RDS Loadmaster 800i?Loadmaster 8000i User manual

Loadmaster 800i/8000i
On-
Board Weighing System
Calibration
RDS Part No.:
Document Issue:
Software Issue:
S/DC/500-10-57
1.31: 20/10/08
PS312-002 rev. 03 (LM8000i)
PS313-002 rev. 03 (LM800i)

2
Electromagnetic Compatibility (EMC)
This product complies with Council 2004/108/EC when
installed and used in accordance with the relevant
instructions.
Service and Technical Support
PLEASE CONTACT YOUR NEAREST DISTRIBUTOR
If
unknown then fax [phone] for further
information.
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.
© Copyright RDS Technology LTD 2008
\UK57 131.DOC

1 – CALIBRATION SUMMARY
1CALIB ATION SUMMA Y ______________________________________________ 4
2LOADMASTE 800I/8000I - COMMON CALIB ATION_____________________ 5
2.1 Sensor Setup _________________________________________________________________________ 5
2.1.1 General setup for loading shovels ....................................................................................................
2.2 Auto al ______________________________________________________________________________ 7
2.2.1 Dyn. Diff. Setup ................................................................................................................................. 7
2.2.2 Static Speed Compensation (‘Static Empty Lift’) .............................................................................. 7
2.2.3 Dynamic Speed Compensation (‘Dyn. Speed Comp’) ..................................................................... 7
Fast Speed calibration (Use Loaded Bucket) ................................................................................... 7
Slow Speed calibration ..................................................................................................................... 8
2.2.4 Static Speed Compensation (‘Static Full Lift’)................................................................................... 8
2.2.5 Static Compensation (‘Static Comp’)................................................................................................ 8
2.2. Zero................................................................................................................................................... 9
2.2.7 Cal Weight (Weight Calibration)........................................................................................................ 9
Dynamic Calibration Routine ............................................................................................................ 9
Static Calibration Routine.................................................................................................................. 9
2.2.8 Angle Calibration (optional) .............................................................................................................. 10
Zero................................................................................................................................................... 10
2.3 alibration Factors ___________________________________________________________________ 11
2.3.1 Displaying Static/Dynamic Factors ................................................................................................... 11
2.3.2 Dynamic Speed Compensation Factors (Dyn. Comp. Factors)........................................................ 11
2.3.3 Static Speed Compensation Factors (Stat. Comp. Factors)............................................................. 12
2.3.4 Surge Setup (optional)...................................................................................................................... 13
2.3.5 Angle Factors (Optional Angle Sensor) ............................................................................................ 13
2.4 'NUDGE' alibration __________________________________________________________________ 14
When to nudge the calibration.......................................................................................................... 14
How to nudge the calibration............................................................................................................ 14
2.5 alibrating alternative attachments ____________________________________________________ 15
2.5.1 Programming an attachment ............................................................................................................ 15
2.5.2 Select an attachment for calibration ................................................................................................. 15
2.5.3 Calibrating an alternative attachment ............................................................................................... 15
3GENE AL SYSTEM SETTINGS __________________________________________ 16
3.1 Output Port Setup ____________________________________________________________________ 16
3.1.1 Set Output Mode............................................................................................................................... 1
ASCII Text Output for Printers ........................................................................................................... 1
Comma-delimited Output.................................................................................................................. 17
Input/Output to the RDS Data Card Module ..................................................................................... 17
Input/Output via Radio Modem......................................................................................................... 17
Input/Output via GSM Modem .......................................................................................................... 17
3.2 Weighing Units_______________________________________________________________________ 17
Units.................................................................................................................................................. 17
Resolution ......................................................................................................................................... 17
Maximum Weight .............................................................................................................................. 17
Overload Log .................................................................................................................................... 17
3.3 Bleep Setup _________________________________________________________________________ 18
3.4 hange PIN Numbers_________________________________________________________________ 18
3.5 Reset Factors ________________________________________________________________________ 18
3.6 Store / Restore / Print al Data ________________________________________________________ 19
3.7 Telemetry Option - Enable/Disable_____________________________________________________ 19
3.8 ‘Module’ _____________________________________________________________________________ 19
4. THE SETUP MENU_____________________________________________________ 20

