SCI WLS555 User manual

WLS555
Installation and Operation Manual
SCI-WLS555 Onboard Weighing System Installation Guide V4.1

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Important Safety Information
Precautionary Statements
Warning–Indicates a potentially hazardous situation which, if not avoided, could lead to
serious injury or death.
Caution–Indicates a potentially hazardous situation which, if not avoided, could lead to a
mild to moderate injury.
Information –Indicates important points that Operators and Installers need to fully
understand.
Refer to Documentation –Indicates important points which must be obtained by
referring to manufacturers Service, Operation, or Maintenance Manuals.
It is your sole responsibility to install, operate, and maintain the SCI system in a manner that will
not cause damage to persons, property, or anything else. Always use safe practices and adhere
to any laws that may be in place.
Do not install, operate, or maintain the SCI system unless you are completely competent and
understand the system and equipment it is being mounted on.
Read this manual completely prior to use and familiarize yourself with the components
and locations.

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Table of Contents
Important Safety Information ..................................................................................................A
Table of Contents..................................................................................................................... 1
1. Introduction....................................................................................................................... 2
1.1. Compatibility Statements.......................................................................................... 2
1.2. Approved Devices...................................................................................................... 2
1.3. How the System Works ............................................................................................. 2
1.4. Components............................................................................................................... 4
1.5. Typical Mounting Locations...................................................................................... 6
2. Installation......................................................................................................................... 7
2.1. Pre-Installation........................................................................................................... 7
2.2. Installation.................................................................................................................. 8
2.2.1. Hydraulics........................................................................................................... 8
2.2.2. Switches.............................................................................................................. 8
2.2.3. Controller ............................................................................................................ 9
2.2.4. Electrical.............................................................................................................. 9
2.2.5. Connecting the Display Device.........................................................................10
3. Operation..........................................................................................................................12
3.1. Display Page Layout ....................................................................................................12
3.2. Menu Layout..............................................................................................................13
3.3. Attachments Page.....................................................................................................15
3.4. Customers Page........................................................................................................17
3.5. Materials Page...........................................................................................................20
3.6. Users Page................................................................................................................22
3.7. Logging Page............................................................................................................23
3.8. Diagnostics Page......................................................................................................24
3.9. Calibration Page........................................................................................................25
3.10. Sensor Configuration...............................................................................................27
3.11. Calibration.................................................................................................................29
3.12 Advanced Configuration..........................................................................................30
Appendix A –Wiring Diagram................................................................................................31
Appendix B –Parts Diagram..................................................................................................32
Appendix C –Hydraulics........................................................................................................33
Appendix D –Electronics.......................................................................................................37
Appendix E –Troubleshooting and Mobile Printers.............................................................38

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1. Introduction
Thank you for purchasing the WLS555 Onboard Weighing System. This product has been
designed to be simple to install and operate. The system operates with communication from the
processor to a mounted tablet or handheld device. Please ensure you have read and
understand the compatibility statements to ensure the best experience.
1.1. Compatibility Statements
The system uses any WiFi enabled device that has an internet browser. Complete testing has
been conducted using Chrome for Windows and Android devices and Safari for Apple products.
Other browsers may function with or without limitations.
1.2. Approved Devices
Device Type
Operating System
Browser
Limitations
PC
Windows 7 and up
Chrome
No Known
Tablet –Android
Android 4.4 and up
Chrome
No Known
Phone –Android
Android 4.4 and up
Chrome
No Known
Tablet –iPad
IOS 12
Safari
Can’t Download Load or Parameter Logs
Phone –iPhone
IOS 12
Safari
Can’t Download Load or Parameter Logs
Phones and other cellular connected devices may require “Mobile Data” to be turned off for full
functionality. If you have issues viewing the home page in your browser, turn mobile data off
while using the scale. To better serve you in the future, please send an email to
[e-mail] with device make, browser used, OS version, and carrier to allow
us to make improvements moving forward.
1.3. How the System Works
Weighing - The system uses sensors in the hydraulic circuit to monitor pressure during
operation of the loader arm. These pressure readings correspond to the calibration data stored
on the module per attachment. The system requires you to make movements past a target area
to register the weight of the contents in the bucket. There are two non-contacting switches
mounted near the loader arm pivot point. These indicate the relative speed and weigh target
area. If the loader arm does not cycle past the target area, the display will not indicate load. If
this happens, simply lower the arm and then raise the arm until a load is registered.
Load Data –The system can read weight and record load information. For the system to
calculate weight, an attachment needs to be set on the home screen. A load is a series of
buckets of various weights, volumes, or pieces accumulated during a load cycle. To complete a
load cycle, you must have Customer, Material, and Attachment set on the home screen and a
load must be started. Every time a bucket is weighed, it will be recorded as part of a load,

