Dynatest FWD User manual

DYNATEST FWD/HWD
TEST SYSTEMS
OWNER’S MANUAL
Version 2.8.17

2017.06.19 FwdMan2.8.17.docx
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Dynatest.
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!IMPORTANT SAFETY REMARKS!
Please Read this first:
For your own safety and the safety of others, please read this advice carefully.
An FWD/HWD is a powerful, hence dangerous piece of equipment that may injure persons in
cases of malfunction or mistreatment.
Things that may happen:
The weight may drop unexpectedly.
Hydraulic oil may leak at high pressure.
Hydraulic leakage may ‘DROP’ the loading plate assembly onto the ground.
A few simple rules for the operator:
Stay clear of the moving parts of the FWD/HWD if at all possible.
Make sure nobody else gets close.
Never place objects like e.g. tools at or near the buffer hit plate.
Do not leave the weight raised to drop position.
Do not leave the subassembly raised and unlocked.
Support the weight or subassembly during maintenance.
During demonstrations, training etc.:
Announce what you are about to do before you press any buttons.

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Overview
1. Introduction..................................................................................................................1-1
2. Tow Vehicle Installation..............................................................................................2-6
3. Computer Configuration...........................................................................................3-19
4. Program Configuration.............................................................................................4-25
5. Preparing for Measurements....................................................................................5-40
6. Weight Setup..............................................................................................................6-46
7. Connecting the Electronics .......................................................................................7-51
8. Leaving Base...............................................................................................................8-54
9. Running the Program................................................................................................9-56
10. Performing the Measurements ...............................................................................10-69
11. The Dynatest FWD/HWD Hardware.....................................................................11-84
12. Transducers/Cables...............................................................................................12-102
13. Calibration..............................................................................................................13-105
14. Setup Details...........................................................................................................14-113
15. The Compact15 System Controller......................................................................15-128
16. Maintenance...........................................................................................................16-135
17. Trouble Shooting....................................................................................................17-137
18. Optional Accessories..............................................................................................18-150
19. Data Formats..........................................................................................................19-153
20. Error Messages ......................................................................................................20-171

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Table of Contents
1. Introduction..................................................................................................................1-1
1.1 Intro...........................................................................................................................1-1
1.2 History.......................................................................................................................1-1
1.3 General Specifications ..............................................................................................1-2
1.4 Performance Specifications.......................................................................................1-5
2. Tow Vehicle Installation..............................................................................................2-6
2.1 Short form Vehicle Installation Guide......................................................................2-6
2.2 Notes for the Vehicle Installation .............................................................................2-9
3. Computer Configuration...........................................................................................3-19
3.1 Requirements ..........................................................................................................3-19
3.2 Network Settings.....................................................................................................3-22
3.3 Virus Protection ......................................................................................................3-22
3.4 Backup ....................................................................................................................3-23
3.5 Software Upgrades..................................................................................................3-23
3.6 Cameras...................................................................................................................3-24
4. Program Configuration.............................................................................................4-25
4.1 Dynatest Data Collection (DDC)............................................................................4-25
4.2 Applet Overview.....................................................................................................4-28
4.3 Completing the Setup..............................................................................................4-29
5. Preparing for Measurements....................................................................................5-40
5.1 Checking the FWD/HWD Hardware......................................................................5-40
5.2 Drop Heights Adjustment .......................................................................................5-41
5.3 “Lock error” and “Plate not low error”...................................................................5-45
6. Weight Setup..............................................................................................................6-46
6.1 Changing the UUFWDUU Weight Setup ..........................................................................6-46
6.2 Changing the UUHWDUU Weight Setup..........................................................................6-48
7. Connecting the Electronics .......................................................................................7-51
7.1 Connecting Transducers/Cables..............................................................................7-51
7.2 Connecting the Computer .......................................................................................7-53
8. Leaving Base...............................................................................................................8-54
8.1 Maintenance Checks ...............................................................................................8-54
8.2 Connect Trailer to Tow Vehicle..............................................................................8-54
8.3 Functional Check ....................................................................................................8-54
8.4 Just Before Leaving... .............................................................................................8-55
8.5 During Driving........................................................................................................8-55
9. Running the Program................................................................................................9-56
9.1 Switch ON...............................................................................................................9-56
9.2 Warnings.................................................................................................................9-56
9.3 Dynatest Data Collection (DDC)............................................................................9-57
9.4 The Data Collection Screen ....................................................................................9-63
9.5 Main Window .........................................................................................................9-64
9.6 Sub-Windows..........................................................................................................9-67
10. Performing the Measurements ...............................................................................10-69
10.1 Test Setups............................................................................................................10-69
10.2 Test Section...........................................................................................................10-75
10.3 Data Files ..............................................................................................................10-77
10.4 Running a Test ......................................................................................................10-78
10.5 Remarks ................................................................................................................10-79
10.6 Auxiliary Outputs X and Y...................................................................................10-79