1 – CALIBRATION SUMMARY
4
1 Calibration Summary
The LM 800i/8000i system operates in a Non-Approved weighing mode. Dynamic or Static weighing is
possible. The system is designed to be easily upgradable for Weights and Measures approved operation,
either for automatic weighing (AWI) or non-automatic weighing (NAWI).
There are a large number of functions within the calibration menu in order to optimise the performance of the
weighing system for a particular loading shovel and the method in which it is to be used. Many settings need
only be made on the initial installation.
The calibration procedure is summarised below. For full information on any of the settings in the calibration
menu (ref. Section 4).
Step 1 Work the machine until it is up to the normal operating temperature.
Step 2 Go to the "Sensor Setup" menu (ref. section 2.1)
(i) Set " am atio" The default value of 1.3000 is OK initially, for almost all makes and models of machine.
Known figures are given below.
Machine Ram Ratio
VOLVO L120, L150 1.34
ALL KOMATSU 1.30
ALL CASE 1.30
ALL CAT MODELS 1.25
For other machines, you can determine the correct ram ratio by the following method: - Do a slow lift and then
a fast lift. If the weight readings are the same, the Ram Ratio is correct. If the fast lift reading is greater then
reduce the ram ratio, and vice versa.
(ii) Set "Dual Sensor" to "DIFF".
(iii) The default settings for "Live Static" (AUTO), and "Mode" (DYN/STAT) enable both dynamic and static weighing
modes, and a live readout for the "last bucket" weighing mode. If you require static weighing mode only or
dynamic weighing mode only, you must change these settings accordingly.
NOTE: Some CASE and Liebherr machines shou d be operated on y in Static weighing mode.
Step 3 Go to the "Auto al" menu (ref. section 2.2)
Follow the screen prompts for the calibration routine ("Dyn. Diff Setup", “Static Empty Lift”, "Dyn. Speed
Comp.", “Static Full Lift”, "Static Comp.", "Zero" and then "Cal Weight"), to establish accurate weighing. To
perform the weight calibration ("Cal Weight"), load the bucket (preferably to its full capacity) with a known
weight of material.
NOTE: If you don't know the exact weight, you can make an estimate and then use the "NUDGE" faci ity afterwards to
correct the ca ibration factors.
The calibration figures resulting from the AUTOCAL procedure will apply to loading attachments 'A' to 'H'. To
ensure accurate results when using a different attachment, adjust the calibration using the NUDGE facility.
Step 4 heck the weight reading (ref. section 2.4)
Zero the system and load a truck. Note the weighbridge (weigh scale) reading against the instrument reading.
If they are different, use the NUDGE facility to enter the two readings. The calibration factors are adjusted
automatically.
Step 5 Operator Instruction.
Please discuss the loading sequence and loading routine with the operator(s) of the loading shovel. Ride with
the operator and explain the weighing methods, auto kick-out, auto / manual entry, and the importance of
smooth operation while weighing.