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providing you have pressed the START button. This data can be retrieved from the Load Log
file for a specific day.
On the Display –When you are looking at the display, to see the load in the bucket, make sure
the Customer, Material, and Attachment (NOTE: there must be 1 customer, 1 material, and 1
attachment. You can assign anything, but must have 1 of each) are selected and simply raise
the loader arm at a smooth and consistent rate. Once the loader arm passes the second
switch, the current bucket total will show in the top section of the display. This allows the
operator to get a weight that may not need to be logged / recorded. In addition, with an empty
bucket, the operator can make this motion and ZERO / TARE the bucket. This is helpful as
material gets stuck in the bucket or can indicate the boom pins are in need of lubrication if the
weight deviates from zero.
To record a load and/or see a load accumulate on the display, the operator must first press the
START button. By pressing the START button, the system will record every movement of the
boom in the up direction as a bucketful being placed into a vehicle / vessel. This will increment
the bucket counter in the upper right corner of the display and accumulate bucket loads in the
Load Total area (see Fig 16 –Item 5). Additionally, once the START button is pressed, the
bottom buttons will change to TIP OFF and FINISH. To end the load, simply press the FINISH
button and the load will complete and be logged into memory. If the system has a printer
configured, it will also print the load ticket once FINISH is pressed. On SCI supplied Brother
printer, pressing the feed button on the printer will reprint the last ticket.
TIP OFF –The TIP OFF function allows the operator to re-weigh the last bucket until they get
the desired amount of material. It works by removing the last bucket weight and count from the
load. Then the operator can shake off material, lower the arm, and raise the arm to re-weigh the
bucketful. This can be repeated as many times as required to get the desired amount. Once
the desired amount is weighed, press FINISH TIP OFF to exit the function, then press FINISH to
complete the load. The TIP OFF function is to weigh material in the bucket, not the material that
was removed.
WIFI Requirements –The control module provides the required WIFI signal for the system
(Tablet and Thermal Printer) to function on its own. The system does not need access to the
INTERNET. To utilize the scale, your device must be connected to the SCI-Scale-XXXXXXXXX
network and your device will say Connected, No Internet. Wifi is a radio communication
standard and has nothing to do with the world wide web. To utilize the Desktop Printing, your
site will require Wifi, in which the control module will connect to it. To utilize Remote Viewer,
your site will require Wifi and Internet access (world wide web).

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1.4. Components Standard Components
Figure 1
1. Controller Assembly –This has the processing module, I/O module, and fuse block.
All other wired components get connected to this assembly.
2. Switch Assembly –This part gets mounted (welded or bolted) to the frame where the
loader arm pivots.
3. Pressure Transducers –These parts get mounted between the cylinder and control
valve to monitor pressure in the cylinder. Note: These must be mounted between the
cylinder and any load holding valves. The mechanical connection is -04 (1/4”) O-Ring
Boss. If you have questions pertaining adapters or pressure ratings, contact our service
department via phone [phone] X2 or email: [email protected]
4. Hydraulic Adapters/Flange Fitting –Adaptors and flanges come in various sizes and
styles to accommodate most equipment. (Shown (Left to Right) -06 JIC Run Tee, -06 O-
Ring Face Seal Run Tee (ORS), Female -04 O-Ring Boss (ORB) to -04 Male Pipe),
flange.
1
3
2
4

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Optional Components
Figure 2
1. Display (Optional) –Samsung Tab Active or Tab A7 Lite Tablet or your device.
2. Display Mount (Optional) –This comes in many variations. Consult your order to
ensure compatibility with your handheld device.
3. Printer (Optional) –This is used to print load tickets on or around the equipment.
3
1
2

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1.5. Typical Mounting Locations
Mounting on Wheel Loader
Figure 3
Mounting on Skid Steer
Figure 4
1. Controller Assembly –Mounted outside cab away from falling debris
2. Switch Assembly –Left hand side at / near loader arm pivot point
3. Pressure Sensors –Where hoses attach to cylinders or tubes from main control valve
4. Display Mount and Printer –Inside cabin near operator station
2
3
4
1
4
3
2
1

