weight displays where xxx is the minimum weight step displayed. The available COUNT BY weight step options are, 1, 2, 5, 10, 20, 50, 100 or 200. Note: The COUNT BY rounding can be momentarily disabled on the display by continually depressing the SELECT key that is used to manually select a particular weight display. LoadMan will display the weight count in increments of 1 as long as the SELECT key is continuously depressed. Releasing the SELECT key causes the display to return to the programmed COUNT BY resolution.

o ACCOUNTS – Configures the number of route account names and numbers that can be displayed (default is 0, 1000 max). This number is automatically set when LoadMan Load Manager Software downloads ACCOUNTS but can be overridden with this command (programming to zero will remove all accounts).


34

Note: Regarding Account Load Names, Account Numbers, Products and Problems:

LoadMan allows up to 1000 different Load Names & corresponding Account Numbers, 250 unique Product Names, 50 Problems and 250 Assets to be captured upon each recording of a load - “RECORDING LOAD”. These account names, products, problems, and assets can be downloaded to the meter with LoadMan’s Load Manager Software.

o PRODUCTS – Configures the number of route product names that can be displayed (default is 0, 250 max). This number is automatically set when LoadMan Load Manager downloads PRODUCTS but can be overridden with this command.

o PROBLEMS – Configures the number of route problems that can be displayed (default is 0, 250 max). This number is automatically set when LoadMan Load Manager downloads PROBLEMS but can be overridden with this command.

o ASSETS – Configures the number of route assets that can be

displayed (default is 0, 255 max). This number is automatically set when LoadMan Load Manager downloads ASSETS, but can be overridden with this command.

o TARGET SETPT– Turns on or off the TARGET weight display. When turned on, this display allows the operator to set a target overload set point that will activate a hardware alarm and/or will trigger a LoadMan display when the target weight has been exceeded.

o FLASH LDNAME – When this display is activated to “YES”, the currently active Load Name will be flashed every few seconds on the weight display, aiding the operator to identify the current account that will be saved when a load is recorded.

o FLASH ACCT# – When this display is activated to “YES”, the currently active ACCOUNT# will be flashed every few seconds on the weight display, aiding the operator to identify the current account that will be saved when a load is recorded.


35

o FLASH STOP# – When this display is activated to “YES”, the currently active STOP# will be flashed every few seconds on the weight display, allowing the operator to identify the current account stop number that will be saved when a load is recorded

o FLASH PRODUCT – When this display is activated to “YES”, the currently active PRODUCT will be displayed. When enabled, and to choose a product name: Locate the PRODUCT display using the /SELECT keys, Locate the particular product name using the /PROGRAM

keys,


When the load is recorded, the product name will be recorded into LoadMan’s data collection memory along with the account name, account number, and any other enabled route options.

Note: Once a product name has been selected, it will remain in effect for all subsequent load recordings. The product name should be re-programmed whenever the product condition changes.

o FLASH PROBLEM – When this display is activated to “YES”, the currently active PROBLEM will be displayed. When enabled, and to choose a problem condition: Locate the current PROBLEM condition display using the

/SELECT keys, Locate the particular problem condition using the

/PROGRAM keys,

Activate the problem condition with the PROGRAM key. SET

When a load is recorded, the problem condition will be recorded into LoadMan’s data collection memory along with the account name, account number and any other enabled route options. Note: Once a problem condition has been selected and recorded with the RECORD command, it will revert back to the NO PROBLEM condition for all subsequent load recordings. New problem conditions should be re-programmed anytime a route problem is encountered and before the next load is recorded.


36

o FLASH OVERLD – When activated to “YES”, LoadMan will place a

message on the display (and activate an optional hardware alarm) anytime the TARGET weight has been exceeded. In the normal operating mode the message, “GROSS >>> TARGET” will display anytime a load exceeds the target weight.

o GEO ROUTE – Route information will be downloaded from

LoadMan Load Manager software when set to YES.

SETUP MODEM – When set to “YES”, the command configures the communications modem. The LoadMan meter may come equipped with an optional cellular modem (either CDMA or GSM). The modem is used to connect and communicate with LoadMan’s Load Manager Software. The Load Manager Software allows remote tracking of trucks, drivers, customers and routes, and exchanges the route and location information through this modem.

o MODEM OPTION – Set this option to “YES” if the LoadMan meter

has been configured with a modem board for remote communications. If the modem is not installed, make certain to choose the “NO” option.

o CONN xxx SEC – Sets the time period (in seconds) between polling connection attempts between the LoadMan meter and the LoadMan Load Manager Software.

o Remote IP Address – The four fields represent the IP address

location that LoadMan will connect for communication with the LoadMan Load Manager Software. RemoteIP1 74 – Displays the current IP1 address. RemoteIP2 93 – Displays the current IP2 address. RemoteIP3 98 – Displays the current IP3 address. RemoteIP4 177 – Displays the current IP4 address.


37

Use the /PROGRAM and PROGRAM keys to program, select SET

and set any new Remote IP Address fields.

SETUP GPS – When set to “YES”, this command programs the logging of GPS coordinates. The LoadMan meter may come equipped with an optional internal GPS chip and antennae. LoadMan’s Load Manager Software uses onboard GPS capability to track and map truck and customer locations. o LOG xxx SEC – Programs the time period (xxx seconds) between

the logging of GPS coordinates into LoadMan’s data collection memory. The factory default setting is 20 seconds.

When the recorded GPS coordinates are uploaded into LoadMan’s Load Manager Software, the software will be able to use the coordinates to track truck routes and aid with several other advanced location based functions.

SET RECORD – LoadMan uses several record options to customize the way that load data is displayed and recorded whenever a load is recorded – “RECORDING LOAD!”. Choose “YES” to program the following RECORD options:

o RECORD&PRINT – When set to “YES”, directs LoadMan to print the

recorded load data to RS232 port #1 (usually connected to an external printer or scoreboard display). Any data that has been configured to record into LoadMan’s data collection memory will also print to the RS232 port when executing the PROGRAM FUNCTION/PRINT TICKET command. If set to “NO”, the load data will still be recorded to LoadMan’s data collection memory, but will not be printed.

o INCR STOP # -- When set to “YES”, LoadMan will automatically increment and select the next stop number (and associated account information) from the downloaded route list after a load has been recorded.

o CONTsp xxxxx LB – Container set point. LoadMan provides this capability to prevent the recording of load data records when there is no container on the forks. When programmed to a positive


38

number, and if the gross weight measured going up is less than this set point value, then the weight will NOT be recorded as a load data record when the load comes back down. If the gross weight measurement going up is greater than this set point value, then the net weight measured coming down WILL be recorded as a valid load data record. When this variable is programmed to zero, then the set point is ignored and any time the forks are raised through the weighing window the load record will be recorded.

o REMOTE SWBOX – When set to “YES”, directs LoadMan to recognize an external switch (sometimes known as a Smash Box) that can be used to activate a ZERO TRUCK command. If the switchbox is not installed, make certain to choose the “OFF” option so LoadMan will ignore the switchbox. The ZERO switch is equivalent to the PROGRAM FUNCTION/ZERO TRUCK command, which will reset the accumulated load weight to zero.

SETUP RS232 – Configures LoadMan’s RS232 ports. LoadMan comes standard with one 9-pin RS232 port (port #2) that is a dedicated for connecting the meter to the motion sensors and loadcells. There is no need to configure this port as it has already been set by the factory. Optionally, the LoadMan meter comes with a second RS232 port (port #1) configured with either another 9-pin connector or with a Bluetooth antenna. To configure a 9-pin RS232 optional port connection:

Choose “RS232 PORT #1?” by pressing the PROGRAM key. SET

“BLUETOOTH --->” should be set to “OFF” as Bluetooth is not available with this configuration.

Then configure the remaining port #1 settings as described below beginning with BAUD RATE.


39

To configure a Bluetooth optional port connection: Choose “RS232 PORT #1?” by pressing the SET PROGRAM key. “BLUETOOTH --->” should be set to “ON”. Then configure the remaining port #1 settings as described below

beginning with BAUD RATE.

o BAUD RATE – Programs the baud rate for the RS232 ports. The baud rate must match the baud rate of the peripheral device that will be connected to the port for LoadMan to properly communicate. The available baud rates are:

Port#1 – 110, 300, 600, 1200, 2400, 4800, 9600, 19200, 38400 baud (factory default is 9600 baud).

