RDS Technology Weighlog 2 User manual

Electro-Magnetic Compatibility (EMC)
This product complies with Council Directive
89/336/EEC when installed and used in accordance
with the relevant instructions.
Service and Technical Support
PLEASE CONTACT YOUR LOCAL DISTRIBUTOR
If unknown then fax: [phone]
© Copyright RDS Technology Ltd 2001
Our policy is one of continuous improvement and
the information in this document is subject to
change without notice. Check that the software
reference matches that displayed by the instrument.
Document number
S/DC/500-10-083 : Issue 4 : 12/7/01
\UK083-4.DTP
User Guide
Weighlog 2
Calibration and Operation
Software Ref: UDJ600-5
Weighing System
1

1. Overview 3____________________________________
2. Maintaining Accuracy 5______________________________
2.1 Machine requirements 5__________________________
2.2 Lifting Procedure) 5_____________________________
3. Preliminary Checks 6________________________________
3.1 Select Channel 6_______________________________
3.2 Check / Change Weighing Mode 6__________________
3.3 Check Zero Weight (Check Tare) 7__________________
3.4 Zero Weight (Tare) 8____________________________
4. Weighing 9_____________________________________
4.1 Dynamic Weighing 9____________________________
4.2 Static Weighing 9_______________________________
5. Reset Totals 10___________________________________
5.1 Reset Sub-total 10_______________________________
5.2 Reset Grand Total 10_____________________________
6. Calibration 11____________________________________
6.1 Weight Calibration 11_____________________________
6.1.1 Display / Change Calibration Factor - 11
6.2 Calibration Procedure 12__________________________
6.2.1 Calibration Example - 13
6.3 Select Units 14_________________________________
7. Faults 15________________________________________
Contents
2

The Weighlog 2 is intended for use on skid-steer loaders, utility tractors with a
loader attachment, wheel loaders, backhoe loaders (loader side only) and gas
powered fork lifts.
It measures, displays and records the net weight lifted, normally based on
sensing the lift system hydraulic pressure. Pressures sensing is problematic
on certain types of equipment due to the design of the hydraulic system. In
these instances strain sensing technology may be used instead.
There are 5 individual display channels available. These can be calibrated for
up to 5 different loader attachments, different trailers or different commodities.
Each channel will display the net bucket weight lifted at any time. If required
the bucket weight can be added to the total for the channel in use and will
also be added to the TOTAL channel, which accumulates weight from all of
the five channels.
The instrument has an illuminated 4 digit LCD display, 3 front panel switches,
an external pushbutton, and an internal audible alarm. An external audible
alarm is optional.
The instrument is normally powered on via the ignition circuit and recalls the
function selected when last used.
With careful operation, system accuracy can be as good as ±1% of full load
although ±2% is more common in practice.
Weighlog readings are not suitable as a legal basis for the sale of goods.
For each channel you can :
& adjust the Calibration Factor
& select either static or dynamic weighing mode.
& set the Zero Weight (Tare).
& display and add the bucket weight to the sub-total.
& reset the Sub-total.
& receive audible alarm confirmation of the tare and loading routines.
Overview
3

The front panel has 3 buttons. The lower two are used most often, while the
third button is behind the logo. This button is used to enter the
program mode.
Display Units
The instrument can display up to 9999 tons. If you prefer to work in lbs units,
this option is selectable from the program mode.
When set to the "USA" readout option, the display will read up to 9990 lbs
rounded to the nearest 10 lbs. Above this threshold (e.g. when displaying any
of the totals) the display will alternate between "lbs x1000" and any
remainder. The instrument can display up to 99,990 lbs
For example, for a total of 22,563 lbs the display will alternate between :
Overview
Enter Program
Mode
Set empty bucket
weight to zero
Fig.1
Fig. 2
Select Sub-total
channels 1-5
or
Grand Total
(Ch. 6)
Channel
Indicator
4

