VOSS OBW 501 User manual

Assembly instructions
VOSSOBW501
SGsensor
Strain gauge sensor for on-board weighing systems
Axle weight measuring –
at its most precise way

Assembly instructions VOSSOBW501
SG sensor
, Page 2 of 22
A. Important notices
Please observe before using the VOSSOBW501
SGsensor
VOSSOBW501
SG sensor
is suitable for axles in commercial vehicles, off-road vehicles and light
duty vehicles.
Only for assembly on axle. Any other use leads to the exclusion of warranty rights.
Before starting with the assembly process of the VOSSOBW501
SG sensor
, carefully read these
assembly instructions and make sure that you have understood these.
Before starting with the assembly process, provide the required materials and tools,
mentioned in chapter “C. Assembly instructions”.
The sensor / system must be installed and connected in accordance with the regulations valid
for the vehicle and country in question.
Make sure ignition is switched off and battery is disconnected before starting any installation.
The sensor has to be stored dry and free from humidity.
Do not remove the sensor from the ESDprotection bag before installing it in the vehicle.
Do not use the sensor data to control safety-relevant vehicle functions, e.g., ABS or ESP.
Liability:
All damages (e.g., recalls, customer services, expenses, compensation, etc.) are limited by
the respective order amount.
Damages shall be paid if VOSS is solely liable (gross negligence or intent required). Only the
actual damage will be compensated.
Under no circumstances shall VOSS be liable to the purchaser for liquidated
damages/contractual penalties and/or financial losses such as expected or lost profits, loss of
production, interest, penalties or for incidental, consequential, special, exemplary or criminal
damages in connection with the contract.
Should VOSS be held liable by third parties (e.g., due to product liability claims), the
purchaser shall indemnify VOSS against all claims.
Any processing of vehicle components must be coordinated with the component
manufacturer.

Assembly instructions VOSSOBW501
SG sensor
, Page 3 of 22
Please observe during the assembly of the VOSSOBW501
SGsensor
The assembly of the VOSSOBW501
SG sensor
must be conducted by professional mechanics
subject to these assembly instructions.
Incorrectly assembled sensors can result in failure of the system.
Before using the sensor, components must be checked. They have to be clean and must not
show any signs of damage. In case of any damage, the sensor has to be replaced.
Handle sensor with care to avoid damage due to mechanical shock and electrostatic
discharge.
VOSSOBW501
SG sensor
is measuring the strain of the material. To make sure the sensor can
measure correctly, the surface has to be clean, straight and free from grease or other release
agents (see chapter “C. Assembly instructions 1. Grinding and cleaning of surfaces”).
To protect the sensor, it hast to be covered by a protection cover and by sealing. The cable has
always to be protected by a corrugated tube. Avoid bending the cable around sharp edges
and below the specified minimum bending radius of 35 mm. The sensor will be adhesive
bonded and the cable fixed on the chassis (see chapter “C. Assembly instructions 2. Assembly
of VOSSOBW501
SG sensor
”). It is recommended to apply a first fixation of supply cable at a
distance of 150 mm behind the protection cover.
The sensor has a 3-wire harness. For connection and setup instructions see chapter
“C. Assembly instructions 3. Setup of VOSSOBW501
SG sensor
”.
Observe the manufacturer's safety instructions and handling of adhesive and sealing material.
System properties
For detailed system properties and technical data please check latest available version of
“Product information VOSSOBW501
SG sensor
”(Art. No. 7007734000) on
www.voss-automotive.net/en/downloads.
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Assembly instructions VOSSOBW501
SG sensor
, Page 4 of 22
B. Components and materials
1. VOSSOBW501
SGsensor
Fig. 1: VOSSOBW501
SG sensor
with cable Fig 2: VOSSOBW501
SG sensor
with metal protection
cover and corrugated tube
2. Electrical connection possibilities
Fig 3: Connector Tyco HDSCS
Pin1: VBAT
Pin2: GND
Pin3: Signal
Fig 4: Open wire; wire configuration:
VBAT (Red)
GND (Brown)
Signal (White)

Assembly instructions VOSSOBW501
SG sensor
, Page 5 of 22
3. Complete sensor set
Fig 5: VOSSOBW501
SG sensor
with Tyco HDSCS and metal protection cover (complete sensor set)