Port#2 – 600, 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200 baud (factory default is 9600 baud).

When the LoadMan meter is programmed for Fork Based Weigh-In-Motion applications, the baud rate for port #2 MUST be set to 9600 baud.

Note: The following options are available only for RS232 PORT #1.

o SCOREBOARD or TICKET PRINT – Programs the RS232 port for printing to a SCOREBOARD display mounted on the truck, or to a serial printer mounted in the truck cab. By default, the LOAD weight will be printed or displayed whenever a load is recorded into data capture memory. Other printer and scoreboard display options can be enabled with the PRINT commands described below.

o BARCODE – LoadMan supports automatic reading of account information with a bar code reader/wand. When set to “ON”, LoadMan configures the RS232 port to read from a barcode reader.

These following display/print options are offered for configuration. Choose “YES” to activate any desired option. o PRT LOADNAME –Prints/Displays the active load account name. o PRT ACCOUNT – Prints/Displays the active load account number.


40

o PRINT STOP# – Prints/Displays the active stop number. o PRT PRODUCT – Prints/Displays the active product name. o PRT PROBLEM – Prints/Displays the active problem condition.

o PRINT TRUCKg – Prints/Displays the truck’s gross weight. That is,

the tare weight plus the accumulated recorded load weights.

o PRINT TRUCKn– Prints/Displays the truck’s net weight. That is, the accumulated recorded load weights.

o PRINT CONTg – Prints/Displays the total gross weight of the

container and its load as the arms are raised.

o PRINT CONT – Prints/Displays the empty container weight (the container tare weight) as the arms are lowered.

o PRINT LOAD – Prints/Displays the net weight of the load that was

dumped into the truck. o COUNTBY – Programs a number by which the load will be rounded

up. Rounding to the next higher number can be set for increments of 2, 5, 10, 20, or 50.

o LINE FEEDS xx – Programs the number of line feeds after every PRINT TICKET printout (default is 2; 1 min; 10 max).

SERIALnum – Displays the serial number of the LoadMan meter.

The serial number programmed into the meter is only needed when the LoadMan data collection software features are used. Whenever data is uploaded to the LoadMan Load Manager Software, LoadMan will add the serial number to every load data record. This feature is especially useful when maintaining records for a fleet of trucks.

SECURITY – When set to “ON”, LoadMan will prompt for a valid passcode whenever the LM200 meter is powered on. When prompted, enter passcode “123”.


41

SET DEFAULTS – Returns all settings to the original factory default settings. See Table 7 below for a listing of the factory default settings. Use the PROGRAM key to choose either “DEFAULTS FOR LB?” or

“DEFAULTS FOR KG?” and press the PROGRAM key to activate. SET

LoadMan responds with the message, “THIS RESETS TO FACTORY DEFAULTS”.

Followed by, ”PROCEED?-----> NO”.

When selecting “YES” and activating with the PROGRAM key, SET

LoadMan responds with the message, “SETTING DEFAULTS”.

Note: LoadMan will abort the process anytime “NO” is selected or if either of the /SELECT keys is pressed.

ERASE DATA – Activating this setup category will permanently erase all data in LoadMan’s data collection memory. When set to “YES”, LoadMan responds with the message,

“THIS WILL ERASE ALL LOAD DATA!”, Followed by, ”PROCEED?-----> NO”.

When selecting “YES” and activating with the PROGRAM key, SET

LoadMan responds with the message, “ERASING ALL DATA” followed by “LOAD DATA ERASED”.

Note: LoadMan will abort the process anytime “NO” is selected or if either of the /SELECT keys are pressed.


42

Table 7.Default Settings (English / Metric)

SHOW NEG WTs YES RECORD

DISPLAY RECORD&PRINT ON

DISPLAY UNITS LB / KG INCR STOP # ON

CYCLE 2 SEC CONTsp 150LB / 70KG

COUNT BY 20 REMOTE SWBOX OFF

ACCOUNTS 0 RS232

PRODUCTS 0 BLUETOOTH OFF

PROBLEMS 0 BAUD RATE 9600

ASSETS 0 TICKET PRINT ON

TARGET SETPT OFF BARCODE READ ON

FLASH LDNAME NO PRT LOADNAME NO

FLASH ACCT# NO PRT ACCOUNT NO

FLASH STOP# NO PRINT STOP# YES

FLASH PRODUCT NO PRT PRODUCT NO

FLASH PROBLEM NO PRT PROBLEM NO

FLASH OVERLD NO PRINT TRUCKg NO

GEO ROUTE NO PRINT TRUCKn YES

MODEM PRINT CONTg NO

MODEM OPTION NO PRINT CONT NO

MODEM USA PRINT LOAD YES

CONN 600 SEC COUNTBY DISABLED

RemoteIP1 74 LINE FEEDS 2

RemoteIP2 93 SERIALnum xxxxxx

RemoteIP3 98 SECURITY OFF

RemoteIP4 177

GPS TARE SETTINGS

LOG 40 SEC TRUCK 0 LB / KG

TROUBLESHOOT – Provides detailed sensor, loadcell, communications and other system information that can be useful for isolating issues. In this mode, each sensor’s response to a load can be examined in detail, and the information can be used to manually change calibration settings. Refer to Table 8. Use the PROGRAM key to advance through the troubleshooting options, and press the SET PROGRAM key to select an option to troubleshoot.


43

Table 8. TROUBLSHOOT Command Options

TROUBLE LOADCELL Displays individual loadcell calibration settings.

TROUBLE COM Provides LoadMan’s communications settings.

TROUBLE VOLTAGE

Displays individual voltage readings.

TROUBLE GPS Provides current GPS location readings.

TRB LOAD RECORDS Displays number of load records in LoadMan’s data collection memory.

TROUBLE POSITION Displays individual arm and fork sensor settings and readings.

TROUBLE CAL Provides zero and span information for the forks.

TROUBLE LOADCELL – Select this option with the PROGRAM key to SET

activate and use the SELECT key to advance through the individual loadcell calibration settings.

CH1 SPAN xxxxxx Current CH1 span setting CH1 xxxxxx LB Current CH2 weight reading CH1 ZERO xxxxxx CH1 zero offset CH2 SPAN xxxxxx Current CH2 span setting CH2 xxxxxx LB Current CH2 weight reading CH2 ZERO xxxxxx CH2 zero offset

(where xxxxxx = weight)

TROUBLE COM – Provides detailed information to aid technicians in

troubleshooting. Select this option with the PROGRAM key to SET

activate and use the SELECT key to advance through the individual loadcell calibration settings. o CONNECT xxx SEC – Displays the number of seconds until the

meter will attempt a cellular modem Internet connection to upload record data to the LoadMan Load Management Software. The default is 600 seconds. Any number up to six digits long can be


44

specified with the SETUP MODEM : CONN commands. The number resets automatically if the connection fails within the specified time.

o CELLSTATE xxx – Used for diagnosing data collection software problems. The number shown represents the current state of the modem, which is used by technicians to help diagnose communications problems. State “7” is common, meaning that the modem is powered and ready. State “51” signifies that the antenna is missing or there is no reception. Although the CELLSTATE number can be as high as 200, generally any number of 80 and above means that communications are established.

o SIM H: – Represents the first 10 SIM card identifying digits. o SIM L: – Represents the second 10 SIM card identifying digits.

o RESET BTOOTH – This resets the Bluetooth port to factory defaults. o OSversion x.x.xx – This number identifies the operating system

used by LoadMan. (Software updates must be compatible with the operating system number.)

TROUBLE VOLTAGE – Select this option to read individual voltage levels.

o VIN Input voltage. o VLC1 Voltage output for LoadCoder CH1. o VLC2 Voltage output for LoadCoder CH2. o VBAT VBAT is the current output voltage of the onboard

rechargeable battery. A fully charged battery is 2.5V to 2.7V

This option also provides temperature voltage readings for the LCD display: o TEMPsensor – xxxx o TEMPscaled – xxxx o CONTRAST – By reprogramming CONTRAST to a higher value, the

LoadMan display contrast will increase (maximum 1500). Similarly, lowering to a lower value will decrease the display contrast.


45

TROUBLE GPS – Select this option to examine current GPS location readings. o LAT deg – Displays the current GPS latitude location reading.

