Ravas SafeLoad User manual
INSTALLATION MANUAL – RAVAS-SafeLoad
1
INSTALLATION MANUAL
RAVAS-SafeLoad
Rev.20211209
Printing/typographical errors and model changes reserved
INSTALLATION MANUAL – RAVAS-SafeLoad
2
PLEASE RETAIN THESE ASSEMBLY INSTRUCTIONS FOR FUTURE REFERENCE
If you have any queries concerning the duration and terms of the guarantee, please contact your
supplier. We would also refer you to our General Sale and Supply Conditions, which are available on
request.
The manufacturer accepts no liability for any damage or injury caused by failure to follow these
instructions, or from negligent operation or assembly, even if this is not expressly stated in this
instruction manual.
In light of our policy of continuous improvement, it is possible that details of the product may differ
from those described in this manual. For this reason, these instructions should only be treated as
guidelines for the installation of the relevant product. This manual has been compiled with all due care,
but the manufacturer cannot be held responsible for any errors or the consequences thereof. All rights
are reserved and no part of this manual may be reproduced in any way.
INSTALLATION MANUAL – RAVAS-SafeLoad
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1.
Introduction ...........................................................................................................5
2.
Warnings & safety measures ...............................................................................5
3.
Overview of the parts ............................................................................................6
4.
Before the installation ..........................................................................................7
4.1.
Capacity of the forklift truck ................................................................................7
4.2.
Maximum pressure in the hydraulic system .......................................................7
4.3.
Battery voltage of the forklift truck ......................................................................7
4.4.
Making the hydraulic system pressure free ........................................................7
4.5.
The condition of mechanical components of the forklift truck .............................8
5.
Installation .............................................................................................................9
5.1.
Hydraulics: installing the T-piece........................................................................9
5.2.
Hydraulics: mounting the oil pressure sensor...................................................12
5.3.
Mechanics: installing the moment force sensors..............................................13
5.4.
Mechanics: Installing the height switch ............................................................14
5.5.
Mechanics: installing the indicator....................................................................15
5.6.
Electronics: mounting the cables......................................................................16
5.7.
Electronics: wiring drawing indicator ................................................................17
5.8.
Electronics: relay option connections ...............................................................18
5.9.
Electronics connecting the power supply cable ................................................19
5.10.
Remove any air from the hydraulic system.......................................................20
6.
Calibration ...........................................................................................................21
6.1.
Preparing for calibration ...................................................................................21
6.2.
Bring the forklift truck to operating temperature................................................22
6.3.
Operating key functions of indicator .................................................................22
6.4.
Calibration procedure .......................................................................................24
7.
Parameter settings..............................................................................................28
7.1.
Parameter setting mode ...................................................................................28
7.2.
Weight parameters ...........................................................................................28
7.3.
Moment parameters .........................................................................................30
7.4.LED bar, logging and backlight parameters......................................................31
7.5Checking the parameters audit trail number for registration (recommended) ..33
INSTALLATION MANUAL – RAVAS-SafeLoad
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8.
Error messages ...................................................................................................34
8.1Error messages ................................................................................................34
8.2Checking the logged errors ..............................................................................36
8.3
Debug mode (for troubleshooting)....................................................................36
9.
User MENU...........................................................................................................37
9.1
Setting the date and time..................................................................................37
9.2
Setting the backlight .........................................................................................37
9.3
Reading the Bluetooth address ........................................................................38
9.4
Passcode..........................................................................................................38
INSTALLATION MANUAL – RAVAS-SafeLoad
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1.
Introduction
This manual describes the assembly of the RAVAS-SafeLoad. The installer must be informed of the
contents of this manual. This manual should be kept in a dry and safe place.
In case of damage or loss the user may request a new copy of the manual from RAVAS.
This manual is based on firmware version 0.31 and higher.
2.
Warnings & safety measures
When installing the RAVAS-SafeLoad, please observe carefully the instructions
and guidelines contained in this manual. Always perform each step in
sequence. If any of the instructions are not clear, please contact RAVAS.
The installation of the RAVAS-SafeLoad should only be performed by an
acknowledged electro and hydraulic technical installer. Possible failures to
the equipment must be communicated to your installer. The equipment should
be checked annually by your installer.
Always follow the safety measures concerning the forklift - or stacker truck
accurately.
The RAVAS-SafeLoad is an advisory system for forklift truck drivers. RAVAS-
SafeLoad does not intervene with the forklift truck’s system hardware,
therefore it remains the sole responsibility of the driver to react to the
warnings as issued by the RAVAS-SafeLoad
Should you have any further questions after reading this manual please contact us at:
RAVAS Europe B.V.
