V400 SERVICE MANUAL - Vulcan On
Contents
1. NE CHECK OUT BOX Z a O LOAD CELL LOAD CELL Leakage Test Specifications Measured between any pin and an unpainted clean surface of the load cell or connector body Electrical Isolation should not be greater than 2 0 nS or less than 500 Meg Ohms Figure 6 B Leakage Test If the load cell cannot be brought to Vulcan specifications contact your Vulcan dealer January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 6 33 6 2 2 TARE TEST PROCEDURE Required Equipment Vulcan V200 Meter Isopropyl Alcohol Cotton Swabs O rings Hair Dryer Channel Lock Pliers Checks each load cell for a high Preload Number caused by mechanical damage or moisture 1 Park the empty truck on level ground 2 Use the Cycle button to lock the meter on Channel A or B where the load cells will be tested k Record the current Tare Weight Current Tare Weight 4 Press and hold the Tare button Use the Up or Down Arrow buttons to change the display to read zero 9 Press and hold the Cal button Write down the current Cal Number Current Cal Number Then change the Cal Number using the Up or Down Arrow buttons to display 2050 January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 34 CHAPTER 6 6 Clean and re connect each load cell to the V2. 4 Lock meter on Channel B using the Cycle button to display Tare Weight If displayed Tare Weight matches 400 Ib Channel B Tare Weight originally set into meter you have successfully calibrated this channel If displayed Tare Weight does not match 100 Ib Channel B Tare Weight originally set into meter continue to fine tune the calibration by repeating the process beginning at section 4 3 5 IMPORTANT Leave the meter on for a minimum of 3 minutes after changing the Tare or Cal Numbers so the new values will be recorded into permanent memory Starting the truck turning the ignition switch during this time will cause the meter to reset and return to a previous settings January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 4 19 4 5 KEEPING RECORDS 1 Lock meter on Channel A using Cycle button 2 Read displayed Tare Weight shown on meter display write below 3 Press and hold the Cal button to display Cal Number write below 4 Lock meter on Channel B using the Cycle button 5 Read displayed Tare Weight shown on meter display write below 6 Press and hold Cal button to display Cal Number write below CALIBRATION NUMBERS OUICK REFERENCE Channel A Tare Number Final Channel A Cal Number Channel B Tare Number Final Channel B Cal Number Most Important e Adjust the Tare Number only when empty e Adjust the Cal Number only when loaded
3. January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 20 CHAPTER 4 January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 5 21 CHAPTER 5 0 MAINTENANCE In order to keep any system functioning properly it is important that the system be properly maintained This includes daily vehicle inspections and preventive maintenance 5 1 DRIVER S DAILY VEHICLE INSPECTION 1 Check load cells mounting brackets and fasteners Make sure they are secure 2 If torque stripes have been applied make sure they are properly aligned To apply a torque stripe Use a durable brightly colored paint Paint a stripe crossing the head of the fastener continuing down the fastened structure as shown Figure 5 A Painting a Torque Stripe gt Check and remove any build up of mud ice or other debris that may obstruct the load cell load path Refer to the drawing below and Section A in Figures 5 C through 5 F January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 22 CHAPTER 5 NO CONTACT ON TOP OF LOAD PATH LOAD PATH LOAD PATH THE MOUNTING m O O LOAD PATH LOAD PATH Figure 5 B Load Path Diagram 4 Check the meter mounting and wiring make sure they are secure 5 Check the green plug attached to the back of the meter Make sure it is secure 6 Check the system Make sure t
4. change 8 IMPORTANT Leave the meter on for a minimum of 3 minutes after changing the Cal Numbers so the new values will be recorded into permanent memory Starting the truck or turning the ignition switch during this time will cause the meter to reset and go back to a previous setting 4 2 PROCEDURE FOR ENTERING TARE WEIGHTS GROSS VEHICLE WEIGHT METHOD 1 Weigh the entire empty truck both front and rear axles using a certified platform scale This is the truck s Tare Weight Enter this number in the space provided Tare Weight of Entire Empty Truck 2 Weigh the entire empty trailer all axles This is the trailer s Tare Weight Enter this number in the space provided Tare Weight of Entire Empty Trailer 3 Stop the empty truck and trailer on level ground January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 4 15 4 With the truck empty lock the meter on Channel A using the Cycle button The displayed weight is the Tare Weight Note The truck and trailer must not be in a twist or turn 5 Press and hold the Tare button to display Tare Reference Number Use the Up or Down Arrow buttons to change the value displayed so when the Tare button is released it matches the Empty Truck weight Note When Tare button is held down the number displayed is not the Tare Weight 6 Lock the meter on Channel B using the Cycle button The displayed weight is the Tare Weight 7 Press an