“NO GPS SIG” will display if no signal is available.

o LON deg – Displays the current GPS longitude location reading. “NO GPS SIG” will display if no signal is available.

o SATTELITES – Displays the number of satellites available for determining GPS coordinates. LoadMan must connect with at least three satellites to determine the vehicle’s GPS coordinates.

o ATLTITUDE – Displays the current GPS altitude reading in meters o Vel East – Displays truck easterly velocity in miles-per-hour (mph) o Vel North – Displays truck northerly velocity in miles-per-hour

(mph)

o NextLOG – Displays the number of seconds until LoadMan will next record the vehicles’ GPS coordinates.

o RECORDS – Displays the number of GPS records currently in flash memory. When the ERASE DATA function is executed or after the LoadMan Load Manager Software collects all the GPS data, this number will be reset to zero. Thereafter, the value is incremented every time a GPS record is stored in LoadMan’s data collection memory.

TRB LOAD RECORDS – Displays the number of load records contained in LoadMan’s data collection memory (RECORDS xxxxxx). When the ERASE DATA function is executed or after the LoadMan Load Manager Software collects all the load data, this number is reset to zero. Thereafter, the value is incremented every time a load data record is stored in LoadMan’s data collection memory. (A second value, ERASE CTR-xxxxxx, signifying the number of times data has been erased, is provided for factory troubleshooting.)

TROUBLE POSITION – Choose this troubleshooting option to examine individual arm and fork sensor settings and readings.


46

o WGH START – Displays the starting set point angle of the weigh-in-

motion window. (Preferred setting is 0.0 degrees.) o WGH END – Displays the ending set point angle of the weigh-in-

motion window. (Preferred setting is 30.0 degrees.) o WGH DUMP – Displays the dump load set point angle of the weigh-

in-motion window. (Preferred setting is 65 degrees.)

The weighing window angle set point settings can be programmed using

the / and PROGRAM keys. SET

o ARM DIRECTION = +/- This display should be used if the arm angle

does not increase in value when the arms are raised. If the arm angle decreases when the arms are raised, then the ARM DIRECTION sign should be reversed. Important Note: If the ARM DIRECTION sign is reprogrammed, use the SELECT key to completely exit the TROUBLE POSITION setup category and save this change to the arm angle sensor. When exiting, LoadMan will confirm the sensor change with, “SAVING

CHANGES!”.

o ARMS xxx.y DEG – Displays the currently measured arm angle in degrees.

o ARM ZERO – The arm’s zero degree calibration constant set when the arms are zeroed.

o FORK DIRECTION = +/- This display should be used if the fork angle does not increase in value when the forks are raised. If the fork angle decreases when the forks are raised, then the FORK DIRECTION sign should be reversed.

Important Note: If the FORK DIRECTION sign is reprogrammed, use the SELECT key to completely exit the TROUBLE POSITION setup category and save this change to the fork angle sensor. When exiting, LoadMan will confirm the sensor change with, “SAVING

CHANGES!”.


47

o FORKS xxx.y DEG – Displays the currently measured fork angle in degrees.

o FORK ZERO – The fork’s zero degree calibration constant set when the forks are zeroed.

o FAgSTRTup – Fork Angle Lag at Start of weigh-in-motion window while forks are going up.

o FAgENDup – Fork Angle Lag at End of weigh-in-motion window while forks are going up.

o FAgENDdn – Fork Angle Lag at End of weigh-in-motion window

while forks are going down.

o FAgSTRTdn – Fork Angle Lag at Start of weigh-in-motion window while forks are going down.

o STATE – (for technical reference only) o STATELst – (for technical reference only) o ResetCtr – Resets the number of times data has been erased to 0.


48

TROUBLE CAL – Provides zero and span information to assist with troubleshooting and calibration of the weight sensors. o ZEROUpCAL – A zero calibration adjustment for weights measured

as the arms are raised.

o ZERODnCAL – A zero calibration adjustment for weights measured as the arms are lowered.

o SPANUpCAL – The SPAN calibration adjustment for weights measured as the arms are raised.

o SPANDnCAL – The span calibration adjustment for weights measured as the arms are lowered.

Note: The following displays appear in the TROUBLE CAL sequence, but are for technical reference only. SampDevUp LoadUpC2 LoadDnC2 SampDevDn LoadUpC3 LoadDnC3 SampUpRaw SampDnRaw NetRaw SampUpC1 SampDnC1 NetC1 SampUpC2 SampDnC2 NetC2 SampUpC3 SampDnC3 NetC3 LoadUpRaw LoadDnRaw LoadUpC1 LoadDnC1

Initial Startup and Calibration

49

INITIAL STARTUP AND CALIBRATION The instructions in this section provide a step-by-step process for verifying and calibrating a newly installed LoadMan Fork Based Weigh-In-Motion system. Follow these steps to insure proper installation and operation. 1. Verify Wiring 2. Power On 3. Verify Angle Sensors 4. Verify Fork Load Cells Respond

Correctly 5. Calibrate Arm Angle 6. Calibrate Fork Angle

7. Verify Angle Measurements Respond Correctly

8. Determine Fork Angle Lag 9. Verify Weigh-In-Motion Response 10. Calibrate System for ZERO FORK

Load 11. Calibrate System Under Load 12. Fine Tune Span Adjust

1. Verify Wiring Begin by verifying that the electronics are wired per the wiring diagram shown in Figure 6 near the end of this manual. Positive 10VDC to 16VDC should connect to the LoadMan 200 Meter at

pins 1 and 2 to power the system. Verify connection of the cable harness from the LoadMan meter to the

arm weigh-in-motion assembly. Then verify the connection of the cable harness from the fork weigh-in-

motion assembly to the arm weigh-in-motion assembly. Finally, verify that the fork loadcells are connected to the fork weigh-in-

motion assembly.

2. Power On With power off, briefly press the front panel POWER button. LoadMan will power on and sign on with the display messages “LOADMAN”, followed by “PROG VERSION X.X” (where X.X is the software version). LoadMan will then confirm that the weigh-in-motion equipment is ready for operation with message, “READY TO WEIGH!”.


50

3. Verify Angle Sensors To verify the angle sensors are responding correctly, first enter the Setup & Calibration Mode as described earlier and use the SELECT key to locate the TROUBLESHOOT display. Weigh-In-Motion Window Press the PROGRAM key two times to locate the TROUBLE POSITION

option and press the key to activate. “WGH START 0.0” should display SET

on the meter. WGH START is the programmable angular set point where the weigh-in-motion window starts the weighing of each load.

If it isn’t programmed to 0.0, use the PROGRAM keys to reset the angle

to 0.0 and press to activate the value. SET

Press the SELECT key to display “WGH END 30.0”. WGH END is the programmable angular set point where the weigh-in-motion window ends the weighing of each load.

If it is not programmed to 30.0, use the PROGRAM keys to reset the

angle to 30.0 and press to activate the value. SET

Press the SELECT key to display “WGH DUMP 65.0”. WGH DUMP is the programmable angular set point where LoadMan “Arms” the recording of the net load weight.

If it is not programmed to 65.0, use the PROGRAM keys to reset the

angle to 65.0 and press to activate the value. SET


51

4. Verify Fork Load Cells Respond Correctly To verify the loadcells are responding correctly, first enter the Setup & Calibration Mode and use the SELECT key to locate the TROUBLESHOOT display. Press the PROGRAM key to locate the TROUBLE LOADCELL option and

press the key to activate. SET

The message, “CH1 SPAN 20000” should display. This is the normal sensitivity used for the CH1 left fork loadcell and should not be changed.

Press SELECT to display “CH1 xxxx.x LB” where xxxxx.x is the current weight reading of the CH1 loadcell. It is not actually calibrated in LBs but instead is 10 times the actual LB weight.

Move the forks to a horizontal position and make a mental note of the CH1 loadcell reading (it will normally bounce around ±20 counts).

Raise the forks to as near vertical as possible. In this position the loadcell reading should decrease 400-2500 LB counts from the horizontal fork reading. If so, then the loadcell is responding correctly. Skip the next step.

If the reading increases while raising the fork to the vertical position (rather than decreasing as normal) then the loadcell is mounted upside down and should be remounted to correct the problem.

Press SELECT to display the message, “CH2 SPAN 2000” and repeat the above procedure for the CH2 loadcell.