The Weighlog translates pressure (or strain) to weight by means of a
calibration factor programmed into the instrument. The accuracy of the
system depends to some extent on the following :
2.1 Machine requirements
1. Operating Temperature :Always allow the machine and the hydraulics to
warm up to the normal operating temperature before commencing weighing.
2. Weighing on level ground :Avoid weighing when on a slope or a side
slope. Wherever possible weigh on a level area.
3. Vehicle movement :Best results are obtained when weighing while the
vehicle is stationary. It is important that the load does not bounce or jerk as it
is lifted.
4. Maintenance : Keep your machine maintained in good condition. Things like
excessively worn bushings, pivot pins and slideways, as well as lack of
lubrication to these areas can have an adverse effect on weighing accuracy.
NOTE: After any major servicing particularly if you have replaced worn components or
carried out welding repairs, you should re-calibrate the weighing system. If the
hydraulic system has been drained and re-filled you should also check for any
air which may have become trapped at the pressure sensor.
2.2 Lifting procedure
The correct lifting procedure is especially important for dynamic weighing.
The load should be lifted smoothly and consistently through the weighing
position. The engine speed should be the same for every weighing. The
engine tachometer if fitted, is useful here.
The best procedure is as follows :
1. Having picked up the load, crowd (roll) the bucket right back as far as it will
go.
2. Pull the lift lever right back with the engine at idle.
3. Increase engine revs to the "weighing speed" and lift smoothly without
bouncing or jerking. Ensure that you lift at the weighing speed as you pass
through the reference position (dynamic weighing).
2 - Maintaining Accuracy
5

3 - Preliminary Checks
3.1 Select channel
Ensure that the correct channel is
selected for the attachment / commod-
ity / trailer to be weighed.
Simply press the button to cycle
through the channels.
3.2 Check / change weighing
mode
1. With the appropriate channel selected,
press the button. The display will
show "dYn" for dynamic weighing
mode or "StAt" for static weighing
mode.
To change the mode:
2. Press and hold the button...
3 ...then press the button to switch
between the weighing modes.
1
23
Fig. 3
Fig. 4
Fig. 5
6

3 - Preliminary Checks
3.3 Check Zero Weight (Check
Tare)
You should check the zero weight
regularly as part of the daily operating
routine. ALWAYS check zero weight if
the machine has been left idle for
some time and has cooled down.
The lifting procedure is different for
Dynamic and Static weighing modes.
Note the weighing mode set on the
channel you have selected and follow
the appropriate procedure below.
1. Ensure that the bucket is completely
empty. Crowd (roll) the bucket right
back as far as it will go.
2.a Dynamic weighing mode :Lift the
bucket through the reference position.
A single beep will be heard. The
display will show a value.
2.b Static weighing mode :Lift the bucket
up to the reference position and stop.
A single beep will be heard. If you lift
too high a second beep is heard and
the display will show 4 dashes (fig. 6).
If so, lower the bucket back down to
the reference position.
3. If the display reads within ±0.02 (20
kgs) or in "USA" units ±40 (40 lbs)
(fig. 7), this is within the repeatability
of the Weighlog system and can be
accepted without zeroing the weight.
Simply continue loading as normal.
4. If the display reads more than ±0.02
(20 kgs) or in "USA" units ±40 (40 lbs)
(fig. 8), then you should zero the
weight (see 3.4).
OK
Not OK
Static mode - Load too high
Fig. 8
Fig. 7
Fig. 6
7

3 - Preliminary Checks
3.4 Zero Weight (Set Tare)
The weight should be zeroed if the
weight reading for an empty bucket is
more than ±0.02 (20 kgs) or in "USA"
units ±40 (40 lbs).
Ensure that the hydraulic system is up
to it's normal operating temperature. It
may be necessary to lift and lower a
full bucket for a few minutes to
exercise the hydraulics and warm the
system up. Observe the correct lifting
routine (section 2.2).
1. Ensure that the bucket is completely
empty. Crowd (roll) the bucket right
back as far as it will go.
2. Press and hold the TARE button (fig
9). The audible alarm will beep five
times and the display will flash 0.00.
3.a Dynamic weighing mode :Lift the
bucket through the reference position.
A single beep will be heard. The
display will show a value.
3.b Static weighing mode :Lift the bucket
up to the reference position and stop.
A single beep will be heard. If you lift
too high a second beep is heard and
the display will show 4 dashes (fig. 6).
If so, lower the bucket back down to
the reference position.
4. As the weight is registered, the display
will continue to flash but may change
to show a number (fig. 10). Press the
REMOTE ENTER BUTTON to zero the
weight (fig. 11). The alarm will sound
one beep to confirm the weight is
zeroed.
5. Repeat the routine several times to
confirm the system is correctly zeroed.
Fig. 9
Fig. 10
Fig. 11
8