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10.7 Closing the Data File.............................................................................................10-80
10.8 Opening a Data File ..............................................................................................10-80
10.9 Exporting Data......................................................................................................10-80
10.10 Monitoring the System’s Status ............................................................................10-81
10.11 Manual Control .....................................................................................................10-83
10.12 Exit........................................................................................................................10-83
11. The Dynatest FWD/HWD Hardware.....................................................................11-84
11.1 General Description ..............................................................................................11-84
11.2 Trailer Specifications............................................................................................11-86
11.3 FWD/HWD Hydraulics.........................................................................................11-87
11.4 Electrical System...................................................................................................11-95
11.5 FWD/HWD Trailer Mounted Power Unit (Generator - Optional) .......................11-98
12. Transducers/Cables...............................................................................................12-102
12.1 UUFWDUU Load Cell 86207........................................................................................12-102
12.2 UUHWDUU Load Cell 86205 .......................................................................................12-103
12.3 Seismic Detector 86211 ......................................................................................12-104
13. Calibration..............................................................................................................13-105
13.1 Relative Deflector Calibration ............................................................................13-105
13.2 Air Temperature Sensor Calibration...................................................................13-110
13.3 Surface Temperature Sensor Calibration............................................................13-111
13.4 DMI Calibration..................................................................................................13-112
14. Setup Details...........................................................................................................14-113
14.1 GPS .....................................................................................................................14-113
14.2 Cameras...............................................................................................................14-122
15. The Compact15 System Controller......................................................................15-128
15.1 Key Features .......................................................................................................15-128
15.2 General Description ............................................................................................15-128
15.3 Notes on Specifications.......................................................................................15-130
15.4 Switch ON...........................................................................................................15-130
15.5 Setup and Diagnostics.........................................................................................15-130
15.6 Description..........................................................................................................15-131
15.7 Manual Operation ...............................................................................................15-133
16. Maintenance...........................................................................................................16-135
16.1 Wheels/Brake System .........................................................................................16-135
16.2 Drop Weight Subassembly..................................................................................16-135
16.3 Electrical/Electronic Parts:..................................................................................16-136
16.4 Hydraulic System................................................................................................16-136
17. Trouble Shooting....................................................................................................17-137
17.1 Checking the Hydraulic Oil Level ......................................................................17-137
17.2 Switching off all Power.......................................................................................17-138
17.3 Checking Trailer Electronics Power ...................................................................17-138
17.4 Checking Trailer Battery Condition....................................................................17-138
17.5 Revealing hyd. leakage error ..............................................................................17-138
17.6 General Functional Checking of the Hydraulics.................................................17-139
17.7 Checking the Lower Plate/Raise Weight mode ..................................................17-146
17.8 Checking the DROP mode..................................................................................17-146
17.9 Checking the LOWER CATCH mode................................................................17-147
17.10 Checking the four Proximity Switch Sensors .....................................................17-147
17.11 Checking the Pressure Switches .........................................................................17-148
18. Optional Accessories..............................................................................................18-150

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18.1 Optional Hardware..............................................................................................18-150
18.2 Data Processing Software ...................................................................................18-152
19. Data Formats..........................................................................................................19-153
19.1 MS Access 2000 (MDB).....................................................................................19-153
19.2 Comma Delimited (F25).....................................................................................19-154
19.3 Nondelimited, 7+ Deflectors (F20).....................................................................19-159
19.4 Nondelimited, 7 Deflectors (FWD/HWD)..........................................................19-164
19.5 Pavement Deflection Data Exchange (DDX) .....................................................19-169
20. Error Messages ......................................................................................................20-171