5. Calibrate Arm Angle If not already done, begin this procedure by first cycling the arms and forks until the message “READY TO WEIGH” is displayed. Enter the Setup & Calibration Mode. Press the SELECT key until “SET ZERO?--->NO” is displayed. Press the PROGRAM key until “ZERO ARM ANGLE?” is displayed and then

press to activate. SET

The display now shows several sequential messages; “THIS IMPACTS YOUR


52

CALIBRATION” and “PROCEED?---->NO”.

Use the PROGRAM key to choose “YES”, and activate with the key. SET

LoadMan displays, “POSITION ARMS TO ZERO ARM ANG” and “READY?----->NO”.

Move the arms to the desired start position of the weigh-in-motion window. Under normal conditions this is the position of the arms when lifting a typical container to about 1-2 feet off the ground.

Once the arms are in position, use the PROGRAM key to choose “YES”,

and activate with the key. SET

LoadMan displays, “ZEROING ARM ANG!” while it is reprogramming the start position of the weigh-in-motion window; and confirms with the message, “SAVING CHANGES!”.

To verify this process worked correctly, enter the TROUBLE POSITION portion of the TROUBLESHOOT display: The new ARM ZERO value should be within 1000 counts of zero. Now verify that the “ARMS xxxxx.x DEG” reads zero degrees when the arm is

in a position that would lift a typical container 1-2 feet off the ground. Furthermore, the arm angle (ARMS) should become more positive when

the arms are raised higher.

6. Calibrate Fork Angle Enter the Setup & Calibration Mode. Press the SELECT key until “SET ZERO?--->NO” is displayed. Press the PROGRAM key until “ZERO FORK ANGLE?” is displayed and press

to activate. SET

The display now shows several sequential messages; “THIS IMPACTS YOUR

CALIBRATION” and “PROCEED?---->NO”.

Use the PROGRAM key to choose “YES”, and activate with the key. SET

LoadMan displays, “POSITION FRKS TO HORIZONTAL ANGLE”, “READY?----->NO”.

Important Note: This next step is critical. The internal calibration assumes that the forks are accurately horizontal when the fork angle displays zero. Any error here will cause an error in the weight measurements. Also Note: This portion of the process requires a level. The level should be used on the vertical fork mounting plate – not the forks – as the forks are usually


53

tapered. Using a level, move the forks until the vertical plate welded to the forks is

vertical. Once the forks are in the horizontal position (or more importantly, the fork

mount plate is accurately vertical), press the PROGRAM key to display

“YES” and activate with the key. SET

LoadMan displays “ZEROING FORK ANG!” while the fork angle is calibrated; and confirms with the message, “SAVING CHANGES!”.

To verify this process worked correctly, enter the TROUBLE POSITION portion of the TROUBLESHOOT display: The new FORK ZERO value should be within 1000 counts of zero. Now verify that the “FORKS xxxxx.x DEG” reads zero degrees when the forks

are in the horizontal position (that is, the fork mount plate is vertical). Furthermore, the fork angle value (FORKS) should become more positive

when the forks are raised higher.

7. Verify Angle Measurements Respond Correctly Verify Arm Angle Response Enter the TROUBLE POSITION portion of the TROUBLESHOOT display. Press the SELECT key until the display reads, “ARMS xxxx.x DEG”. Lift a container from the ground until the arm angle reads 0.0 degrees. The

container should be 1 to 2 feet off the ground at the ARMS 0.0 degrees reading. Also, the arm angle should increase as the arms are raised and decrease as the arms are lowered.

Press the SELECT key until the display reads, “ARM ZERO xxxx”. The ARM ZERO value must be within 1000 counts of zero.

If okay (within 1000 counts) skip the next step. If not okay:

o Program the ARM ZERO value to zero (0) using the /PROGRAM keys

and the . SET

o Return to the step, “Calibrate Arm Angle”, and repeat the instructions.

Verify Fork Angle Response Return to the TROUBLE POSITION portion of the TROUBLESHOOT display. Press the SELECT key until the display reads, “FORKS xxxx.x DEG.


54

Position the forks until the fork angle reads 0.0 degrees. At the FORKS 0.0 degrees reading, the forks should be horizontal or more importantly, the fork mounting plate surface should be vertical. Also, the fork angle should increase as the forks are raised and decrease as the forks are lowered.

Press the SELECT key until the display reads, “FORK ZERO xxxx”. The FORK ZERO value must be within 1000 counts of zero.

If okay (within 1000 counts) skip the next step. If not okay:

o Program the FORK ZERO value to zero (0) using the /PROGRAM

keys and . SET

o Return to the step, “Calibrate Fork Angle”, and repeat the instructions.

8. Determine Fork Angle Lag The output of the loadcell mounted on the forks is a direct function of the angle of the forks. So the fork angle sensor must provide accurate angle measurements for the weight to be measured accurately. Because of several variables like arm and fork equipment, arm speed, container weights and inertia, the electronics that capture the fork angle can sometimes lag the actual angle; and this lagging will lead to inaccurate load weight measurements. This calibration process will help determine two fork angle lag values that LoadMan will use to calculate and record accurate load weights. Begin this calibration process by entering the Setup & Calibration

Troubleshooting menu and press the PROGRAM key to locate the

TROUBLE POSITION option. Press PROGRAM to activate. SET

This calibration process will require the operator to cycle the arms through the weigh-in-motion window several times and observe angle lag data from the LoadMan meter. During the cycling process, LoadMan will capture “fork angle lag” data and then present this angle lag information in the next four displays of the TROUBLE POSITION section. Refer to Table 9.


55

Table 9. TROUBLESHOOT/TROUBLE POSITION (Lag Values)

LoadMan Display Description Direction of Forks

FAgSTRTup x.x Fork Angle Lag at Start of weigh-in-motion window.

Going Up

FAgENDup x.x Fork Angle lag at End of weigh-in-motion window.

Going Up

FAgENDdn x.x Fork Angle lag at End of weigh-in-motion window.

Going Down

FAgSTRTdn x.x Fork Angle lag at Start of weigh-in-motion window.

Going Down

Start the process by picking up an empty container, and prepare to cycle

the container through the weighing window (up and down). Make certain that the forks are level (0 degrees) when they pass through the start of the weighing window (Weigh Start = 0.0 DEG).

Perform a normal and complete cycle the arm/forks. After cycling the arm/forks through the weighing window, use the

/SELECT keys to view the four fork lag values described in the above table, and then enter the four values as displayed.


56

Repeat the arm/fork cycle through the weighing window 2 or 3 more times

and enter the fork lag values into the table. Recall that the weighing window starts at 0.0 degrees and ends at 30.0

degrees. Most likely, the table will show that the forks were not exactly at 0.0 degrees and 30.0 degrees during the up and down of the cycling process. The noted difference is the “fork angle lag”.

For Example:

Fork Angle Lag Cycle 1 Cycle 2 Cycle 3 Cycle 4 Avg Lag

FAgSTRTup -1.0

-1.1 -1.1 -0.9 -1.05

FAgENDup 29.5 (0.5 lag)

29.0 (1.0 lag)

28.5 (1.5 lag)

29.0 (1.0) lag

1.0

FAgENDdn 30.5 (0.5 lag)

31.0 (1.0 lag)

30.5 (0.5 lag)

30.5 (0.5 lag)

0.6

FAgSTRTdn 1.0

0.5 0.5 0.8 0.75

9. Verify Weigh-In-Motion Response To verify the weigh-in-motion response, first exit the Setup & Calibration Mode: Use the SELECT key and choose the display, “EXIT SETUP?-->NO”. Use the PROGRAM key to change “NO” to “YES” and press SET to activate.

LoadMan should now be in the Normal Operating Mode.

The display should now read, “READY TO WEIGH!”. Raise the arms up through a complete weighing cycle. If everything is

working properly the system should respond with the following: o WEIGHING LOAD! while the arms are in the weigh-in-motion window. o GROSS xxxxx LB as the arms pass the end of the weigh-in-motion

window. o DUMP xxxxx LB and LOAD xxxxx LB (alternating) when the arms pass up

through the dump set point. This message indicates that the Record Load Data and Auto Accumulate functions have been armed.

Now lower the arms and the display should show: o LOWER ARMS! while passing down through the dump set point. o WEIGHING TARE! as the arms pass down through the weighing


57

window. o NET xxxxx LB after the arms have passed below the start point of the

weigh-in-motion widow. This is the net payload that was measured and dumped into the vehicle.

o RECORDING WEIGHT! – indicates that the weighing process is complete and the load has been recorded.