There are two fundamentally different ways of weighing with the Weighlog -
Dynamic weighing and Static weighing. You can select the weighing method
for each of the five channels on the instrument.
4.1 Dynamic weighing
Dynamic weighing means that the weight is measured without interrupting the
lift. The load is lifted straight through the reference position. Dynamic
weighing can give consistent results without significantly slowing down the
loading cycle, but it does rely on a certain degree of care on the part of the
operator (section 2.2).
1. Lift the load through the reference position. The alarm will sound one beep.
The display will then show the net weight in the bucket.
The weight will remain displayed until you lower the bucket below the
reference position.
2. With the bucket in the raised position, press the Remote Enter Button to add
the weight to the sub-total for the selected channel (and to the TOTAL
channel).
4.2 Static weighing
Static weighing requires the load to be lifted or lowered to the reference
position and held there. The display will show a "live reading" which will
fluctuate as the machine settles. You can tip off excess material as required,
therefore static weighing is ideal for the last bucket load if you are aiming to
reach a target load.
1. Lift the load up to the weighing position. The alarm will sound one beep and
the "live" weight will be displayed. If you go too high the display will show 4
bars (fig. 6).
2. It is a peculiarity of hydraulic systems that the pressure (and therefore the
load reading) will diminish for some time after the load is stopped at the
reference position, therefore you should allow a short while for the weight
reading to settle down.
3. Press the Remote Enter Button to add the weight to the sub-total for the
selected channel (and to the TOTAL channel).
4 - Weighing
9

5 - Reset Totals
5.1 Reset Sub Totals
Channels 1 to 5 can be reset
independently.
1. Select the appropriate channel 1 - 5.
2. Press and hold the Remote Enter
button for 5 seconds. The display will
flash 5 times and then go to zero.
The TOTAL channel is not affected.
5.2 Reset Grand Total
1. Select the TOTAL channel.
2. Press and hold the TARE button for 5
seconds (fig. 12). The display will
begin to flash.
3. Continue holding the TARE button
while you press the button (fig.
13).
The alarm will beep and the display
will go to zero.
Fig. 12
Fig. 13
10

6.1 Weight Calibration
Accurate results from the Weighlog can only be achieved if the calibration
procedure has been carried out carefully and in the correct sequence.
You must set the zero weight of the empty bucket/forks/trailer and a weight
calibration factor, for each channel to be used.
The calibration factor is an arbitrary number relating the hydraulic pressure
(or strain measurement) in the lift system to the load in the bucket. This factor
must be set independently for each vehicle, attachment or trailer and each
channel of the Weighlog.
6.1.1 Display/Change Calibration Factor
6 - Calibration
1. Select the appropriate channel.
2. Press and hold the button. The
display will show "dYn" or "StAt" for 3
seconds, before changing to show the
calibration factor for that channel (fig.
14). The default factor is 1.00
The left hand digit will be flashing.
To change the factor :
3 While holding the button, PRESS
and RELEASE the button to
advance to the digit you want to
change.
01.00, 01.00, 01.00, 01.00
4. HOLD the button to cycle the
digit from 0 to 9 (fig.15).
01.10, 01.20, 01.30, 01.40
5. Release the button and the next
digit will flash.
6. Repeat step 4 for other digits (or if you
need to correct a mistake).
Fig. 14
Fig. 15
11