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Full Table of Contents
1. Introduction..................................................................................................................1-1
1.1 Intro...........................................................................................................................1-1
1.2 History.......................................................................................................................1-1
1.3 General Specifications ..............................................................................................1-2
1.3.1 The FWD/HWD Mechanics............................................................................1-3
1.3.2 The Compact15 System Controller .................................................................1-4
1.3.3 The Remote Control Box.................................................................................1-4
1.3.4 The Computer..................................................................................................1-4
1.3.5 FwdWin, a Windows based FWD/HWD Field Program ................................1-4
1.4 Performance Specifications.......................................................................................1-5
1.4.1 Accuracy..........................................................................................................1-5
1.4.2 Reproducibility................................................................................................1-5
2. Tow Vehicle Installation..............................................................................................2-6
2.1 Short form Vehicle Installation Guide......................................................................2-6
2.1.1 General Remarks .............................................................................................2-6
2.1.2 Vehicle Type....................................................................................................2-6
2.1.3 Trailer Hitch ....................................................................................................2-6
2.1.4 Trailer Lights Socket (provided) .....................................................................2-6
2.1.5 Additional 12V Alternator...............................................................................2-6
2.1.6 Using/ (Replacing) the Existing Vehicle Alternator........................................2-6
2.1.7 Battery Separation Relay (provided if needed) ...............................................2-7
2.1.8 Electronics Buffer Battery (provided if required) ...........................................2-7
2.1.9 Heavy Fuse Box (provided).............................................................................2-7
2.1.10 12V Power Socket for Trailer (provided)........................................................2-7
2.1.11 Power Inverter (provided if needed)................................................................2-7
2.1.12 Throttle Regulator............................................................................................2-7
2.1.13 Alarm Connection Plug (provided) .................................................................2-7
2.1.14 Emergency Switch...........................................................................................2-7
2.1.15 Cable Access Opening.....................................................................................2-8
2.1.16 Placing the Computer ......................................................................................2-8
2.1.17 Air Conditioning..............................................................................................2-8
2.1.18 Warning Signs / Flasher Lights .......................................................................2-8
2.2 Notes for the Vehicle Installation .............................................................................2-9
2.2.1 Trailer Hitch Requirements .............................................................................2-9
2.2.2 Trailer Tail Lights Wiring .............................................................................2-10
2.2.3 System Powering...........................................................................................2-11
2.2.4 Plate-Low Alarm Connection........................................................................2-15
2.2.5 Cable Access Opening...................................................................................2-17
2.2.6 Placing the Computer and the Remote Control Box .....................................2-17
2.2.7 Warning Signs / Flasher Lights .....................................................................2-18
3. Computer Configuration...........................................................................................3-19
3.1 Requirements ..........................................................................................................3-19
3.2 Network Settings.....................................................................................................3-22
3.3 Virus Protection ......................................................................................................3-22
3.4 Backup ....................................................................................................................3-23
3.5 Software Upgrades..................................................................................................3-23
3.6 Cameras...................................................................................................................3-24
3.6.1 Camera Applet...............................................................................................3-24
3.6.2 HCamera Applet............................................................................................3-24

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4. Program Configuration.............................................................................................4-25
4.1 Dynatest Data Collection (DDC)............................................................................4-25
4.1.1 Vehicle ID......................................................................................................4-25
4.1.2 Driver.............................................................................................................4-25
4.1.3 User................................................................................................................4-26
4.1.4 Administrator.................................................................................................4-26
4.1.5 Options...........................................................................................................4-26
4.1.6 Entering the Main Program ...........................................................................4-27
4.2 Applet Overview.....................................................................................................4-28
4.3 Completing the Setup..............................................................................................4-29
4.3.1 Entering the Data Collection Screen .............................................................4-30
4.3.2 Loading Unit..................................................................................................4-30
4.3.3 Compact15 System Controller.......................................................................4-32
4.3.4 Load Cell .......................................................................................................4-32
4.3.5 Deflectors.......................................................................................................4-33
4.3.6 Program Options............................................................................................4-34
4.3.7 Air Temperature Sensor.................................................................................4-36
4.3.8 Surface Temperature Sensor..........................................................................4-37
4.3.9 Distance Measuring Instrument.....................................................................4-38
4.3.10 Global Positioning System (Optional)...........................................................4-39
5. Preparing for Measurements....................................................................................5-40
5.1 Checking the FWD/HWD Hardware......................................................................5-40
5.2 Drop Heights Adjustment .......................................................................................5-41
5.3 “Lock error” and “Plate not low error”...................................................................5-45
6. Weight Setup..............................................................................................................6-46
6.1 Changing the UUFWDUU Weight Setup ..........................................................................6-46
6.2 Changing the UUHWDUU Weight Setup..........................................................................6-48
7. Connecting the Electronics .......................................................................................7-51
7.1 Connecting Transducers/Cables..............................................................................7-51
7.1.1 Note on Load Cell Cable connection:............................................................7-52
7.1.2 Note on Placing the Deflectors......................................................................7-52
7.1.3 Important Notice!!!........................................................................................7-52
7.2 Connecting the Computer .......................................................................................7-53
7.2.1 Interface connections.....................................................................................7-53
7.2.2 Power Connections........................................................................................7-53
8. Leaving Base...............................................................................................................8-54
8.1 Maintenance Checks ...............................................................................................8-54
8.1.1 Tire Pressure..................................................................................................8-54
8.1.2 Hydraulic Oil Level.......................................................................................8-54
8.1.3 Battery Acid Level.........................................................................................8-54
8.2 Connect Trailer to Tow Vehicle..............................................................................8-54
8.2.1 Hook to Hitch ................................................................................................8-54
8.2.2 Rear Lights Connection.................................................................................8-54
8.2.3 Front Support Wheel .....................................................................................8-54
8.2.4 Power Cable...................................................................................................8-54
8.2.5 Network Cable...............................................................................................8-54
8.3 Functional Check ....................................................................................................8-54
8.4 Just Before Leaving... .............................................................................................8-55
8.4.1 Transport Locks (Automated or Manual)......................................................8-55
8.4.2 Raise/Lower Bar Locking Pin .......................................................................8-55
8.4.3 Trailer Handbrake..........................................................................................8-55

