Orbit Controls OC 3010 User manual

OC3010_GBM_21009
BRAKE TESTER
DECELEROMETER
OWNER’S MANUAL
Version 8.++
ORBIT CONTROLS AG
Zürcherstrasse 137
CH-8952 Schlieren/ZH
Tel: + 41 44 730 2753
Fax: + 41 44 730 2783
[email protected]
www.orbitcontrols.ch

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Dear Customer,
Thank you for ordering the Decelerometer OC 3010.
The instrument has been carefully checked in all operation modes and finally precisely
calibrated. The test chart is enclosed.
WARRANTY
The instrument has 24 month warranty for all parts and labour involved with the repair. The
warranty does not apply to damaged, overloaded or modified instruments or instruments with
broken seal at the rear cover.
We will be pleased to answer all your questions not only to this instrument but also to all our
calibrators and measuring equipment. Please call our customer service or write to us
[email protected]
Thank you.
ORBIT CONTROLS AG
Zürcherstrasse 137
8952 Schlieren
Switzerland
Tel: +41 - 44 - 730 27 53
Fax: +41 - 44 - 730 27 83
www.orbitcontrols.ch
PLEASE NOTE
The instrument is supplied from internal rechargeable NiMH battery. Please make sure that
the battery is correctly charged from the enclosed battery charger as soon as the warning will
appear at the display. The time for the full charge is approx. 3hours.

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Index
Page
Chapter 1
- Application and measurements 1.1 7
- Specifications 1.2 7
- Decelerometer accessories and options 1.3 8
- Principle of measurement 1.4 9
- Auxiliary Sensors 1.5 9
- Report printing 1.6 10
Chapter 2
- Control Panel and Configuration 2.1 11
- Configuration 2.2 13
- Calibration, Measurements and Printing 2.3 13
- Calibration 2.3.1 13
- Measurement 2.3.2 14
- Printing 2.3.3 14
- Menu Selection 2.4 15
- Data Clearing 2.4.1 15
- Recording Interval 2.4.2 16
- Six possibilities to initiate the measurement 2.4.3 17
- Threshold 2.4.4 18
- Display Contrast 2.4.5 18
- Backlight 2.4.6 18
- Time and Date 2.4.7 19
- Header of the report 2.4.8 17
- Filter 2.4.9 20
- Automatic Shut – Off 2.4.10 20
- Basic Menu Settings 2.4.11 20
- Connection to a PC 2.5 21
- How to connect the PC and start communication 2.5.1 21
- Stability of the Measurement 2.6 25
- Additional languages 2.7 25
Chapter 3
- Service and Maintenance 3.1 26
- Battery Charging 3.2 26
- Replacement of paper and ink ribbon 3.3 26

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Glossary
Application
Fast check up of brake systems of the traffic vehicles intended for:
•stations for the technical inspections of cars
•car repair shops
•car owners
•the benefit of judicial experts and police
Type:
Portable Decelerometer set with built-in printer, LCD display and keyboard, including
the software for PC Windows. Optional connections of force sensor or pressure sensor
are provided.
Measured quantities:
The measurement of the overall brake deceleration and its dependence on the
controlling force applied to the brake pedal or its dependence on the air pressure in the
air pressure brakes. The results of measurements are graphs of the time dependencies
and the numerical calculated average value of the overall deceleration
Specifications:
Maximal braking deceleration ... 10 m/s2
Controlling force applied to the brake pedal ... up to 1000 N (option)
Air pressure in the air pressure brake.... up to 1 MPa (option)
Hydro pressure in the oil pressure brake.... up to 20 MPa (option)
Weight... up to 8T (option)
Sampling rate 1..50s for OC3010
Sampling rate 5..300s for OC3010XL
Printing
•graph with numerical values
•date and time of measurements
•company headings
•two lines of measurement confirmation

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Power supply
•build in NiMH rechargeable battery. Charging from AC adapter.
Measured data memory
•storage of 128 measurements. Possibility of printing any of the stored
measurements.
Decelerometer OC3010 accessories
•force sensor for the measurement of the force applied to the brake pedal
•pressure sensor for the air pressure measurement in the air pressure brake
•pressure sensor for the hydro pressure measurement in the Forklifts
•weight sensor for the load capacity measurement in the Forklifts
•AC adapter for charging of the NiMH battery
•external start button
•interface cable for connection to PC computer
•Software Program for Windows
•User’s manual
•Carrying Case