In a few seconds LoadMan should indicate that it is ready for the next load with the message, “READY TO WEIGH!”.

If all of this has worked correctly, proceed to the next step. If not, return to step 3, ”Verify Angle Sensors are Responding Correctly”, and redo the process until all is working correctly.

10. Calibrate System for ZERO FORK Load Begin this step by entering the INSTALL section of the Setup & Calibration

Mode and program the LoadMan meter to “SHOW NEGATIVE WEIGHTS” by choosing “YES”. (Later after completing this calibration, the meter can be reprogrammed to hide negative net weights if desired.)

Furthermore, to obtain the most accurate calibration results, advance forward to the INSTALL/SET DISPLAYS section and set the COUNT BY value to one (1).

Remove any container from the forks.

With LoadMan showing READY TO WEIGH, press the SELECT key to find the PROGRAM FUNCTION display. Press the PROGRAM key to locate the

ZERO FORK LOAD display; press to activate; and follow this procedure: SET

o LoadMan starts this process with the messages “REMOVE FORK LOAD” and “SET FORK ANGLE = 0”.

o Position the forks until they are perfectly horizontal. LoadMan will provide instant feedback on the current fork ± angle. When the fork angle is within a degree of zero, LoadMan stops providing ± angle feedback and moves to the next step of the ZERO FORK LOAD process.

o When the following messages display, “TO ZERO FORKS” and “RAISE ARMS

SLOW” (alternating), slowly raise the arms until LoadMan indicates that the ZERO FORK LOAD process has completed successfully with the message, “ZERO COMPLETE”.

o The forks have been successfully calibrated to zero and the system is READY TO WEIGH. Lower the arms.


58

Calibrate Forks Going Up Verify that the fork load going up is calibrated to zero. Begin this process in the READY TO WEIGH state. With no load on the forks, very slowly raise the arms and forks through the

weighing window to verify if the GROSS xxxxx LB measurement going up is zero.

Perform several slow lifts going up to find an average gross weight. If zero, then skip this next fork calibration step.

If the average gross weight going up is not zero, the meter should be fine-tuned to allow for the variance from zero. o Go to the TROUBLESHOOT section of the Setup & Calibration Mode and

choose the section titled TROUBLE CAL. o Fine tune the ZEROUpCAL setting to account for the average gross

weight variance. For example, if the average gross weight is -10 LB going up, then decrease the ZEROUpCAL 10 counts from the current setting (in KG mode, change the count 2.2X larger than the LB mode). For this example, if the current value for ZEROUpCAL is zero (0), then program ZEROUpCAL to -10 (negative 10).

o After programming the adjustment, SAVE CHANGES; EXIT SETUP; and return to the READY TO WEIGH state.

o Verify that the GROSS xxxxx LB averages zero (0) over several slow test weights.

Calibrate Forks Going Down After LoadMan returns to the READY TO WEIGH display, verify if the fork load going down is calibrated to zero: With no load on the forks, slowly raise, and then very slowly lower the arms

through the weigh-in-motion window to verify if the NET xxxxx LB measurement going down is zero.

Do several measurements going down to find an average net weight. If zero, then skip this next fork calibration step.

If the average net weight going down is not zero, the meter should be fine-tuned to allow for the variance from zero. o Go to the TROUBLESHOOT section of the Setup & Calibration Mode and

choose the section titled TROUBLE CAL. o Fine tune the ZERODnCAL setting to account for the average net weight

variance. For example, if the average net weight is +10 LB going down, then adjust the ZERODnCAL 10 counts from the current setting (in KG mode, change the count 2.2X larger than the LB mode). For example, if ZERODnCAL is zero (0), then program ZERODnCAL to 10 (ten).


59

o After programming the adjustment, SAVE CHANGES; EXIT SETUP; and return to the READY TO WEIGH state.

o Verify that the NET xxxxx LB averages zero (0) over several slow test weights.

11. Calibrate System Under Load This step requires an empty container of a known weight, so have an empty container weighed on a known accurate scale. When LoadMan is READY TO WEIGH, pick up the empty container and

move through the weigh-in-motion window at the slowest speed possible. Do this several times to obtain the average GROSS xxxxx LB reading going up and note this average gross weight reading.

Next, perform a span truck calibration process. o Use the PROGRAM key to select “SPAN TRUCK?” and activate with the

PROGRAM key. SET

o LoadMan responds with directions to “ENTER METER LOAD”. o Use the programming keys to enter the average of weight readings that

were just obtained from the LoadMan meter. Press the PROGRAM SET

key to save. o Press the SELECT key and LoadMan will respond with the directions,

“ENTER CAL LOAD”. o Use the programming keys to enter the weight reading obtained from

the calibrated scale. Press the PROGRAM key to save. SET

o Now press the SELECT key and LoadMan will respond with the directions, “DO AUTOCAL?-->NO”. This display is confirming that the weights have been entered properly.

o To confirm that the weight entries are correct, select “YES” and press

. SET

o LoadMan will now complete the SPAN calibration and confirm with, “DOING SPAN ADJUST” and “SPAN COMPLETE!”.

o EXIT SETUP and return to the READY TO WEIGH state.

At the READY TO WEIGH state, slowly pick up the empty container and move up through the weigh-in-motion window.

Lower the empty container down through the weigh-in-motion window at the slowest speed possible. Do this several times to obtain an average NET xxxxx LB reading going down.

If the NET reading is not zero (0) then use to the TROUBLE CAL section of


60

the TROUBLESHOOT Setup & Calibration category to either increase or decrease the SPANDnCAL value to correct the error using the ratio calculation:

Ratio = Gross Weight Going Up ÷ (Gross Weight Up – Net Weight Down)

For example, if the average NET weight reading is +20 LB and the average GROSS reading was 720 LB, then the system going down is measuring only 720-20 = 700 LB. So the SPANDnCAL value needs to be adjusted by the

ratio: 720÷700 = 1.02857

Reprogram SPANDnCAL by multiplying the current value times(x) the weight ratio. Then EXIT SETUP.

Continue this calibration process until the weights going up and going down are equal, and the NET xxxxx LB reading is zero (0).

Once this calibration procedure is completed, the SPANUpCAL and the SPANDnCAL values may not be equal, but they should not be different by more than 500 counts for a system that is operating properly.

12. Fine Tune Span Adjust Sometimes, even after the ZERO and SPAN calibration adjustments have successfully completed as instructed in the previous procedures, the weighing accuracy can still be off. For this case, it is best to perform a span operation on the entire truck.

Note: Prior to performing SET SPAN on a truck load of material, LoadMan must display a zero TRUCK net weight when the vehicle is empty. If not, then perform a PROGRAM FUNCTION/ZERO TRUCK command when the vehicle is empty. Otherwise an inaccurate calibration will result. Load the truck (at least 50% full) and obtain the weight reading from a known calibrated tipping scale.

Use the PROGRAM key to select “SPAN TRUCK?” and activate with the SET

PROGRAM key. LoadMan responds with directions to “ENTER METER LOAD”. Use the programming keys to enter the weight reading obtained from the

LoadMan meter. This would be the truck’s gross weight (TRUCKg). Press the

key to save. SET

Press the SELECT and LoadMan will respond with the directions, “ENTER


61

CAL LOAD”. Use the programming keys to enter the weight readings obtained from the

calibrated scale. Press the key to save. SET

Now press the SELECT key and LoadMan will respond with the directions, “DO AUTOCAL?-->NO”. This display is confirming that the weights have been entered properly.

To confirm that the weight entries are correct, select “YES” and press . SET

LoadMan will now complete the SPAN calibration and confirm with, “DOING

SPAN ADJUST” and “SPAN COMPLETE!”. Now EXIT SETUP. The LOAD readings should now increase or decrease by the same ratio as the

METER ÷ TRUCKg ratio. So the procedure essentially reprogrammed the

SPANDUpCAL and SPANDnCAL values by this ratio. These new values can be viewed in the TROUBLE CAL section of the TROUBLESHOOT Setup & Calibration category.

Reminder: During these calibration procedures, COUNT BY was programmed to 1 and SHOW NEGATIVE WTS was set to YES. Reprogram these values if desired for the normal operating of the weighing system.


