VPG TruckWeigh Use and care manual

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TruckWeigh®
Installation, Setup and Calibration Manual

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TruckWeigh®

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Important installation information and liability
waiver
VPG designs and manufactures on-board vehicle weighing equipment. These installation guidelines
are provided solely for the use of trained installers and represent the correct, safe and recommended
method of installation.
These guidelines must be followed fully to ensure proper, safe installation. Failure to do so may result
in serious consequences including, but not limited to, failure of the system to function properly and
damage to the weighing equipment that could jeopardize the stability and safety of the vehicle.
VPG accepts no responsibility or liability for consequences arising from any improper installation of
the weighing equipment including but not limited to, any misapplication or misinterpretation of the
installation information contained herein.
Strict observance of these guidelines should help to ensure accurate weight measurement and
enable safe operation of the vehicle. Failure of our on-board vehicle weighing equipment due to poor
installation workmanship or incorrectly installed elements remains solely the responsibility of the
installer.
VPG does not accept responsibility for the structural integrity of the vehicle concerned, for any part
thereof, and for its proper, safe operation.
The company also reserves the right to make any amendments and alterations to this document deemed
necessary. You should ensure you have the current version of this information by contacting VPG prior to
performing installation, such as on our website at www.vpgsensors.com
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Contents
Important installation information and
liability waiver 3
Introduction and scope 6
Introduction 6
Scope 6
About this document 6
Important installation information 7
Installation 9
Components 10
Tools 17
Installation overview 18
Typical system schematics 20
Articulated vehicle 20
Rigid vehicles 21
How to install the junction box 22
Connecting the internal domain cable 23
Sensor types 25
Sensor installation positions 26
Air pressure transducer 27
Axle transducer on a leaf spring 28
Axle transducer on a rear steel spring bogie
(tandem axle) 29
Axle transducer on a rear rubber bogie 30
Axle transducer on a front strut 31
How to install an air pressure transducer
32
How to install a steel axle transducer 35
How to install the display unit 37
Additional device options 40
Conguration 41
Overview 42
Display unit operation 43
Action buttons 43
Gross display mode 44
Net display mode 45
Axle display mode 45
Trailer display mode 46
Menu password 46
How to congure the weighing options 48
Power on screen 48
Trailer / axle groups 50
Weighing units 52
Count by 53
Net weighing 53
Reading stability 54
How to congure the system 56
RS232 serial outputs (activate external devices)
57
CAN serial output 60
Vehicle ID 62
Printer 64
Output settings for external devices 66
Change PIN 68
Reset defaults 70
Time/date 72
Auto power o 73
How to input the vehicle conguration 74
Junction box orientation 75
Axle conguration 76
Sensor conguration 80
How to congure alarms 82
Activate alarms 83
Setting alarm weights 84
Setting set point alarms 85
Axle underload alarm 85
Calibration 87
Overview 88
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Weighing the vehicle 89
Weigh pads 89
Weigh bridge 89
How to calibrate the system 91
Zero calibration 92
Span calibration 94
System options 99
Overview 100
Display settings 101
Language options 103
Diagnostics 105
Live view 105
Alarms 106
Conguration 107
Inputs / outputs 109
Volts / temperatures 109
Logs 109
System messages 111
USB functions 112
Update rmware 112
Save to USB 113
Appendix A 115
System conguration table 116
Zero and span weights tables 117
Zero weights: 117
Span weights: 118
Appendix B 119
1160 Back Panel D Type Connector
Pinouts 120
9 Way Male D Connector – Standard RS232 Port
(DTE) 120
25 Female D Connector – 1160 General
Purpose Expansion Port 121
Appendix C 123
Alarms and Messages 124
Warning and Status Messages 124
Message Box Text and Messages 124
Log Error Code Text 124
Alarm Icons 125
Appendix D 127
TRUCKWEIGH II 128
Axle Overload Protection for Larger Capacity
Vehicles Greater than 7720 lbs (US), 3.5 tonne
(RoW) 128
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Introduction and scope
Please read this installation guide completely to ensure that all instructions are fully understood
before you install TruckWeigh®
Introduction
TruckWeigh® is a vehicle payload optimisation, overload monitoring and load distribution system for use
on vehicles with steel spring or air suspension or a combination of the two.
Scope
This document is intended as a guide to the installation and commissioning of TruckWeigh®.
It covers two transducer types currently supported in a TruckWeigh® system:
• TruckWeigh® axle transducers. These measure suspension deection on mechanical spring
suspension systems
• Air pressure transducers. These measure changes to air pressure on air suspension systems
Dierent system congurations can be used to support dierent chassis types. The system can be
congured to use either type of transducer and any combination of the two.
About this document
Any display screenshots used in this document are intended as an illustration of the function being
described. As such, any specic detail or settings shown will dier from one installation to another.
The documentation uses the following conventions:
Important. These are important notes and appear inside a green border
Caution. These notes warn of an operation which may cause damage to the TruckWeigh® system.
These notes appear inside an orange border
Warning. These notes warn of an operaon which may cause injury to the installer. The note is
highlighted in a yellow banner
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Important installation information
To ensure a reliable and properly functioning system particular importance should be paid to the
following:
• TruckWeigh® axle transducer installation. A suitable location for the transducer should be carefully
identied and that location should then be prepared for the transducer to be attached. See “How to
install a steel axle transducer” on page 35
• TruckWeigh® axle transducer orientation. Axle transducers must be mounted to the vehicle with the
correct orientation. See “How to install a steel axle transducer” on page 35
• Accurate recording of sensor serial numbers in their sensor positions. It is recommended that you use
the system conguration table to record this information and refer to it when you are conguring the
system. See “System conguration table” on page 116
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TruckWeigh®