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8.5 During Driving........................................................................................................8-55
9. Running the Program................................................................................................9-56
9.1 Switch ON...............................................................................................................9-56
9.2 Warnings.................................................................................................................9-56
9.2.1 Emergencies...................................................................................................9-56
9.2.2 Stopping a Sequence......................................................................................9-56
9.2.3 Driving...........................................................................................................9-57
9.3 Dynatest Data Collection (DDC)............................................................................9-57
9.3.1 Applets...........................................................................................................9-57
9.3.1.1 Network .............................................................................................9-58
9.3.1.2 DMI....................................................................................................9-58
9.3.1.3 Speedometer.......................................................................................9-59
9.3.1.4 Thermometers....................................................................................9-59
9.3.1.5 GPS....................................................................................................9-59
9.3.1.6 Camera...............................................................................................9-60
9.3.1.7 Ground Penetrating Radar .................................................................9-61
9.3.2 Simulation Mode ...........................................................................................9-62
9.3.3 Entering the Main Program ...........................................................................9-62
9.4 The Data Collection Screen ....................................................................................9-63
9.5 Main Window .........................................................................................................9-64
9.5.1 Navigating with the Keyboard.......................................................................9-64
9.5.2 Special Keys ..................................................................................................9-66
9.6 Sub-Windows..........................................................................................................9-67
9.6.1 LED Panel......................................................................................................9-68
9.6.2 Time Histories ...............................................................................................9-68
9.6.3 Surface Moduli ..............................................................................................9-68
9.6.4 Surface Moduli Chart ....................................................................................9-68
10. Performing the Measurements ...............................................................................10-69
10.1 Test Setups............................................................................................................10-69
10.2 Test Section...........................................................................................................10-75
10.3 Data Files ..............................................................................................................10-77
10.4 Running a Test ......................................................................................................10-78
10.5 Remarks ................................................................................................................10-79
10.6 Auxiliary Outputs X and Y...................................................................................10-79
10.7 Closing the Data File.............................................................................................10-80
10.8 Opening a Data File ..............................................................................................10-80
10.9 Exporting Data......................................................................................................10-80
10.10 Monitoring the System’s Status ............................................................................10-81
10.11 Manual Control .....................................................................................................10-83
10.12 Exit........................................................................................................................10-83
11. The Dynatest FWD/HWD Hardware.....................................................................11-84
11.1 General Description ..............................................................................................11-84
11.2 Trailer Specifications............................................................................................11-86
11.3 FWD/HWD Hydraulics.........................................................................................11-87
11.3.1 General Description.....................................................................................11-87
11.3.2 Adjusting the Hyd. Pump Excess Pressure..................................................11-93
11.4 Electrical System...................................................................................................11-95
11.4.1 Transducers..................................................................................................11-95
11.4.2 FWD/HWD Control Circuits.......................................................................11-96
11.4.3 Trailer Status Switches................................................................................11-96
11.4.4 Hyd. Unit Connections ................................................................................11-97
11.4.5 Trailer Powering..........................................................................................11-97