62

Troubleshooting Guide

63

TROUBLESHOOTING GUIDE This section of the manual provides a guide to troubleshooting common issues with the LoadMan Fork Based Weigh-In-Motion System. It is assumed that the reader has already become familiar with using the programming keys and understands how to access Setup & Calibration functions that are all detailed in the chapter titled Setup & Calibration Mode. LoadMan must receive all sensor signals in order to display the valid weighing display message “READY TO WEIGH”. The four sensor signals are:

Left Fork Loadcell Signal

Right Fork Loadcell Signal

Fork Angle Sensor Signal

Arm Angle Sensor Signal If any of these signals are not detected, then LoadMan suspends all weighing functions and enters into a Troubleshooting Diagnostic Mode. When LoadMan enters this mode, one to three diagnostic messages will be displayed:

NO ARM SENSOR! or ARM SENSOR OK!

NO RGHTFORK SIG! or RGHTFORK SIG OK!

NO LEFTFORK SIG! or LEFTFORK SIG OK!

1. NO ARM SENSOR! This message is displayed when there is no communication to the Arm Weigh-In-Motion sensor. The arm weigh-in-motion assembly contains a microcomputer and arm angle sensor. The microcomputer gathers all four sensor signals (arm and fork) and communicates their measurements to the LoadMan in-cab meter for processing and display. If LoadMan cannot detect the arm assembly microcomputer, then neither will the angle sensors be detected. If this is the case, then the other two diagnostic messages, “NO RGHT FORK SIG!” and “NO

LEFTFORK SIG!” will also be displayed. The right and left fork signals might be fine at this point, but of course are not detected if the arm assembly microcomputer is not communicating. There are three sources to the problem:


64

a) The cable connection from the LM200 LoadMan meter to the arm

weigh-in-motion assembly box has failed. Make certain that the 7 pin male connector is firmly plugged into the arm assembly box mounted on the arm of the vehicle. Also, make sure that the 9-pin male connector is firmly plugged into LoadMan meter RS232 port#2.

b) The arm weigh-in-motion assembly has failed. This unit is a potted assembly to survive harsh outdoor environments. The unit is not field-repairable and must be replaced or rebuilt.

c) The LoadMan meter has failed. The meter is not a field-repairable for this type of communication failure. It must be replaced with a new or rebuilt unit.

2. NO LEFTFORK SIG! and NO RGHTFORK SIG! If these two messages are displayed, first make certain that the message ARM SENSOR OK! is also displayed. If not – NO ARM SENSOR! is displayed – then go back to the previous troubleshooting section. The microcomputer inside the arm weigh-in-motion assembly reports whether it is receiving the fork loadcell signals. The fork weigh-in-motion assembly contains the digital to analog converters for both the right and left fork loadcells and also the fork angle sensor (which is independent of the arm angle sensor).

a) LoadMan must receive both loadcell signals before it can exit out of the Troubleshooting Diagnostic Mode. Check the cable that connects the arm weigh-in-motion assembly to the fork weigh-in-motion assembly and verify that they are plugged tightly into each module.

b) If the cables are connected securely, then check the cable harness for damage and perform a continuity check. This cable harness has a 7-pin connector on each end, and all connections go pin-to-pin (i.e., pin-A to pin-A, pin-B to pin-B).

c) If the cable is OK but the messages NO LEFTFORK SIG! and NO RGHTFORK SIG! still display: o Attempt to disconnect both loadcell cables that plug into the fork

weigh-in-motion box to eliminate a fault in one or both of the


65

loadcells. o If after unplugging both loadcells the messages NO LEFTFORK SIG!

and NO RGHTFORK SIG! still display, then the fork weigh-in-motion box has most likely failed.

o The fork weigh-in-motion module is a potted assembly to survive harsh outdoor environments. The unit is not field-repairable and must be replaced or rebuilt.

3. NO LEFTFORK SIG! but RGHTFORK SIG OK! LEFTFORK SIG OK! but NO RGHTFORK SIG If one of the loadcell signals is present but the other is not, then it is most likely that one of the loadcells has failed. Swap the two loadcells on the fork weigh-in-motion assembly and see if the error message reverses. If it does, then one of the loadcells has failed. Swap the loadcells again to make certain which loadcell has failed. When isolated, replace the failed loadcell.

4. Load Measurements Inaccurate Load measurements that are not repeatable or are inaccurate can be traced to one of the following:

One or both loadcells have failed.

The fork digital to analog converter (LoadCoder) has failed.

Fork angle measurements are faulty.

Arm angle measurements are faulty. Checking Loadcell Response and Fork LoadCoder Press the PROGRAM key to locate the TROUBLE LOADCELL option and

press the key to activate. SET

Press SELECT to display “CH1 xxxx.x LB” where xxxxx.x is the current weight reading of the CH1 loadcell. These readings are not actually calibrated in LBs but instead are 10 times the actual LB weight. And since the sensitivity is 10x, the count will bounce around ±20 counts.

Move the forks to a horizontal position. The CH1 fork load should read near 0 counts.

Raise the forks to as near vertical as possible. When raising the forks near vertical, the load on the forks comes off the loadcell and the reading should decrease 400-1000 LB counts (depending on the weight of the forks).

Pick up an empty container and verify that the loadcell responds in a


66

positive direction. o If the loadcell responds in a negative direction under load, then the

loadcell is mounted upside down and must be removed and rotated 180°.

o If the loadcell reading is bouncing 100s of counts, drifting, or will not repeat to the same reading under a given container load, then: either the loadcell has failed; else the fork weigh-in-motion analog to digital converter has failed; else a loadcell cable has been damaged; or the connector is loose and has moisture/dirt in the contacts.

Check for damaged loadcell cables or dirty contacts. If the contacts are dirty then the pins should be cleaned with isopropyl alcohol and a Q-tip. The signals on these pins are on the order of less than one millionth of a volt so any film residue or moisture on the contacts can cause the loadcell’s signals to drift wildly. If the problem persists after cleaning the contacts then the fork weigh-in-motion box should be replaced. If replacing the fork weigh-in-motion box does not fix the problem then the loadcell should be replaced.

Press SELECT to display the message, “CH2 xxxx.x LB” and repeat the above procedure for the CH2 loadcell.

Checking Fork and Arm Angle Measurements LoadMan relies heavily on the accuracy of the fork and arm angles to determine accurate weight measurement results. The loadcell weight measurement response is a direct function of the fork angle. Any error in the fork angle will have a major effect on the overall accuracy of the weighing system. Furthermore, the arm angle informs LoadMan when to look at the fork loadcell signals. Any error in the arm angle can cause LoadMan to look at the loadcell weight measurement response in the wrong part of the weighing cycle. To check on the fork angle calibration: Go into the TROUBLE POSITION option of the TROUBLESHOOT Setup &

Calibration category to view the current fork angle, “FORKS xxxx.x DEG”. Place a level on the fork mounting plate and move the forks until the fork

mounting plate is perfectly vertical (this makes certain that the forks are perfectly horizontal).


67

When the fork mounting plate is vertical the “FORKS xxxx.x DEG” display should measure 0.0 degrees. If not, go to step 6 of the Initial Startup and Calibration Procedure and follow the directions for calibrating the fork angle.

To check on the arm angle calibration: While still in the TROUBLE POSITION option of the TROUBLESHOOT Setup &

Calibration category, view the current arm angle, “ARMS xxxx.x DEG”.

The arm angle should read zero degrees when a typical container is lifted 1 to 2 feed off the ground.

If not, then got to step 5 of the Initial Startup and Calibration Procedure and follow the directions for calibrating the arm angle.


68

Collecting Load Data

69

COLLECTING LOAD DATA When a load is recorded, load data is stored into LoadMan’s data collection memory. The load information is recorded and stored as shown in Table 10.

Table 10. Recorded Load Data

LOAD DATA CONDITIONS FOR RECORDING DATA

Date & Time

Load Name Optional (INSTALL/DISPLAYS/ACCOUNTS)

Account Number Optional (INSTALL/DISPLAYS/ACCOUNTS)

Stop Number

Container Gross Weight

Load Weight (Dumped Load)

Container Net Weight (Empty)

Net Truck Weight (Payload Weight)

Product Optional (INSTALL/DISPLAYS/PRODUCT)

Problem Optional (INSTALL/DISPLAYS/PROBLEM)

GPS Coordinates If GPS modem and signal available

After each recording of a load, LoadMan sequences (when auto sequence enabled) to the next Stop Number and its corresponding Load Name and Account Number, and is therefore automatically setup for the next collection.