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Chapter 1
1.1 Application and measurements
Decelerometer is used for measurements of overall brake decelerations of traffic vehicles.
The value of deceleration is measured, as well as its dependence on the controlling force
applied to the brake pedal, or its dependence on the air pressure in the air pressure
brakes. The results of measurements are the graphical records time related the numerical
calculated average value of overall deceleration and the average value of control force or
the average value of air pressure.
The following three options can be ordered:
- Decelerometer only
- Decelerometer with external sensor for controlling force applied to the brake pedal
- Decelerometer with external sensor for air pressure in the air pressure brake system
The measurement of the controlling force applied to the brake pedal and the measurement
of the air pressure in the air pressure brakes is possible only with the external force sensor
or with the external pressure sensor. After the selected sensor is connected, the
Decelerometer will be configured automatically. The external sensors are supplied as
accessories.
External sensors from different Decelerometers are not exchangeable
without the manufacturer’s calibration.
The measurement is very easy. The instrument must be placed onto the vehicle whereas
the arrow on the instrument shows the direction of travel. With the levelling screws and
built-in levelling libel the instrument is adjusted into exact horizontal position. After
switching-on, the display scrolls the instructions. When the calibration is finished, the
vehicle can be set into the motion. The measurement will start by pressing the starting
button. Than the vehicle is slowed-down until it stops by its own braking system. The
wheels are not allowed to block. The maximal values appear at the display and the
detailed report is printed. The results of measurements will remain in the internal memory
as long as the power is switched-on.
1.2 Specifications
Design and specifications of the Decelerometer are based on the regulation of Ministry of
transport, “About regular technical inspections and emission measurements of the road-
bound vehicles “.
Measurement Ranges:
- Braking deceleration 0 - 20 ms-2
- Controlling force applied to the brake pedal 0 - 1000 N
- Air pressure in the air pressure brake 0 - 1 MPa
Accuracy of the measurements:
- braking deceleration ± 3 %
- controlling force applied to the brake pedal ± 35 N
- air pressure in the air pressure brake ± 25 kPa.

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Printing:
- Company headings
- Date and Time
- Graphics with numerical values
- Two lines containing the confirmation of measurement
- Additional information about Decelerometer configuration
Power supply:
- build in NiMH rechargeable battery, charging from AC adapter
Memory:
- Internal memory for up to 128 measurements. Printing of any stored measurement
Features:
- Two line LCD display with back light
- Keypad with 9 keys
- Built-in matrix printer
- Possible connection to PC with control and evaluation program
1.3 Decelerometer accessories and options
The Decelerometer contains the microcontroller supported measuring circuits, set of
options and accessories which facilitate the measurements:
- Decelerometer OC3010
- External start button
- AC adapter for NiMH battery
- interface cable for connection to PC computer
- CD with program for PC (Windows)
- Extra paper for the printer
- Users manual
- Carrying Case
Option (extra order)
- Pressure sensor 1MPa with a cable
- Force sensor 1000N with a cable
- Pressure hydro sensor 20MPa with a cable
- Weight sensor 8T with a cable
The use of the pressure or the force sensor depends on the application. The interface
cable to PC computer may be connected. The Decelerometer may be configured and used
as stand alone unit or as a data acquisition system for collecting the data and transferring
them to a PC. With the help of external start button the measurement can be initiated by
the operator of the vehicle.

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1.4 The principle of measurement
The measurement is performed by simultaneous recording the deceleration and the
controlling force applied to the brake pedal or by recording of the vehicle deceleration and
the air pressure in the air braking system. All data are stored in the internal memory after
the button Start has been applied. The measurement of the deceleration, the controlling
force applied to the brake pedal and the air pressure in the air brakes is realised with the
build-in deceleration sensor, the force sensor or the pressure sensor. At the end of the
measurement the maximal values are shown at the display and a detailed report is printed.
During the printing the calculation is performed for the average value of the overall
deceleration, the average value of control force or the average value of the air pressure.
Before the measurement starts, the recording interval has to be set. The range of setting is
from 1 to 50 seconds (5 to 300 seconds for OC3010XL). An averaging filter is available
with selectable filtering constants from 0 (no filter) to 10 (long time constant).
The measurements can be initialized:
- Starting button MEAS
- External starting button
- Setting the threshold value
or combination of the above.
The recording clearly shows whether the measured smallest average value of the overall
deceleration is as prescribed in the vehicle manual and whether the controlling force
applied to the brake pedal or the air pressure have achieved the required values.
The results of measurements (up to 128 data sets) will be stored in the memory and might
be printed. With the help of the supplied program, the records can be downloaded to a PC.
After each measurement the Hydro sensor or the Weight sensor can be connected and
used. Press the button MEAS again. After the display shows steady reading, press MEAS
again. The pressure or weight measurements are stored.
1.5 Auxiliary Sensors
For measurement of Forklifts the hydraulic sensor can be used connected to the forklift
hydraulic installation. For weight measurement of the Forklifts an external weight sensor is
optionally available.