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Installation
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Components
Below is a list of components which are used in a TruckWeigh® installation.
Check that you have all of the appropriate components for your installation before starting.
TruckWeigh® Display Unit
A single TruckWeigh® display unit is
supplied for the vehicle
Display Cage
A single display mounting cage is
supplied for the display unit
Axle Transducer
A single cable with a connector at
one end and the axle transducer at
the other
This is supplied for steel axle
suspension systems.
A single transducer is supplied
for each transducer position. See
“Sensor installation positions”on
page 26.
Bonding tape is supplied for each
transducer
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Air Pressure Transducer and Internal
domain cable with Air Pressure Brass
Fitting
The parts for the air pressure
transducer are supplied in a bag. A
single air transducer is made up from
a T-connector, a brass sensor tting
and two plastic air pipe ttings
This is supplied for air suspension
systems
A single transducer and a single
transducer cable is supplied for each
transducer position. See “Sensor
installation positions” on page 26.
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Junction Box
A single junction is supplied for the
rigid vehicle or tractor unit
Additional junction boxes are
supplied for each trailer unit
Internal Domain Junction Box Cable
The cable is identied by the grey
junction box connectors
Internal Domain Junction Box Cable
2 way
The cable is identied by the grey
junction box connector and 2 male
internal domain cable connectors
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Internal Domain Extension Cable
These cables are used to connect
sensors together
The cable is identied by the grey
cable connectors
Internal Cable with Y-Splitter
A single internal domain cable
with y-splitter is supplied for each
transducer
The cable is identied by a single
female internal domain cable
connector and two male internal
domain cable connectors
External Domain Junction Box Cable
A single external domain output
cable is supplied for each junction
box
The cable is identied by the black
junction box connector at one end
and the external domain cable
connector at the other
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External Domain Junction Box CAN
Cable, Cable Onput and Output
The cable is identied by the black
junction box connector at one end
and two external domain cable
connectors at the other, one for
input and one for output
External domain cable
A single external domain cable is
supplied for the system
The cable is identied by the
external domain cable connector at
one end and the display connector
at the other
Power Cable
A single power cable is supplied for
the display unit
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Tractor Suzi
Trailer Suzi
Rigid Suzi
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Double Ended Suzi
Cable Protector and Cable Ties
Cable protector is supplied and can
be cut as required
Cable ties are also supplied
Surface Cleaning Wipes
Double Sided Bonding Tape
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Tools
Check that you have the following tools before starting an installation.
Tool Check
Screwdriver set
Hex driver set
Torx driver set
Socket set
Multimeter
Side cutters
Drill set
G-Clamp
Spanner set (including 18 mm and 24
mm
Air pipe cutters
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Installation overview
Ensure the engine of the vehicle is o and the parking brake is applied before starng the
installaon
It is recommended that you use a mechanics pit inside a workshop to install the TruckWeigh®
system
The TruckWeigh® display unit is used to display sensor information once the system has been installed,
congured and calibrated.
The display unit is connected to the external domain cable. The external domain is a series of junction
boxes connected together. One junction box is installed on the chassis of the vehicle. One junction box is
also installed on the chassis of each trailer unit.
Each junction box is connected to an internal domain. The internal domain is a series of sensors
connected together. Multiple sensors are used to send information back to the junction box via the
internal domain cable. The junction box then transmits information back to the display unit via the
external domain cable.
External domain
Internal domain Internal domain
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There are three main steps to installing the TruckWeigh® system:
• Junction box installation. This must be installed on the chassis of the vehicle. It must be located in
an appropriate position between the suspension systems and the cab of the vehicle. The internal
domain cable must be routed to each sensor position.
• Sensor installation. The type of sensors you install will depend on the suspension systems in
operation on the vehicle. Air pressure transducers are installed on air suspension systems. Axle
transducers are installed on steel axle suspension systems. The sensors must be installed in an
appropriate position on the suspension system and linked to the junction box with the internal
domain cables.
• Install the display unit. The display unit must be installed in the cab of the vehicle. It must be linked
to the junction box with the external domain cable and connected to the vehicles power supply. See
“How to install the display unit” on page 37.
It is recommended that the junction box is installed rst, followed by the sensors and the display
unit. However, these steps can be performed in any order.
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Typical system schematics
Below are two examples of system schematics showing where junction boxes and transducers are tted
in relation to the vehicle.
These are two example schematics, but a variety of congurations may be used.
A single junction box is required for a single chassis. Rigid vehicles will only require one junction
box. Articulated vehicles will require a junction box for the tractor and a junction box for every
trailer
Articulated vehicle
Leaf
Spring
Leaf
Spring
Leaf
Spring
Air
Spring
Air
Spring
Air
Spring
Truck Air
System
Truck Air
System
TruckWeigh®
Display unit
Junction Box and Axle Transducers Junction Box and Air
Transducers
Suspension Air Bags
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