Out-of-Sequence or Unplanned Collections It may sometimes be necessary to collect a load out-of-sequence or to record a load that was unplanned during a collection route. There are several options available through the front panel PROGRAM buttons for these and similar situations.


70

Programming the STOP# Display If a printed copy of the route schedule is available, then the stop numbers will be listed for each stop on the route. Use the route schedule to find the stop number of the account that needs collected and recorded out-of-sequence. Then use the SELECT and PROGRAM front panel keys to select the new stop number before recording a load.

For example, LoadMan is currently displaying STOP #45, but instead, STOP #198 needs to be collected and recorded. Using the /SELECT keys, locate the STOP # display; then use the /PROGRAM keys to change #45 to #198. This will direct LoadMan to go directly to Stop #198 and the corresponding load name and account number for the stop.

Note: If a stop number is entered that is not found in the route list (i.e., a stop number that is higher than any on the list) then LoadMan will go to and display the highest stop number in the route list. Programming the ACCOUNT # Display If the account number is known, use the SELECT and PROGRAM front panel keys

to enter the account number before recording the load. Then, when the SET

PROGRAM key is pressed, LoadMan will search the downloaded route list for the entered account number. If the account number is found in the downloaded route list, LoadMan will display/confirm with the associated stop number and account number.

If the account number is not found in the downloaded route list, then LoadMan automatically creates the new account and displays the message “CREATING

ACCOUNT”; followed by the display of a new stop number and the newly created account number. The new stop number will be added to the downloaded route list, along with the new account number, and a newly created load name “UNPLANNED STOP XX”; where XX represents the number of unplanned stops in memory. This new stop number, account number and load name will be added after the last stop in the currently downloaded route list. Selecting a Load Name Using the LOAD NAME Display To select a specific load name from the list of downloaded route load names, first use the /SELECT keys to locate the current LOAD NAME display. The PROGRAM key will sequentially display the next load name from the route list. A flashing curser will indicate that LoadMan has entered the Program Operating Mode. Pressing the PROGRAM key will sequence forward to the next load


71

name, while the PROGRAM key will sequence in reverse. Press the SET

PROGRAM key to select and load a displayed load name. Recording a Product Some companies will download routes that include specific product names for describing their pickup services (e.g., cardboard, recycles, garbage, yard clippings, etc.). To choose and record a product for the current Stop #:

PRODUCT displays must first be enabled with the SET DISPLAY/FLASH PRODUCT command.

Locate the PRODUCT display using the /SELECT keys. Locate the particular product name using the /PROGRAM keys.


When the load is recorded, the product name will be recorded into LoadMan’s data collection memory along with the stop #, account name, account number and any other enabled route options.

Note: Once a product name has been selected, it will remain in effect for all subsequent load recordings. The product name should be re-programmed whenever the product condition changes. Recording Unexpected Problems Sometimes a problem will occur in the process of picking up or delivering a load and it is valuable to record that problem for a particular route stop (e.g., no container, road blocked, gate locked, etc.). To choose and record a problem for the current Stop #:

PROBLEM displays must first be enabled with the SET DISPLAY/FLASH PROBLEM command.

Locate the PROBLEM display using the /SELECT keys. Locate the particular problem name using the /PROGRAM keys.

Activate the problem name with the PROGRAM key. SET

When the load is recorded, the problem condition will be recorded into LoadMan’s data collection memory along with the stop #, account name, account number and any other enabled route options.

Note: Once a problem condition has been selected and recorded, it will revert back to the NO PROBLEM condition for all subsequent load recordings. New problem conditions should be re-programmed anytime a problem is encountered and before a load is picked up and recorded.


72

Wiring Diagram

73

Wiring Diagram

Figure 6. Fork Based Weigh-In-Motion Wiring Diagram

Error Messages

74

Appendix A – Error Messages Error Message Condition and Possible Resolution

ABORTING CAL Process for calibrating the Span has been interrupted. Repeat the process.

ABORTING ZERO Process for zeroing arm, fork or load has been interrupted. Repeat the process.

AUTOCAL ERROR #1 ABORTING TRK CAL

When calibration is attempted, LoadMan will make one final check to make sure things are acceptable. If the SPAN numbers go to zero (0) then there

is a problem. Likewise if the SPAN goes to values greater

than 999,999 then there is a problem. If this occurs, LoadMan aborts the AutoCal and reports an Error 1 message; meaning that that AutoCal failed due to an incorrect entry.

NO ARM SENSOR! Message displayed when there is no communication to the Arm Weigh-In-Motion sensor. See section titled Troubleshooting Guide.

NO LEFTFORK SIG! No signal from the left fork loadcell. See section titled, Troubleshooting Guide.

NO RGHTFORK SIG! No signal from right fork loadcell. See section titled Troubleshooting Guide.

SECURITY FAILED Security passcode is incorrect. Setup & Calibration cannot be accessed without a correct security passcode.

TRUCK IS NOT EMPTY Message when attempting to ZERO TRUCK and LoadMan detects a payload greater than 1500 LBs. Payload must be removed

ZERO COMMAND FAILED Process for zeroing the loadcells has been interrupted or took too long. Repeat the process.

Command Tree

75

Appendix B – Setup & Configuration Command Tree

SET ZERO? ZERO ARM ANGLE? (follow displayed directions)ZERO FORK ANGLE? (follow displayed directions.)ZERO FORK LOAD? (follow displayed directions)

SET SPAN? SPANLOAD? ENTER METER LOADENTER CAL LOADDO AUTOCAL? NO/YES

SET TARE? TRUCK xxxxxx

INSTALL? SHOW NEG WTS? NO/YES<75<150

SET DISPLAYS? DISPLAY UNITS=LB or KGCYCLE = xxx SECCOUNT BY = (1,2,5,10,20,50,100,200)ACCOUNTS xxxPRODUCTS xxxPROBLEMS xxxASSETS xxxTARGET SETPT ON/OFFFLASH LDNAME NO/YESFLASH ACCT# NO/YESFLASH STOP# NO/YESFLASH PRODUCT NO/YESFLASH PROBLEM NO/YESFLASH OVERLD NO/YESGEO ROUTE? NO/YES

SETUP MODEM? NO/YES MODEM OPTION NO/YESMODEM USA/CANADACONN xxx SECRemote IP1 74Remote IP2 93Remote IP3 98Remote IP4 177

SETUP GPS? LOG xxx SEC

SET RECORD? RECORD&PRINT OFF/ONINCR STOP # ON/OFFCONTsp xxxxxxREMOTE SWBOX OFF/ON

Command Tree

76

SETUP RS232? NO/YES RS232 PORT #1? BLUETOOTH OFF/ONBAUD RATE (110 to 38.4k)TICKET PRINT or SCOREBOARDBARCODE READ OFF/ONPRT LOADNAME NO/YESPRT ACCOUNT? NO/YESPRINT STOP# NO/YESPRT PRODUCT? NO/YESPRT PROBLEM? NO/YESPRINT TRUCKg NO/YESPRINT TRUCKn NO/YESPRINT CONTg? NO/YESPRINT CONT? NO/YESPRINT LOAD? NO/YESCOUNTBY DISABLED/ENABLEDLINE FEEDS (1 to 10)

RS232 PORT #2? BAUD RATE (600 to 115.24k)

SERIALnum (displays current serial number)

SECURITY OFF/ON

SET DEFAULTS? DEFAULTS FOR LB/KG?