Assembly instructions VOSSOBW501
SG sensor
, Page 6 of 22
C. Assembly instructions
Use of arrow symbols in pictures:
Indicates special points of interest described in the text.
Indicates required manual actions and their direction.
Indicates operations that should be avoided.
1. Grinding and cleaning of surfaces
Before starting cleaning, make sure that the vehicle is safely parked, the engine of vehicle is turned off (no
voltage on electrical supply lines), and the vehicle axle is ina temperature range of +10 °C to +30 °C
(+50 °F to +86 °F).
Provide the following materials/tools: angel grinder with grain 80, drilling machine with 60 and 120
grain, abrasive paper 120, abrasive paper 240, cleaning cloths, lint-free cloths and cleaning solvent:
acetone + 2-propanol (mixing ratio 1:1).
Use the middle of the axle as assembly area for the VOSSOBW501
SG sensor
. Minimum
100 mm x 60 mm needed as installation space incl. protection cover. The surface of sensor installation
(ca. 30 mm x 20 mm) has to be grinded flat.
Use gloves, while working. Prepare yourself with further personal protective equipment, if needed
according to local regulations. We recommend wearing working gloves and safety goggles.
Step 1
Before starting the grinding process, area must be free from
grease and release agents.
Polish the surface by using angle grinder with grain 80.
Do not grind an indentation.
Fig. 6: Polishing the surface with grinder
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Assembly instructions VOSSOBW501
SG sensor
, Page 7 of 22
Step 2
Polish the surface by using drilling machine with grain 60.
Fig. 7: Polishing the surface using drilling machine with
grain 60
Step 3
Continuously polish the surface by using drilling machine
with grain 120.
Fig. 8: Polishing the surface using drilling machine with
grain 120
Step 4
Grind the surface fine by hand by using abrasive paper with
grain 120.
This step should be performed on an area at least as
large as the sensing part, ca. 30 mm x 20 mm.
Fig. 9: Fine grinding of the surface by hand by using abrasive
paper with grain 120
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Assembly instructions VOSSOBW501
SG sensor
, Page 8 of 22
Step 5
Grind the surface fine by hand by using abrasive paper with
grain 240.
This step should be performed on an area at least as
large as the sensing part, ca. 30 mm x 20 mm.
Fig. 10: Fine grinding of the surface by hand by using
abrasive paper with grain 240
Step 6
Final result of the grinding process.
Fig. 11: Finally grinded surface
Step 7
Wipe clean the entire grinded surface with cleaning solvent
and a cleaning cloth.
Fig. 12: Cleaning of surface
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Assembly instructions VOSSOBW501
SG sensor
, Page 9 of 22
Step 8
Use lint-free cloth and cleaning solvent for the final cleaning.
During this process, you need to change the cloth,
until the cloth remains white after wiping. This may
take several attempts. Prepared surface has to be
completely free of dirt, paint, dust, oil and grease.
Fig. 13: Cleaning of surface with lint-free cloth
Step 8.1
Use lint-free cloth and cleaning solvent for the final cleaning.
During this process, you need to change the cloth,
until the cloth remains white after wiping. This may
take several attempts. Prepared surface has to be
completely free of dirt, paint, dust, oil and grease.
Fig. 14: Still dirty lint-free cloth during cleaning process
Step 9
Use lint-free cloth and cleaning solvent for the final cleaning.
During this process, you need to change the cloth,
until the cloth remains white after wiping. This may
take several attempts. Prepared surface has to be
completely free of dirt, paint, dust, oil and grease.
Fig. 15: Final cleaning of surface
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Assembly instructions VOSSOBW501
SG sensor
, Page 10 of 22
Step 9.1
Use lint-free cloth and cleaning solvent for the final cleaning.
During this process, you need to change the cloth,
until the cloth remains white after wiping. This may
take several attempts. Prepared surface has to be
completely free of dirt, paint, dust, oil and grease.
Fig. 16: Finally white lint-free cloth after cleaning process
Step 10
Final result of the cleaning process.
Fig. 17: Final result of the cleaning process
Step 11
Grind the protection cover by hand with abrasive paper with
grain 120 or 240.
Fig. 18: Grinding of protection cover
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Assembly instructions VOSSOBW501
SG sensor
, Page 11 of 22
Step 12
Wipe clean all grinded surfaces of the protection cover with
a white lint-free cloth and cleaning solvent.
Fig. 19: Cleaning of protection cover
Step 13
Carefully wipe all the surface of the sensor with lint-free cloth
and cleaning solvent.
Fig. 20: Wiping of sensor