6.2 Calibration procedure
1. Decide which attachment/commodity applies to which channel. Make a note
of this on the chart provided at the back of this manual.
2. Decide whether static weighing or dynamic weighing is appropriate.
Select the appropriate channel and then select the weighing mode - "StAt" or
"dYn"(section 3.2).
3. Start by setting the calibration factor to the maximum lift capacity of the
machine (e.g. if the lift capacity is 1.5 tons, then set the factor to 1.500).
4. Set the zero weight (section 3.4).
5. Fill the bucket with a typical load, the weight of which is known or can be
determined on a weighbridge or portable weigh scales.
NOTE: If you are loading bags of known weight, ensure that they are evenly
distributed in the bucket (or on the pallet).
6. Lift the bucket load a number of times and note the weight displayed each
time. Observe the procedures for accurate weighing (section 2.2). The
displayed weight should not vary by more than ±0.02 (20 kgs) or if in "USA"
display mode ±40 (lbs).
7. If not already known, determine the true weight of the bucket load on the
weigh scales
8. The actual calibration factor can now be determined by a simple calculation
using the true weight and the displayed weight as follows :
Correct factor = existing factor xtrue weight
Weighlog reading
9. Program the correct factor into the Weighlog (section 6.1.1).
10. Lift the load again several times, checking that the Weighlog reading is
correct.
6 - Calibration
12

6.2.1 Calibration example
Calibrating a front end loader with a bucket capacity of 1.5 tonnes.
1. Set the calibration factor initially to 1.500.
2. A bucket load is weighed and the Weighlog reading is 1.15 tonnes. The same
load is weighed on the weigh scales and the true weight is 0.850 tonnes.
3. Using the correction calculation :
Correct factor = existing factor xtrue weight
Weighlog reading
= 1.50 x0.850
1.15
= 1.1087
4. Re-program with a factor of 1.109
So, if the Weighlog reading is more than the true weight, the factor is
decreased and vice versa, if the Weighlog reading is less than the true
weight, the factor is increased.
Therefore, if you find a consistent discrepancy between the Weighlog
readings and the weighbridge readings, intuitively, you can then nudge the
cal factor up or down as required
E.g. If the Weighlog reading is 10% high, then reduce the cal. factor by 10%.
6 - Calibration
13

6 - Calibration
6.3 Select Units
The display resolution can be set to
suit "lbs" readout or "tons" readout.
1. Select the TOTAL channel.
2. Hold the button. The display will
show either "Eur" for tons or "USA" for
lbs (fig. 16).
3. Continue holding the button and
press the button to change the
setting (fig.17).
Fig. 16
Fig. 17
14

Error message: "Prog"
The instrument memory has been corrupted. You can attempt a "Power On
Reset".
1. Switch the power supply off.
2. Press and hold all three buttons and switch the power on. If the instrument
can recover itself, it will perform a short self test routine and return to the
normal display. If not, then contact your local RDS distributor.
NOTE: All calibration settings, sub-totals and the grand total will be reset to the
factory default values.
Error message: "Err"
If the display shows "Err" then there is no pressure signal being received,
indicating either a poor connection in the sensor wiring or a faulty sensor.
Visually inspect the wiring loom and connections first, then if necessary check
continuity of the sensor lead wires between the "Harting" connector terminals
labelled LOAD SENSOR and the Weatherpak connector on the other end of
the load sensor lead. If the wiring is OK then contact your local RDS
distributor.
Changing loading attachments
If after changing the loading attachment and zeroing the weight, you find that
the weight readings are no longer correct, it is usually because the centre of
gravity of the machine has been slightly altered by the different attachment.
This will affect the load-pressure relationship and therefore the calibration
factor must be adjusted to suit. Perform the weight calibration routine to
establish the correct factor (section 6.2).
7 - Faults
15

Channel Attachment/Trailer/Commodity Weighing Mode Cal. Factor
1
2
3
4
5
8 - Notes
16

Issue 4: 12/7/01 Re-formatted :- ref. UK263-1.DTP
17

Your local distributor is :
18