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1.6 Report printing
When the measurements are stored, the report can be printed. The record contains the
company’s head (can be disabled), time and date, and the measured values and the time.
The maximum deceleration value and the duration of the measurement will be printed as
well. After entering the time interval, the average value of overall deceleration and the
average value of the force or the air pressure will be calculated and printed.
If Hydro sensor or Weight sensor is used, their results will be printed as well. Two lines of
text are added to the printed report, containing the identification of the vehicle and the
confirmation of the measurement.
The printing on the 57.5mm wide paper is in ink. This will guarantee a long lasting quality.
The printing of one report takes about 15 seconds. The report may be printed several
times. The interval however in which the average values have to be calculated must be
entered all the time. The reports of previous measurements may be printed more times as
well.

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Chapter 2
2.1 Control Panel and Configuration
The Decelerometer OC3010 is controlled by using the front panel keyboard, with power-
ON/OFF keys. Three keys are used in the measurement mode, four keys in the menu
mode.
With the keys ON and OFF the power is applied to the instrument. After the power is
switched on, the display shows
The internal memory and the calibration data are tested. The time and date is displayed for
3 seconds, provided that the internal clock is set. After the test the following text will be
displayed:
The instrument has to be set into exact horizontal position with the help of levelling screws
and built-in levelling libel. This step is mandatory in order to guarantee the correct function
of the Decelerometer. Pressing of any key initiates the calibration, the setting of zero offset
and starting of the configuration test. At the end the selected configuration is displayed for
a short time.
Brake tester ***
***Decelerometer
Set horizont
position, please

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Decelerometer only - Most of all applications:
Decelerometer and external force sensor:
Decelerometer and external pressure sensor:
Decelerometer and external hydraulic sensor
Decelerometer and external weight sensor
The instrument requests for switching into the measuring or the menu mode.
Selection by MEAS or MENU. When a measurement has already been done, this
information appears, e.g. with Decelerometer only:
Select function:
Measure-menu
Decelerometer
Decelerometer
Force sensor
Decelerometer
Pressure sensor
Measure N. 1
Max 9.8 m/s2
Decelerometer
Hydr. sensor
Decelerometer
Weight

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Decelerometer and external force sensor:
Decelerometer and external pressure sensor:
When the Decelerometer is switched ON and OFF more time per day, the key MENU can
be pressed to cancel the control procedure after the display shows:
2.2 Configuration
By pressing the appropriate keys in the mode measurement, the measurement, the
calibration or the printing can be started, or the previous measurement can be displayed.
By pressing MENU the menu mode is initiated - see § 2.4.
2.3 Calibration, Measurements and Printing.
2.3.1 Calibration
In the measuring mode the instrument measures, calibrates or prints the data. Any of
these activities may be selected by depressing one of the keys MEAS, CAL or PRN. After
pressing CAL the offsets of the deceleration sensor, the force sensor or the pressure
sensor are set for zero reference values.
At the end of the calibration the display shows:
Measure N. 1
9.8 m/s2500N
Measure N. 1
9.8 m/s2 300kPa
Calibration
Offset
End of
Calibration
Brake tester ***
***Decelerometer

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2.3.2 Measurement
By pressing MEAS, the mode changes into measurement. The Display waits some
seconds until the conditions for correct measurements are fulfilled. This time depends on
the Decelerometer configuration, on the set threshold and on the mode how the
measurement will be started. As soon as these conditions are met, the measurement
starts and the results are recorded during the time interval set in the mode menu. The
values of deceleration, force or pressure are calculated. The measured data are filtered in
accordance with the filter setting. At the end of measurement the maximal values of
deceleration, force or pressure are displayed as well as the serial number of the
measurement.
2.3.3 Printing
By pressing PRN, the paper will be advanced. When the key is pressed longer, the data
will be printed in graphics.
Printout
After the graphics is finished, the average values of overall deceleration, force or pressure
will be printed. The beginning and the end of the time interval, in which the average values
have to be calculated, must be entered with up or down arrow keys. The interval in which
the deceleration is steady - nearly constant, has to be selected.
Papier eject
or printing
For printing
Push button
start 0.8 s
value 6.0m/s2
Printing.....
Wait, please