ERASE DATA? (erases all load data)

TROUBLESHOOT TROUBLE CAL? ZEROUpCAL xxxxxxZERODnCAL xxxxxxSPANUpCAL xxxxxxSPANDnCAL xxxxxxSampDevUp xxxxxxSampDevDn xxxxxxSampUpRaw xSampUpC1 xSampUpC2 xSampUpC3 xLoadUpRaw xLoadUpC1 xLoadUpC2 xLoadUpC3 xSampDnRaw xSampDnC1 xSampDnC2 xSampDnC3 xLoadDnRaw xNetRaw xNetC1 xNetC2 xNetC3 x

Command Tree

77

TROUBLE POSITION WGH START x.xWGH END x.xWGH DUMP x.xARM DIRECTION= -/+ARMS x.x DEGARM ZERO -/+xxFORKDIRECTION=-/+FORKS x.x DEGFORK ZERO xFAgSTRTup x.xFAgENDup x.xFAgENDdn x.xFAgSTRTdn x.xSTATE xSTATELst xxxxxxResetCtr xxx

TRB LOAD RECORDS RECORDS xxxxxxERASE CTR x

TROUBLE GPS? LAT (latitude)LON (longitude)SATELLITES xxxxxxALTITUDE xxx MVEL East x mphVEL North x mphNextLOG xx SECRECORDS xxxxxx

TROUBLE VOLTAGE? VIN xx.xx VVLC1 xx.xx VVLC2 xx.xx VVBAT x.xx VTEMPsensor xxxxTEMPscaled xxxCONTRAST xxxx

TROUBLE COM? CONNECT xxx SECCELLSTATE xxxSIM H: (If MODEM ON)SIM L: (If MODEM ON)RESET BTOOTH NO/YESOSversion x.x.xx

TROUBLE LOADCELL CH1 SPAN xxxxxCH1 xxxx.x LBCH1 ZERO xCH2 SPAN xxxxxCH2 xxxx.x LBCH2 ZERO x

EXIT SETUP? NO/YES

Downloading LoadMan Meter Software

78

Appendix C – Downloading LoadMan Meter Software A circumstance could take place that might require an update to the LoadMan meter software. The process for updating the meter is fairly simple and is described on the LoadMan software website:

www.loadmansoftware.com

http://www.loadmansoftware.com/

INDEX

79

INDEX

A

ABORTING CAL error message · 74 ABORTING ZERO error message · 74 ACCOUNT# · 17, 34 ACCOUNTS command · 33 Activating Setup & Calibration · 5, 6, 26 ARM DIRECTION · 46 ARM ZERO · 46 ARMS DEG · 46 ASSETS command · 34 ATLTITUDE · 45 AUTOCAL ERROR #1 error message · 74

B

BARCODE command · 39 BAUD RATE command · 39 Bluetooth · 38

C

Calibrate Fork Angle · 52 Calibrate System for ZERO FORK Load ·

57 Calibrate System Under Load · 59 CELLSTATE · 44 COLLECTING LOAD DATA · 69 CONN SEC command · 36 CONNECT · 43 Connectivity & Communications · 9 CONTRAST · 44 CONTsp command · 37 COUNT BY command · 33

COUNTBY command · 40 CYCLE command · 33 CYCLE DISPLAY · 8, 20, 22

D

DATE and TIME · 20 Determine Fork Angle Lag · 54 disabling COUNT BY · 33 DISPLAY UNITS command · 33 Downloading Software · 78 DUMP LOAD · 15

E

English units · 7 ERASE DATA · 7, 25 ERASE DATA command · 41 Error Messages · 74

F

FAgENDdn · 47 FAgENDup · 47 FAgSTRTdn · 47 FAgSTRTup · 47 Fine Tune Span Adjust · 60 FLASH ACCT# command · 34 FLASH LDNAME command · 34 FLASH OVERLD command · 36 FLASH PROBLEM command · 35 FLASH PRODUCT command · 35 FLASH STOP# command · 35 Fork Angle Lag · 54 FORK DIRECTION · 46

INDEX

80

FORK ZERO · 47 FORKS DEG · 47 Front Panel and Display · 4

G

GEO ROUTE command · 36 global positioning · 37 GPS · 9, 10 GROSS · 14

I

INCR STOP # command · 37 INFORMATION DISPLAY · 14 Initial Startup and Calibration · 49 INSTALL · 7, 25, 30 Installation Commands · 30

L

LAST · 16 LAT deg · 45 LEFTFORK SIG OK! but NO RGHTFORK

SIG · 65 LINE FEEDS command · 40 Load Manager Software · 11 LOAD NAME · 17 LoadMan Load Manager Software · 3,

17, 33, 36, 40, 45 LoadMan Operating Modes · 5 LOG command · 37 LON deg · 45 LOWER ARMS · 15

M

Measurement Units · 7 Metric units · 7

modem connection speed · 36 MODEM OPTION command · 36

N

NET · 15 NextLOG · 45 NO ARM SENSOR · 63 NO ARM SENSOR! error message · 74 NO LEFTFORK SIG · 64 NO LEFTFORK SIG! but RGHTFORK SIG

OK · 65 NO LEFTFORK SIG! error message · 74 NO RGHTFORK SIG · 64 NO RGHTFORK SIG! error message · 74 NORMAL OPERATING MODE · 13

O

OPERATIONAL BASICS · 3 OSversion · 44

P

POWER button · 49 PRINT CONT command · 40 PRINT CONTg command · 40 PRINT LAST LOAD · 8, 20, 21 PRINT LOAD command · 40 PRINT STOP# command · 40 PRINT TOTAL command · 40 PRINT TRUCKn command · 40 PROBLEM display · 19 PROBLEMS command · 34 PRODUCT NAME · 18 PRODUCTS command · 34 PROGRAM FUNCTION · 20 PROGRAM FUNCTION Display · 8 PROGRAM Keys (SET, , ) · 4 Program Version (LoadMan) · 3

INDEX

81

Programming the ACCOUNT # Display · 70

Programming the STOP# Display · 70 PRT ACCOUNT command · 39 PRT LOADNAME command · 39 PRT PROBLEM command · 40 PRT PRODUCT command · 40

R

READY TO WEIGH · 14 RECORD&PRINT command · 37 RECORDING LOAD · 15 Recording Unexpected Problems · 71 RECORDS · 45 REMOTE SWBOX command · 38 RemoteIP1/IP2/IP3/IP4 · 36 RESET BTOOTH · 44 ResetCtr · 47 Route Display · 17 RS232 Ports · 9

S

SAFETY WARNING · iii SATTELITES · 45 SCOREBOARD command · 39 SECURITY FAILED error message · 74 SECURITY OFF · 26 SECURITY ON · 26 SELECT Keys (, ) · 5 SERIALnum · 30 SERIALnum command · 40 SET DEFAULTS · 7, 25 SET DEFAULTS command · 41 SET DISPLAYS · 30, 31 SET RECORD · 30 SET RECORD command · 37 SET SPAN · 7, 25, 28 SET SPAN calibration procedure · 28 SET TARE · 7, 25, 29 SET ZERO · 7, 25, 27

setting IP addresses · 36 Setup & Calibration Commands · 25, 27 Setup & Calibration Mode · 5, 25 SETUP GPS · 30 SETUP GPS command · 37 SETUP MODEM · 30 SETUP MODEM command · 36 SETUP RS232 · 30 SETUP RS232 command · 38 SHOW GROSS · 8, 20, 21 SHOW NEG WTS · 30 SHOW NET · 8, 20, 21 SIM CARD # · 44 SPANDnCAL · 48 SPANUpCAL · 48 STATE · 47 STATELst · 47 STOP # · 18 STOP# · 35

T

TARGET · 16, 32, 36 TARGET command · 34 TEMPscaled · 44 TEMPsensor · 44 TICKET PRINT command · 39 tonnes · 7 TRB LOAD RECORDS command · 45 TROUBLE CAL command · 48 TROUBLE COM command · 43 TROUBLE GPS command · 45 TROUBLE LOADCELL command · 43 TROUBLE POSITION command · 45 TROUBLE VOLTAGE command · 44 TROUBLESHOOT · 7, 25 TROUBLESHOOT command · 42 TROUBLESHOOTING GUIDE · 63 TRUCK · 16 TRUCK IS NOT EMPTY error message ·

74

INDEX

82

U

Unplanned Collections · 69

V

VBAT · 44 Verify Angle Measurements · 53 Verify Angle Sensors · 50 Verify Fork Load Cells · 51 Verify Weigh-In-Motion Response · 56 Verify Wiring · 49 VIN · 44 VLC1 · 44 VLC2 · 44

W

WEIGHING LOAD · 14 WEIGHING TARE · 15

Weigh-In-Motion Window · 50 Weight and Message Display · 5 Weight Display · 14 WEIGHT DISPLAY · 16 WGH DUMP · 46 WGH END · 46 WGH START · 46

Z

ZERO ARM ANGLE · 27 ZERO COMMAND FAILED error

message · 74 ZERO FORK ANGLE · 27 ZERO FORK LOAD · 8, 20, 22, 28 ZERO TRUCK · 8, 20, 23 ZERODnCAL · 48 ZEROUpCAL · 48

Documents

LoadMan LM200 Reference Guide...SETUP & CALIBRATION MODE 25 ... DUMP LOAD Weighing is complete and load is ready to dump. WEIGHING TARE Measuring the empty container weight while arms