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2. Installation
2.1. Pre-Installation
- Find, using service manual or pressure gauge, the pressure of the loader arm circuits (up and
down motion). Refer to manufacturer’s manual for information on how to get the pressures and
relieve system pressure.
- Record the pressures
Piston:_____________________________________________________________psi
Rod:_______________________________________________________________psi
- Compare Pressure Sensors to values to ensure the Pressure Sensor rating meets or exceeds
machine values.
- Determine Pressure Sensor mounting locations (see Figure 5).This is generally an adapter
between the steel tubes coming from the main control valve to a hose connected to the lifting
cylinders.
- Record Adapter size and type
Piston Hose connection size_______________________________________________
Rod Hose connection size_________________________________________________
- Compare the adapters in the kit to ensure they are of the same size and type. See Appendix C.
Figure 5
CAT 938K –Near Articulation Point
-16ORS Adapter

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2.2. Installation
2.2.1. Hydraulics
A. Lower the boom to ground and engage the float functionality. Turn the equipment off.
Follow any instructions for servicing the hydraulic system found in the equipment
Operator’s or Service Manuals.
B. Locate appropriate locations to install the pressure transducers in both the piston and
rod side circuits (when applicable) (See Figure 5). The location should be free of any
danger of contacting structure or falling debris. Additional adapters or hoses may be
needed to tee the sensors into the circuits. Ideal locations include areas where hoses
and tubes join.
C. After ensuring the residual pressure is removed from the circuit and all potential energy
is dissipated, break the desired connections and insert the required adapters to “Tee” in
the sensors (See Figure 6). Before tightening, ensure to bleed / purge any air in the
fittings / circuit. Use proper tightening techniques to ensure hoses and tubes don’t have
implied torque that will cause connections to loosen. Apply the proper torque to all
fittings. Refer to equipment Operator’s or Service Manual for tightening specifications.
Figure 6
CAT 938K
2.2.2. Switches
A. With the boom lowered to the ground, start the machine and position the boom at the
height you wish to weigh at. Important point to think about when selecting the height is
that the movement of the boom will need to be about 5 deg or greater when weighing. If
you are loading standard dump trucks or scooping material above grade level, you may
want the weighing point to be higher than other applications. If you select a height and
do not like the performance, you can move the sensors. However, if the sensors get
moved, the system will require recalibration. If your loader is equipped with an
automatic stop, the weigh height should be slightly under that height so when the arm
stops it does not affect the cylinder pressures.
B. The kit comes with a “universal” bracket that can be used in most applications. If
needed, you can install the sensors in your own bracket. The bracket can be bolted or

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welded to the structure (See Figure 7) but needs to have the bottom target not engage
until the boom is lifted at some height above ground and the second target needs to be
about 5 deg higher than the first in the boom movement (See Figure 8). An example of
placement on a skid steer is illustrated in Figure 9. These sensors detect any ferrous
material and ideally are mounted such that the boom arms are what triggers them. The
sensors have a sensing distance of 1/8” – 1/2”. DO NOT DRILL OR WELD ON ROPS /
FOPS STRUCTURES.
Figure 7 Figure 8 Figure 9
CAT 938K Wheel Loader Bobcat T650 Skid Steer
2.2.3. Controller
A. The controller and I/O module come installed on a mounting plate. This mounting plate
needs to be mounted somewhere on the vehicle in a location it will not come in contact
with moving parts or falling debris. This assembly is weather rated and has WiFi
communication, thus cannot be installed inside a shielded enclosure. Pick a location
and bolt the mounting plate to the equipment. Do not weld the controller plate to the
structure, doing so will destroy the electronics and is not covered under warranty.
2.2.4. Electrical
A. There are 5 pigtails coming off of the controller assembly. 2 are for the pressure
sensors, 2 are for the switches, and 1 is for connection to the power supply. The power
supply harness has 3 wires. Black is to be connected to chassis ground. Red is to be
connected to Chassis (Battery) supply. Yellow is to be connected to switched power and
will turn the system on. The switch can be ignition or its own dedicated switch to turn the
system on and off. The system can operate on any voltage between 9 and 32vdc. The
voltage supplied to the red and yellow wires must be the same. The other 4 are labeled
and need to be connected with their corresponding sensor / switch.
B. Once connected and all wired up, ensure wiring is tied up away from heat sources and
pinch points that could chaff or cut the wires.