2 - LM800/ 8000 COMMON CALIBRATION
5
2 Loadmaster 800i/8000i - Common Calibration
2.1 Sensor Setup
Sensor setup should be done before any other calibration. The sensor settings apply regardless of which
attachment is selected.
Select the 'Sensor Setup' screen (figure. 2).
*Default Factory PIN = 4084
"No. of samples" is the number of times the instrument takes a signal
from the pressure sensor(s).
"Sample Time" is the time taken for each sample in seconds.
"Auto Static" is the time delay after reaching the weighing position
before the instrument samples the weight. This delay allows the system
to settle down and helps to give consistent readings.
"Live Static" -The 'Off' setting has the effect of 'freezing' the weight reading when weighing in Static weighing
mode. The 'On' setting allows a 'live' readout when the bucket is in the weighing position. This is not suitable for
'weighing on the move' operation. See '2.3.2 Static Compensation' for the best setup for 'live static' weighing.
“Static Speed” - Enables speed compensation for static weighing. This setting needs to be switched ‘On’ for
certain machines, and in particular, CAT 9 , 972 and 980 models. The majority of other loaders will not
require ‘Static Speed Compensation’
"Dual Sensor:" "Off" Single load sensor installation
"Dual" (Not used)
"Diff" Dual pressure sensor installations (Static or Dynamic operation). The second sensor measures back-
pressure on the return side of the lift ram circuit.
"Sum" Strain sensor applications. Sensor readings are added.
"Avg" Strain sensor applications. Sensor readings are averaged.
The 'Dual Sensor' setting should always be set to 'Diff'. This enables the system to zero at any lift speed..
"Ram Ratio" is the ratio of the area A1/A2 of each side of the ram piston (figure 3). The default value of 1.3000
is OK initially, for almost all makes and models of machine. You can determine the correct ram ratio by the
following method. Do a slow lift and then a fast lift. If the weight readings are the same, the Ram Ratio is
correct. If the fast lift reading is greater then reduce the ram ratio, and vice versa.
Figure 3
"Nudge Key" - The option to switch off the NUDGE facility so that it no longer appears on the 'SETUP' screen.
"Zero heck" - Enables the "ZERO CHECK” function. (Default 'OFF' for LM800/8000).
"Mode" - This selects which weighing mode should be used. On LM 8000 models, "Dyn/Stat" is the default.
"Dyn" only or "Stat" only can be selected.
"Angle Sensor" Optiona .
Enables the angle sensor input and selects the vertical axis orientation of the sensor. Select the icon matching
the orientation of the electrical junction box (looking forwards from the cab).
1. Calibration (Enter PIN*)
8. Sensor Setup
Figure 2

2 - LM800/ 8000 COMMON CALIBRATION
“Sample type” : “STD” sets the system to sample a dynamic weigh procedure in the standard format, as used
in the Loadmaster 8000 series with earlier S/W version PS300-02 rev.38
“ADV” sets the system to sample a dynamic weigh procedure in a new format. This mode should generally be
selected, as it should be consistently more accurate in use.
Where this option is selected it will be necessary to mount the Ref / Dir sensors about 200mm from the boom
pivot pin, centre,set.
2.1.1 General setup for loading shovels
Check that the initial settings are as given below. These are suitable for
almost all makes and model of machine whether operated in Dynamic
weighing mode or in Static weighing mode.
Setting Dynamic or Static mode
Num. Samples 1
Sample Time 1.2
Auto Static 2.0
Ram Ratio 1.3000
Live Static On
Static Speed Off (‘On’ for CAT 9 , 972 and 980)
Dual Sensor Diff
Nudge On
Zero Check Off
Mode Dyn/Stat
Angle Sensor Off
Sample type ‘ADV’ (in accordance with Ref. /Dir. Sensor installation)

2 - LM800/ 8000 COMMON CALIBRATION
7
2.2 Auto Cal
After "Sensor Setup", do an "Auto Cal".
The instrument will automatically advance from Auto Cal step 1 (Diff.
Setup) to step 5 (Cal Weight). You can however, still select from the
Auto Cal menu in any order.
2.2.1 Dyn. Diff. Setup
This function is active only when the "Dual Sensor" setting on the "Sensor
Setup" page is set to "Diff". Diff. Setup compensates for oil temperature
(LM 9000 only) and backpressure fluctuation in the hydraulics.
Follow the screen prompts.
Lift an EMPTY bucket at fast speed and press ENTER.
Lift an EMPTY bucket at slow speed and press ENTER.
The instrument then displays the message " alibration Done". Press the
'ESC' key to continue the Auto Cal. (‘Static Empty Lift’).
2.2.2 Static Speed Compensation (‘Static Empty Lift’)
NOTE: This function is enab ed on y when the "Static Speed" setting on the
"Sensor Setup" page is set to "On", otherwise this screen wi not appear.
Follow the screen prompts.
Lift an EMPTY bucket at fast speed to the static weigh point (kickout),
allow the system to weigh and then press ENTER.
Lift an EMPTY bucket at slow speed to the static weigh point (kickout),
allow the system to weigh and then press ENTER. The instrument then
displays the message " alibration Done".
2.2.3 Dynamic Speed Compensation (‘Dyn. Speed Comp’)
By defau t, dynamic speed compensation is switched off unti the Auto
Ca routine is performed.
Fast Speed calibration (Use Loaded Bucket)
Fill the bucket (you don't need to zero beforehand). With the menu
pointer opposite the symbol, lift the bucket at full speed. The
instrument will bleep once then display the frequency output of each
pressure sensor, and the lift speed in milliseconds.
Press ENTER to confirm. The menu pointer will then move opposite the
icon and display the prompt "Slow Lift" (fig. ).
1. Calibration (Enter PIN*)
1. Auto Cal
Figure 4
Figure 5a
Figure 6
Figure 5b