Veilingweg 17 Phone: +31 (0)418-515220
5301 KM Zaltbommel Internet: www.ravas.com
Changes reserved.
READ
CAREFULLY
ATTENTION
INSTALLATION MANUAL – RAVAS-SafeLoad
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3.
Overview of the parts
The RAVAS-SafeLoad system exists of four main parts:
1. Indicator
2. Oil pressure sensor
3. Moment force sensors
4. Height switch
The pressure sensor has to be connected to a T-link on the hydraulic system of the forklift truck.
The indicator, the control panel, runs on 12 Volt DC (variances of 9VDCup to 18VDC are regulated
and filtered by an integrated regulator board) .
The power supply of the indicator can be connected to the battery of the forklift. The most common
voltages for fork-lift trucks are 12, 24, 48 and 80 V. In cases where the battery voltages are higher
then 12 VDC, the system demands a DC-DC voltage converter with an output of 12 Vdc. Only by
RAVAS approved convertors may be used. If other convertors are used the warranty of the indicator is
no longer valid.
See MyRAVAS.com for the parts list.
parts list see www.ravas.com
INSTALLATION MANUAL – RAVAS-SafeLoad 7
4.
Before the installation
Before you start with the installation, check the forklift truck on the following points:
4.1.
Capacity of the forklift truck
The RAVAS-SafeLoad can be installed on forklift trucks with a capacity of maximum 99 ton.
The load diagram can be followed for setting the different maximum capacities per height and load
position in parameter 005 of the weight parameter settings. (see page 27)
4.2.
Maximum pressure in the hydraulic system
The RAVAS-SafeLoad will operate optimally at an oil pressure up to 350 bar.
4.3.
Battery voltage of the forklift truck
The most common voltages for forklift trucks are 12, 24, 48 and 80 VDC. The RAVAS-SafeLoad
operates on 12 Vdc and can handle voltage differences between 9VDC and 18VDC. In cases where
the battery voltage is greater than 12 Vdc, the system requires a DC-DC power converter with an
output voltage of 12 Vdc.
The article number of this part is: EB-CON-RAVAS-SAFELOAD.
If other convertors are used the warranty of the indicator is no longer valid!
4.4.
Making the hydraulic system pressure free
Before installation of the RAVAS-SafeLoad, the hydraulic system of the forklift truck must be pressure
free. There are two ways to do this:
Option 1: Place the forks on the ground in their lowest position and make the hydraulic system
pressure free, by tilting the mast forwards. Be sure the chain is slack!
Option 2: Lift the forks and position them on top of a supporting surface. Make the hydraulic
system pressure free, by lowering the lifting cylinder into its lowest position. Be sure
the chain is slack!
INSTALLATION MANUAL – RAVAS-SafeLoad 8
4.5.
The condition of mechanical components of the forklift truck
After installation of the RAVAS-SafeLoad system on the forklift truck, the truck is part of the system. In
particular the mechanical parts of the forklift truck, such as the mast, mast roles and bearings, will
influence the accuracy of the weightings. For this reason it is important that these components are in
good condition:
-no local wear in the mast of the forklift truck
-clean the system
-good lubrication of the mast and chains
-regular maintenance so that the condition of the system is constant
-no whistling and cracking sounds from the mast when lifting and lowering the forks
min -10°C
15°F
max 40°C
105°F
0 0
IP65
INSTALLATION MANUAL – RAVAS-SafeLoad
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5.
Installation
5.1.
Hydraulics: installing the T-piece
We recommend to have the installation of the sensor in the hydraulic system of the forklift
performed by an authorized lift truck dealer.
- Ensure that there is no pressure on the main cylinder line.
- The sensor is mounted with a T-piece in the high-pressure hose, between the valves and
the cylinder.
- The connection on the sensor is G¼” BSP male.
- Protect the cable against moving, sharp or warm parts with the supplied protective cover.
- Mount the T-piece so that the sensor and the cable connection are pointing downwards.
This will prevent air getting into the sensor.
Choose a place where you can mount the sensor:
- Mount the sensor in the pressure hose that steers the cylinder. In most cases there is one
cylinder which moves the carriage plate. The sensor is mounted as close to the cylinder
as possible.
- When the pressure hose splits to multiple cylinders, the sensor has to be mounted before
the split.
- Do not mount the sensor too close to the engine. Large differences in temperature can
influence the accuracy of the system.
- If the truck is used intensively, a piece of pipe or hose of ± 50 cm can be mounted
between the sensor and the T-piece. The sensor is sensitive to temperature differences.
If the moving oil becomes warm, the standing oil in this pipe or hose will remain cool.