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The selected values have to be confirmed by pressing the right arrow cursor. The
beginning of the interval is determined first. The end of the interval has to be confirmed
afterwards.
The average values of measured parameters are calculated within the selected interval
only. The second part of the report is printed afterwards.
By pressing MEAS again, the new measurement can be initiated. The previous
measurements are not deleted, but stored in the memory. Up to 128 measurements can
be memorized. By using the down arrow key the previous measurement can be recalled.
With the up arrow key the next measurement can be started. The serial number of the
selected measurement is displayed. The memory can store up to 128 measurements. Next
measurements may be started as described in 2.4.1.
2.4 Menu Selection
By pressing MENU the instrument enters the menu mode. In the Menu Mode the time
interval, the recording, the starting way of the measurement, setting of the threshold, the
display contrast, the backlight, the time and the date, the texts of the head, the transfer
rate and the filter can be set by using the up the down and the right arrows. By pressing
MEAS the measuring mode is initiated - see § 2.3.
2.4.1 Data Clearing
By pressing the key MENU following text appears:
With the key right arrow the measured data N (1...128), the time hh:mm:ss and date
dd.mm will be deleted. All records 2…128 are shifted to 1...127. After erasing all data the
following text will be displayed:
Data clearing N
hh:mm:ss dd.mm
*** No data **
************
end 2.5 s
value 3.4m/s2

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All data can be deleted at the same time when the key right arrow is pressed for a longer
time.
When the key right arrow is pressed for a long time, the entire data content is erased.
The display is flashing during the data are erased. It takes around 5 seconds.
When PRN is pressed, the paper is advanced. When pressed longer, the list of all stored
measurements is printed.
2.4.2 Recording Interval
After pressing the key MENU following text is displayed:
With up and down arrows the recording interval can be set from 1 to 50 seconds (5 to 300
seconds for OC3010XL).
Sample setting
time : xx [s]
All clearing
push button
All clearing
Clearing xx%
All clearing
Watt….

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2.4.3 Six possibilities to initiate the measurement
After pressing MENU one of the six possible ways of initiating the measurement can be
selected. The selection is with up or down arrow keys.
1. Start with the key MEAS
2. Start with the external button
3. Start when the deceleration threshold is higher then the value set
4. Start when the force/pressure threshold is higher then the value set
5. Start with external button and the deceleration threshold higher then the value set
6. Start with external button and force/pressure threshold higher then the value set
Start definition
External=button
Start definition
Decel. threshold
Start definition
Thr. force/pres
Start definition
Butt + thres.dec.
Start definition
Butt+thr.fr/pr
Start definition
Internal= M

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2.4.4 Threshold
By pressing MENU the display will show:
By using the up and down arrows the threshold can be set in % from the upper limit XX.
The upper limit of deceleration is 10 m/s2, for the force 1000N and for the pressure 1MPa.
The limit of deceleration, force or pressure will be selected in accordance with the
configuration of the Decelerometer - see § 1.1.
2.4.5 Display Contrast
After pressing MENU the display will show:
Set the required contrast with up and down arrows.
2.4.6 Backlight
After pressing MENU the display will show:
Set the required light with up and down arrows.
With the backlight ON the operating time from the battery is much shorter.
Threshold set
Value: xx %
Contrast sel
higher - lower
Backgr. light
on - off

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2.4.7 Time and Date
After pressing MENU the display will show:
The flashing digit can be selected with the right arrow cursor. The value can be set with
up and down arrows.
2.4.8 Header of the Report
By pressing MENU the display will show:
Line 1:
The text is a factory default. Each line contains three parts. The bottom line contains one
third of the text which is going to be printed. The text can be changed with the cursor keys
or from PC by using the SW program enclosed. The exclamation mark at the first position
on the line prevents the printing of the text. The letter being set is flashing. The cursor can
be moved to the right only. After the first part of the first line is displayed, the entry of the
second part of the first text line and then the third part of the first line can be performed.
After the third part of the line is entered, the cursor will return to the first position of the line.
The following three lines will be set similarly. By pressing MENU the next line will be
enabled for entry.
Line 2:
Line 3:
Time hh:mm:ss
Date dd.mm.yyyy
Text line 1
Decelerometer OC
Text line 2
Orbit Controls
Text line 3
Switzerland
Write to EEprom

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Line 4:
2.4.9 Filter
By pressing MENU the display shows:
The filter degree can be set within the range 0 to 10 with up or down arrows. The higher
the constant the smoother the graphics but the accuracy decays.
2.4.10 Automatic Shut-Off
By pressing the key ON the instrument will energise. It switches automatically OFF when
no further key is pressed. By regular operation the instrument switches-off after 10
minutes.
2.4.11 Basic Menu Settings
The factory default settings are suitable for most general applications.
Recording interval 5 s
Initialising the measurement with the deceleration threshold
Threshold value 20 %
Display contrast higher
Backlight YES
Time and Date set in the factory
Header of the report set in the factory
Filter degree 1
After the setting the Decelerometer can be placed into the vehicle, switched-on and
levelled into the horizontal position. The vehicle can be moved to the required speed, the
key MEAS pressed. The vehicle can start to decelerate. When the vehicle stops due to the
function of its own braking system, the report of the measurements will be printed. The
recording time is 5 sec. The measurements will start at the beginning of the braking action.
Text line 4
orbitcontrols.ch
Filter degree
Value: 1