2 - LM800/ 8000 COMMON CALIBRATION
8
Slow Speed calibration
1. With the menu pointer opposite the symbol, lower the bucket then
slowly lift through the weighing position again. If you lift too quickly, the
display will flash 'Error'. If so, lower the bucket and try again. The
instrument will bleep once, then display the frequency output of each
pressure sensor, and the sample time in milliseconds (fig. 7).
2. Press ENTER to confirm.
3. The instrument then displays the message "Speed ompensation Set".
4. Press the 'ESC' key to continue AUTOCAL (Static Full Lift).
NOTE: The percent figures re ate to the 'Proportiona Sca ing' function. This
function predicts the difference in Speed Compensation required for ight
and heavy oads in the bucket. This compensates for hydrau ic
inefficiencies and the frictiona behaviour of the ift system.
2.2.4 Static Speed Compensation (‘Static Full Lift’)
On machines where a substantial difference in displayed weight is experienced with changes in engine speed /
speed of lift (for example G series Caterpillar loaders) this option can be turned to ON. Doing so will enable
the Static Speed Compensation items within the Autocal menu and will turn on the Speed Compensated Static
weighing function. This will allow the Loadmaster to apply a compensation value to the displayed weight
based on the speed of lift, and should result in far more stable displayed weights where changes in speed of
lift are experienced.
NOTE: This function is enab ed on y when the "Static Speed" setting on the "Sensor Setup" page is set to "On",
otherwise this screen wi not appear.
Follow the screen prompts.
Lift a FULL bucket at fast speed to the static weigh point (kickout), allow
the system to weigh and then press ENTER.
Lift a FULL bucket at slow speed to the static weigh point (kickout), allow
the system to weigh and then press ENTER. The instrument then
displays the message "Speed ompensation Set".
2.2.5 Static Compensation (‘Static Comp’)
By defau t, Static Compensation is switched off unti the Auto Ca routine
is performed.
Static compensation takes effect when the bucket is stationary at the
weighing position. It enables the live static reading to become more
stable over the sampling period and improves the accuracy of the weight
reading.
Calibration is fully automatic. At the screen prompt, lift a FULL bucket
SLOWLY to the weighing position. The screen then plots two graphs
each with 30 samples for load sensors A and B (something similar to fig.
8). The calibration routine runs for 45 seconds and then displays the
message 'Calibration Done'.
Press the 'ESC' key to continue AUTOCAL (Zero).
Figure 7
Figure 8
Figure7b