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2.2.5. Connecting the Display Device
A. The system utilizes a customer supplied or optional mobile device, the ruggedized
Samsung Galaxy Tablet available for purchase through SCI, as the system display. The
requirements of the mobile device are that it has a WiFi connection and a web browser.
Tested web browsers include Chrome (all), Firefox, Internet (Android), and Safari
(Apple). All are available through the Google Play Store or Apple iTunes for free. If the
tablet is purchased through SCI, it will come setup ready for use with the WLS555
system.
B. Once a device is selected, you need to start the scale system up by turning the machine
on from section 2.2.4.A. Connect to the WiFi Network ID SCI-Scale XXXXXXXXXXX.
The XXXXXXXXXXX represents the serial number of the system. The password for the
connection is Weight4It. Once connected, open your browser and search for
WLS555.local/ or 192.168.5.1/. This will pull up the login page for the system. For login
info, review the Users section of this manual. Tip: If using Chrome, you can press
the Chrome menu button and then touch on Add to Home Page. This will add an icon
and link to the mobile devices home page like an app. Similar can happen on other
devices and browsers (See Figures 10-15).
Figure 10 Figure 11

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Figure 12 Figure 13
Figure 14 Figure 15

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3. Operation
3.1. Display Page Layout
A. The display page consists of several objects that are touch / clickable areas that navigate
to other windows or pages. See Figure 16 and table below for layout and function.
Figure 16
#
Name
Description
1
Menu
Press to open Menu. Can also swipe from left of home screen.
2
Alerts
Press to show active alerts. From popup window, you can download alert log.
3
Load
Shows current Bucket load. Will read when loader arm is lifted through load sensors.
4
Bucket Count
Shows number of all buckets in load.
5
Load Total
Shows accumulated load total of all buckets in load.
6
Target Load
Touch to set desired target load. By setting target load, a status bar (%) will appear
below Total and Target Load button showing Total/Target percentage.
7
Customer
Press to select customer from list.
8
Material
Press to select material from list
9
Attachment
Press to select attachment from list
10
Start Load
Start load button. Press to start a load.
11
Zero
Press to Zero Bucket load. This accommodates for stuck material.
12
FULL Screen
Press to toggle between Full screen and window view.
13
Connected/Refresh
Press to refresh page. Green when connected. Red when not connected.
1
10
3
2
6
11
4
9
7
5
8
12
13

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3.2. Menu Layout
The menu layout is as follows:
Menu
- Home –Returns to Home Page
- Attachments –Goes to Attachments Page
- Customers –Goes to Customers Page
- Materials –Goes to Materials Page
- Logging –Goes to Logging Page
- Diagnostics –Goes to Diagnostics Page
- Calibration –Goes to Calibration Page
- Tickets –Goes to Tickets Page
- Users –Goes to Users Page
- WiFi –Goes to WiFi Page
Logout (Exit Door) –Push to logout of the system.
Settings (Gear) –These are the Scale settings. Access by pressing the gear symbol in
the menu.
- User –These settings are specific to the user and is stored on the user’s device.
oUnits
▪Weight –User selected unit for weight
▪Volume –User selected unit for volume
▪Pressure –User selected unit for pressure
▪Temperature –User selected unit for temperature
oLanguage –User selected language
- System –These are settings that store on the scale itself.
oScale Settings
▪Machine ID –An identification name for the unit the scale is installed
on. Will print on load tickets and transmit to telematics system
▪Calculate Price –Toggle on to have the system calculate price
▪Sales Tax Rate –Enter tax rate for area that will be applied when
calculating price.
▪Price Rounding –Used to round the sales unit.
▪Unit Rounding –Used to round the displayed unit.
▪Confirm Stop Load –Turn on to require confirmation when finishing a
load
▪Stop Load Comments –Turn on to enable users the ability to enter
comments when a load is finished.
▪Single Bucket Limit –0 is off. Any other number will trigger an alarm
when the bucket load exceeds this limit. Used where concerns of
machine stability are an issue.
▪Target Exceeded Alarm –Turn on to enable an output for an alarm
when Accumulated load exceeds Target setting.