Assembly instructions VOSSOBW501
SG sensor
, Page 12 of 22
2. Assembly of VOSSOBW501
SG sensor
Before using the VOSSOBW501
SG sensor
, components must be checked. They have to be clean and
must not show any signs of damage.
To make sure the sensor can measure correctly, the surface has to be flat, clean and completely free
from dirt, paint, dust, oil and grease (see chapter “C. Assembly instructions, 1. Grinding and cleaning
of surfaces”).
Provide the following materials/tools: scriber, adhesive Panacol GTH-T with two-part adhesive
applicator, an adhesive and sealing compound (CARSYSTEM®UNIFLEX PU with single part cartridge
press is recommended, or comparable products), spray paint (with corrosion protection; varies
depending on individual vehicle) and cable ties.
Use new, clean gloves, while working with mentioned chemicals. Prepare yourself with further personal
protective equipment, if needed according to local regulations.
Step 1
Mark at the edges center positionof prepared surface for
sensor with scriber.
Do not use pencil or pen. Surface will not be clean
anymore.
Do not contaminate the cleaned surface.
Fig. 21: Marking center position
Step 2
Carefully place the sensor on the center position of the
cleaned surface.
Do not contaminate the cleaned surface and the
sensor.
Fig. 22: Placing the sensor on the cleaned surface
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Assembly instructions VOSSOBW501
SG sensor
, Page 13 of 22
Step 3
Align the sensor and prefix the cable with cable ties.
Do not completely fix the cable ties for final aligning
later (see step 7).
Do not contaminate the cleaned surface and the
sensor.
Fig. 23: Aligning the sensor and prefixing the cable ties
Step 4
Prepare the adhesive: use the shown pieces on the right
(Fig. 24): Panacol GTH-T with mixer tip and two-part
adhesive applicator.
Use only one mixer tip for one sensor assembly. For
two sensors only if adhesive is added to both sensors
in less than one minute. Remember to order extra
mixer tips if needed.
The storage temperature of the adhesive must be in
accordance with the manufacturer's
recommendations.
Fig. 24: Panacol GTH-T with mixer tip and two-part adhesive
applicator
Step 4.1
Prepare the adhesive: keep the cartridge in an upright
position for at least 2 minutes, then remove the cap and
attach the mixer tip.
Fig. 25: Preparing the adhesive: attaching mixer tip
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Assembly instructions VOSSOBW501
SG sensor
, Page 14 of 22
Step 4.2
Prepare the adhesive: insert the adhesive in the two-part
adhesive applicator
Fig. 26: Inserting the adhesive in the two-part adhesive
applicator
Step 4.3
Prepare the adhesive: start dispensing the adhesive
upwards until the air bubbles in mixer tip have gone.
Fig. 27: Preparing the adhesive: dispending adhesive
Step 4.4
Prepare the adhesive: discard a certain amount of the
adhesive, which should be as long and wide as the mixer tip
to guarantee a good mixture of the adhesive.
Fig. 28: Preparing the adhesive: discarding adhesive