2 - LM800/ 8000 COMMON CALIBRATION
9
2.2.6 Zero
1. Lift the empty bucket at maximum speed. The instrument will bleep once when the weight is taken. ENTERING
to set "Dynamic Zero" is automatic.
2. Lift the bucket to the weighing position. The instrument will bleep twice. ENTERING to set "Static Zero" is
automatic.
3. Press the "ESC" key to continue AUTOCAL (Cal Weight).
NOTE: Sticky materia , bucket wear, or fau ty e ectronics can cause variation from zero.
Zero the system for each each different attachment used. Zero measurements are viewed on the “Dynamic
Factors” and “Static Factors” screens.
2.2.7 Cal Weight (Weight Calibration)
If both dynamic and static weighing (Dyn/Stat) mode is enabled, then
both a dynamic calibration routine and static, weight calibration routine
are performed. If either dynamic weighing only ("Dyn"), or static weighing
only ("Stat") mode is set, then the appropriate calibration routine will
apply.
1. Zero the empty bucket.
2. Load the bucket (preferably to its full capacity) with a known weight of
material.
NOTE: If you don't know the exact weight, you can make an estimate and then
use the "NUDGE" faci ity afterwards to correct the ca ibration factors.
3. Select the "Cal Weight" screen (fig. 9).
Dynamic Calibration outine
NOTE: If you want to do the static ca ibration first, press the key.
indicates that speed compensation is enab ed.
4. Lift the bucket at maximum speed through the weighing position. The
screen will display a weight reading and the message 'Enter New Load'
(fig. 10).
5. Key-in the known weight (or the estimated weight) and press ENTER.
The instrument now calculates the Dynamic Cal. factor based on the
weight entered. The screen will display the message " onfirmed".
Static Calibration outine
Normally, the "Static Calibration" routine follows automatically after the
Dynamic calibration routine (see note above). The message "Lift Full
Bucket To Reference Position" is displayed (fig. 11).
. Lift the full bucket to the weighing position. The display will give a weight
reading and the message "Enter New Load" (fig. 12).
7. Key-in the known weight (or the estimated weight) and press ENTER.
The instrument now calculates the Static Cal. factor based on the weight,
then displays the message " alibration Done".
8. Press the 'ESC' key to continue AUTOCAL (Angle Calibration).
NOTE: The Ang e Ca ibration routine and Temperature Ca ibration routine are
disab ed. Pressing the "ESC" key returns you to the AUTOCAL menu.
A ternative y, exit ca ibration mode by se ecting the MAIN screen.
Figure 9
Figure 10
Figure 11
Figure 12

2 - LM800/ 8000 COMMON CALIBRATION
10
2.2.8 Angle Calibration (optional)
NOTE: A factors in the "Ang e Factors" screen shou d be manua y set to zero
(except the A arm Thresho d Ang e which is 10° by defau t) before
carrying out the ang e ca ibration. This is especia y important if you have to
reca ibrate the ang e compensation, after the first attempt was incorrect.
Calibration consists of a Zero routine (you have the option to skip this
step) followed by five lift sequences. The live readings of both angles are
displayed in the box.
shows dynamic weighing mode is selected. Press and hold the
key to switch between static and dynamic weighing. Only Dynamic or
Static compensation should be carried out, not both. If mainly weighing
Dynamically, carry out this procedure dynamically, and vice versa.
Zero
1. Select "Set Angle Zero" using the down arrow key and press ENTER.
2. Park the loader on level ground. Press the ENTER key to zero both
offsets. The next screen is then displayed (fig.15).
The icons at the bottom of this and
subsequent screens indicate the required position and the present angle.
3. With the loader still on level ground, lift a
3
/
4
full bucket. A weight is
displayed. Press ENTER to confirm and move to the next screen.
NOTE: If either s ope ang e indicated inside the box is over 2 degrees, a warning
triang e f ashes on-screen, and the appropriate icon f ashes inside the
box.
4. Move the machine so that it is on a forward slope (i.e.8
0
), following the
icons on the lower part of the screen. The adjacent slope (i.e. right
hand/left hand) should be not more than 2 degrees off level. Again, the
warning triangle will flash if the angle is exceeded. Repeat the lift and
press ENTER to confirm and move to the next screen.
5. Repeat the lift sequence as prompted by the calibration screens, on a
backward slope, then a right hand slope, and finally a left-hand slope.
When the last lift is entered, the screen will display the message "Angle
Calibration Complete".
. Press the 'ESC' key to finish AUTOCAL .
If a re-calibration is required, all factors on the ANGLE FACTORS page
must be manually set to ZERO before carrying out the procedure again
Figure 14
Figure 15