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▪Target Exceeded Alarm Duration –The time, in seconds, that an
alarm will be triggered when Accumulated load exceeds target. 0 is
continuous.
▪Thermal Printer –Toggle on if there is a Brother or Zebra printer
installed
▪Desktop Printer –Toggle on to utilize standard network printing
devices. This also creates pdf files of load tickets on the system.
▪Invoice Start At –The starting number of the load tickets. If this
changes once set initially, it may erase historical data.
oCompany Information
▪Name –Name of the business of the loader (Seller of Material)
▪Address –Address of the business of the loader
▪City –City of the business of the loader
▪State –State of the business of the loader.
▪Zip –Zip of the business of the loader
▪Phone –Phone of the business of the loader
- EEPROM
oTransducer Number –The number of installed transducers
oSample Window Size –The number of pressure readings averaged
symmetrically about the weight trigger point. These readings are at 10ms
intervals. Used to filter erratic readings.
oTransducer Piston Volt Min –Minimum voltage reading of piston transducer
at atmospheric pressure.
oTransducer Piston Volt Max –Max voltage of pressure piston transducer
(should be 4500 in all cases).
oTransducer Piston Press Min –Minimum pressure (should be 0 in all cases).
oTransducer Piston Press Max –Maximum Pressure setting of the piston
transducer installed. Should equal pressure rating on transducer.
oCylinder Ratio –Area of the rod subtracted from piston area, then divided by
the area of the piston on the piston side. Provides a percentage of rod side
area for reduction in opposing force on lift cylinder. 1000 = 100%
oTransducer Rod Volt Min –Minimum voltage reading of rod transducer at
atmospheric pressure.
oTransducer Rod Volt Max –Max voltage of pressure rod transducer (should
be 4500 in all cases).
oTransducer Rod Press Min –Minimum pressure (should be 0 in all cases).
oTransducer Rod Press Max –Maximum Pressure setting of the rod
transducer installed. Should equal pressure rating on transducer.
Info (Circle with i)
oContact info
oSoftware info
oMemory Usage

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3.3. Attachments Page
Here we maintain the Attachments for the machine. For example, for a given machine
you may have a quick attachment system that allows for easy configuration of an
Excavation Bucket and Pallet Forks. You will need to enter both attachments into the
scale prior to calibrating to indicate load and/or usage. At minimum, 1 attachment
needs to be configured. Unlimited attachments can be configured. Attachments have
the following fields: Name, Long Name, Serial Number, Scale Enabled toggle, and a
selectable Icon. To add an Attachment, go to Menu>Attachment. Press the plus sign in
upper right to Add an attachment. Enter the data into the corresponding field and click
Submit to save. See Figures 17 and 18. Return to Home when done. (* is required)
Fields
- Alias –This is the abbreviated name of the Attachment *
- Long Name –This is the complete name of the Attachment. Keep to 20 Characters
or less to ensure the name will fit on the print ticket. *
- Serial Number –This is a field to capture the Attachment serial number. The Load
calibration depends greatly on the correct attachment selection to match what is
installed.
- Scale Enabled –This needs to be turned on to use the attachment with the scale
functionality. If this is turned off, you will not be able to see load or calibrate. *
- Icon –This allows you to select an icon to represent the attachment. You can
choose from the following list. Bucket (Standard), Bucket (Alt), Bucket (Snow),
Bucket (4-IN-1), Grapple, Forks, Lift, Bale Spear, Rake, Sweeper, Bin, Other. *
Figure 17

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Figure 18

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3.4. Customers Page
Here we maintain the customers for load operations. For example, for a given business
you may have 100 or more customers. In this page you can adjust discount level,
taxable, Names, Addresses, etc. At minimum, you must enter 1 customer. This
customer can be called anything, but the Name will show up on tickets. 200 plus
Customers can be configured. Customers have the following fields: Alias, Long Name,
Phone Number, Address, Address 2, City, State, Zip Code, Project Number, Discount,
Taxable, Print Address, Require PO, and Require Truck Number. To add a Customer,
go to Menu>Customers touch the plus sign in the upper right to add a customer. Fill
out the appropriate fields and click Submit to save. See Figures 19 and 20. Return to
Home when done. (* is required)
Fields
- Alias –Abbreviated Name of Customer *
- Long Name –Full Name of Customer *
- Phone Number –Phone Number of Customer
- Address –Address of Customer
- Address 2 –Second Line for address of Customer
- City –City of Customer
- State –State of Customer
- Zip Code –Zip Code of Customer
- Project Number –Allows for a Specific Customer Project Code.
- Discount –Allows for a discount to be applied to Customer (in % - Price will be 1-
Discount%)
- Taxable –Turn on to add tax to customer.
- Require PO –Turn on to open a dialog box where PO number must be entered to
start a load.
- Require Truck Number –Turn on to open a dialog box where Truck Number must be
entered to start a load.

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Figure 19