Assembly instructions VOSSOBW501
SG sensor
, Page 15 of 22
Step 5
Before applying the adhesive do a final cleaning of the
sensor installation surfaces with cleaning solvent and lint-fee
cloth as a precaution.
Apply the adhesive to the sensor.
Apply enough adhesive to only one area, so that it can
spread over the surface from there. Do not distribute it
with mixer tip.
When adhesive bonding, temperature of the axle
should be above +10 °C (+50 °F).
Fig. 29: Applying the adhesive
Step 6
Immediately after applying the adhesive, attach the sensor to
the prepared surface, and apply pressure with your thumb
for a minimum of 5 minutes @+20 °C (+68 °F).
The assembly takes place with the main deformation
direction with 0 ° or 180 °.
Fig. 30: Attaching the sensor
Step 7
Finally, carefully align the cable and fix the cable ties to
avoid mechanical stress to the sensor.
Do not apply pressure to sensor.
Fig. 31: Aligning the cables and fixing the cable ties
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Assembly instructions VOSSOBW501
SG sensor
, Page 16 of 22
Axle temperature Time after sensor is adhesive bonded with Panacol GTH-T
+10 °C to +30 °C
(+50 °F to +86 °F) T1 T2 T3 T4
15 min 30 min ** 5 hours 24 hours
T1 - You can do first test of sensor. One or two persons can enter the vehicle.
T2 - Protection cover can be mounted. One hour later paint or corrosion spray can be added.
T3 - Vehicle can be driven for LO and HI calibration.****
T4 - Vehicle can be driven with normal load - recommandation.
** - Vehicle can be moved without any problems.
**** - We recommend vehicle to be unloaded after HI calibration until next day.
Table 1: Time after sensor(s) are adhesive bonded with Panacol GTH-T
Step 8
Prepare the adhesive and sealing compound for connecting
the sensor to the axle.
We recommend CARSYSTEM®UNIFLEX PU for best
performance.
Optional Teroson MS 9399 can be used (shown in Fig.
33 – 37).
Fig. 32: CARSYSTEM®UNIFLEX PU
Step 9
Carefully apply the adhesive and sealing compound
completely underneath the sensor to fill up the whole space
between the surface and the sensor.
Do not apply pressure to sensor.
Fig. 33: Applying the adhesive and sealing compound
underneath the sensor
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Assembly instructions VOSSOBW501
SG sensor
, Page 17 of 22
Step 10
Apply the adhesive and sealing compound underneath the
end of the sensor and underneath the cable.
Do not fix and fill up the corrugated tube with the
adhesive and sealing compound to ensure that water
could drain later in operation.
Fig. 34: Applying the adhesive and sealing compound
underneath the cable
Step 11
Completely fill up the protection cover, including shoulders,
with the adhesive and sealing compound.
Avoid air bubbles, if possible. Hold the nozzle inside
the adhesive and sealing compound during filling.
Nozzle can be shortened with knife to make it easier
and faster to fill up the protection cover with the
adhesive and sealing compound
Fig. 35: Filled up cover
Step 12
Carefully put the cover over the sensor.
Distance between surface and cover can vary from 2-5
mm. Do not try to push it completely to the surface.
Make sure that no adhesive and sealing compound
reaches the corrugated tube to ensure that water
could drain later in operation.
Fig. 36: Fixing the cover
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Assembly instructions VOSSOBW501
SG sensor
, Page 18 of 22
Step 13
Carefully smooth out the sealant and remove the excess of
adhesive and sealing compound.
Distance between surface and cover can vary from 2-5
mm. Do not try to push it completely to the surface.
Make sure that no adhesive and sealing compound
reaches the corrugated tube to ensure that water
could drain later in operation.
Fig. 37: Smoothing out the sealant
Step 14
At least 1 hour after fixing, paint the cover with corrosion
protection.
Fig. 38: Painting the cover
Step 15
Completely assembled VOSSOBW501
SG sensor
installation
Fig. 39: Completely assembled VOSSOBW501
SG sensor
installation
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Assembly instructions VOSSOBW501
SG sensor
, Page 19 of 22
3. Setup of VOSSOBW501
SG sensor
3.1 Pre-calibration
Before using VOSSOBW501
SG sensor
a pre-calibration according to the used application is needed.
The pre-calibration can be carried out by the associated ECU used in the vehicle or by a
separate Sensor Control Unit (SCU). For pre-calibration by an ECU, please proceed with the ECU
manual. For pre-calibration by the Kimax-SCU a detailed description and manual is available on:
www.kimax.com/support/#usermanuals.
Before start, please make sure that the correct calibration unit – Kimax-SCU (Sensor Control Unit) –
is available.
Use the instructions from the software for a proper set up.
Step 1
Connect the VOSSOBW501
SG sensor
to the Kimax-SCU by
using the following cable connection (Fig. 40):
VBAT (Red)
GND (Brown)
Signal (White)
or with the corresponding counter part of the Tyco HDSCS
connector:
Pin1: VBAT
Pin2: GND
Pin3: Signal
Fig. 40: Kimax-SCU
Step 2
Connect the Kimax-SCU to power supply, it can be +12/24 V
from vehicle battery or sourced by +12 V DC. Connect the
adapter to the main 120/230 V supply (Fig. 40).
Step 3
Select the “polarity” for the sensor to offer an increasing
output signal at increasingaxle load. This can be
realized by selecting positive or negative slope.
Set, whether a positive slope of the analog output
voltage is required, when the sensor is strained or
compressed. This option depends on the installation
direction of the sensor (Fig. 41). All further details are
presented in the Kimax-SCU manual.
Fig. 41: Vehicle front axle
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Wheel-
support
Load
Load
Compression
Tension
Wheel-
support

Assembly instructions VOSSOBW501
SG sensor
, Page 20 of 22
Step 4
Adjust the offset setting of the output signal at empty vehicle to a value in a range of >0.5 V to <1.3 V by the offset function
(e.g., 1 V). For this, the Kimax-SCU offers a simple way to carry out an automatic adjustment of slope and offset (Fig. 42).
Step 5
In case the analog output voltage has already saturated at 4.5 V, although the maximum total weight of the vehicle has not
yet been reached, the gain must be reduced.
Caution: If the gain is changed in this step, step 4 must be performed again. Therefore, the Kimax-SCU offers a
simple way to carry out an automatic adjustment of slope, offset and gain (Fig. 42), also explained in detail in the
Kimax-SCU manual.
Fig. 42: Sensor characteristics
4.5
3.5
3.0
2.5
1.5
1.0
-140-210 01500 2250 Measured value [µStrain]
V
out
[V]
0.5
2.0
4.0
5.0
2000
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