The sensor will not be effected by temperature differences.
- Place the sensor close to the cylinder. There is often more room there and it is easier to
reach.
- Choose, if possible, a place to mount the sensor where there are the least steering and
safety valves between the sensor and the cylinder.
INSTALLATION MANUAL – RAVAS-SafeLoad 10
Type A: 1 central cylinder
1. 2.
S19
Mount the T-piece into
the delivery line of the
truck near the cylinder
for the diversion of the
pressure to the
SafeLoad.
INSTALLATION MANUAL – RAVAS-SafeLoad 11
Type B: 2 cylinders on both sides
Mount the T-piece into
the delivery line of the
truck near the cylinder
for the diversion of the
pressure to the
SafeLoad
1. 2.
S19
INSTALLATION MANUAL – RAVAS-SafeLoad 12
5.2.
Hydraulics: mounting the oil pressure sensor
2.
S19
The connector on the
sensor is G 1/4 "BSP
male.
1.
INSTALLATION MANUAL – RAVAS-SafeLoad 13
5.3.
Mechanics: installing the moment force sensors
The moment force sensors should be placed in line with the tilting cilinder of the forklift truck.
This can be either inside or outside the truck, wherever it will fit best, just as long as they are
in line with the tilting cilinders. See examples of mounting positions underneath.
The moment force sensors consist of parts:
2 moment force sensors with 2 meters cable length, to be installed in the line of the tilting cylinders
for the mast (fixed part)
2 protection caps, to be installed over the force sensors
1 junction box, to be installed at a suitable place in the truck.
For mounting the force sensors you may drill holes or use stud welds.
INSTALLATION MANUAL – RAVAS-SafeLoad 14
5.4.
Mechanics: Installing the height switch
The height switch should be placed at the mast of the forklift truck in a position where it
detects the start of lifting the last (second or third) part of the mast, so at the change over
point. Most likely this would be at position 1. (See sketch above) or position 2 could also be a
possibility for mounting the sensor. The sensor is delivered with 2 mounting brackets for easy
mounting.
Height switch is activated in lowest
position of the mast
Height switch is deactivated as soon as the second or
third mast stage is reached
For mounting the height switch brackets we recommend using Loctite adhesive materials:
Adhesive 326
Activator 7649
INSTALLATION MANUAL – RAVAS-SafeLoad 15
5.5.
Mechanics: installing the indicator
Position of the indicator
Installing the indicator
The indicator should be easy
to reach and read out!
INSTALLATION MANUAL – RAVAS-SafeLoad 16
5.6.
Electronics: mounting the cables
Four cables should be mounted:
- cable for the oil pressure sensor
- cable for the moment sensors (2 cables connected to the moment sensors are going to
the junction box, 1 cable leaving the junction box should be connected to the indicator)
- cable for the power supply
- cable for the height switch
When mounting the cables, it is important that the cable is kept tidy and protected. Keep the cable out
of sight as much as possible, this makes that the whole looks tidy and it minimizes the possibility of
damage to the cable.
It may be necessary to thread the cable through small openings, openings through which the 18mm
connector does not fit. In that case it may be necessary to dismount the cable and the connector, you
have to dismount the cable at the indicator.
The system is supplied with a protective cover for the cable. This can be used where:
the cable is near parts of the lift truck that become hot;
the cable is mounted near moving parts.
INSTALLATION MANUAL – RAVAS-SafeLoad 17
5.7.
Electronics: wiring drawing indicator
INSTALLATION MANUAL – RAVAS-SafeLoad 18
5.8.
Electronics: relay option connections
INSTALLATION MANUAL – RAVAS-SafeLoad 19
5.9.
Electronics connecting the power supply cable
3.15A fuse in
the 12 V wire
Arrange power supply from the truck
The RAVAS-SafeLoad indicator is standardly suited for 12 VDC power supplied trucks, so it can be
connected to a 12VDC power supply only. (variance 9 to 18VDC)
For trucks which have a ‘dirty’ power supply a filter is recommended. The RAVAS-SafeLoad comes
standard with an internal 12V regulator board. (art.no. EB-REG-12V12V-120MA).
Other power supply voltages from truck are available as an option. In that case the RAVAS-SafeLoad
indicator will be equipped with an internal power convertor EB-CON-RAVAS-SAFELOAD. This power
convertor board can be used for truck with power supplies from 24VDC up to 80VDC.
If other convertors are used the warranty of the indicator is no longer valid!
INSTALLATION MANUAL – RAVAS-SafeLoad 20
5.10.
Remove any air from the hydraulic system
Bring the forks to maximum
height twice to remove any
remaining air from the
hydraulic system.
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