5. compress O ring preventing scale errors which can occur from moisture entering into the load cell connector Caution Do not over tighten the connectors as this can damage them Route orange Vulcoder cable to cab Note On truck to trailer connection these wires may be routed using the existing truck trailer wire harness if two unused ungrounded wires are available Additionally you may follow the existing wire harness and use a separate connector of your choice between the truck and trailer Find suitable location for the meter and install mounting bracket Secure cable so it does not obstruct other in cab equipment strain relief Vulcoder orange cable and cut to length Unplug terminal block from back of meter strip wires and make all wire connections to terminal block refer to Figures 1 E and 1 F Do not plug terminal block into meter at this time Disassemble positive fuse holder red wire Connect fused power leads directly to battery for best operation If not connecting directly to the battery be sure to use a location that has the proper 12 Vdc available at all times refer to Section 7 4 System Specifications January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 1 Note Some trucks are configured with variable voltage supplies never apply more than 16 Vdc to the Vulcan system Apply grease to the positive connector at the battery post to inhibit corr
6. Numbers and Tare Weight 6 3 3 Err 3 Indicates that the meter is not receiving a signal from the Vulcoder or that a very large over range signal is being sent to the meter Possible Causes ly There is usually an open circuit between the meter and Vulcoder This is the most common reason 2 Disconnected or broken green or white Vulcoder wires between the back of the meter and the Vulcoder 3 Faulty Vulcoder or meter 4 Faulty load cell 5 Moisture in the load cell connectors What to Do 1 Check the wires in the green plug at the back of the meter and ensure that they are firmly in place Unplug and plug the connector back in the meter to check for proper connection 2 Check the voltage at the back of the meter and Vulcoder Make sure the voltages match the required voltages in Section 7 4 System Specifications 3 Check the orange cable for broken wires January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 6 A 4 Check the voltage at the load cell connector Refer to the reguired load cell voltages in Section 7 4 System Specifications Repair or replace the Vulcoder as necessary 5 Disconnect one load cell and then the other to see if this clears the error code If the error code is cleared the load cell may be faulty Conduct all three load cell tests Leakage Tare and Resistance refer to Sections 6 2 1 through 6 2 3 6 Replace the O rin
7. Procedure 27 5 3 2 Re Assemble Procedure 28 January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 2 CONTENTS 6 0 TROUBLESHOOTING ee Ree Eege 29 6 1 Vulcan Check Out EE 30 6 2 Load Cell Evaluation Tests 31 6 2 1 Leakage Test Procedure ENEE 31 6 22 Tare Test EES 33 6 2 3 Resistance Test Procedure nn nine 35 6 2 4 Vulcoder Check Out Procedure A 36 6 3 W200 Meter ee 36 SG M eg eve We be Wee O UP Ure Wr BP URED O Sr Sr ent O O O O Sry erty were 37 Gee aE A ZR OR O O OKR OR O TORO RO OR RO O O OR O R SOV O OR O 38 B3032 Ell EE 38 0 04 e EE 39 pcs amy ald to EE 39 63 6 END Gi zo u K a V S A EO yl B LN 39 GE E rie ele EE A0 6 4 1 No Indicator Display Or Functioning Lobts 40 6 4 2 Unable To Enter Tare Or Calibration Numbers 41 6 4 3 Meter Reading Drifts Or Wanders With Time ee 42 6 4 4 Meter Reading Does Not Change When Truck Is Being Loaded 44 6 5 Troubleshooting Worksheet Ae 45 6 6 Troubleshooting Assistance And Replacement Parts 47 7 0 APPENDIX 33s ek oz oouna ddgessiescntancesidevtceesdeveded sce mins nt eee had aa EK KA 48 7 1 Starting Calibration Tute 49 7 2 Identify V200 Vulcoders 50 7 3 Fine Tuning Your Scale System E 51 7 4 System Specifications EE 53 January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 1 es CHAPTER 1 0 VULCAN V200 ON BOARD SCALE SYSTEM Vul
8. Use 3 amp fast blow fuses only 3 Check that the power supply wires are attached correctly at the 12 Vdc power source and to the green connector at the back of the meter Check the battery connections for corrosion 4 If a spare meter is available the quickest and easiest next step is to change the meter If the new meter works try the old meter again If the old meter now works the problem was likely the meter s internal circuit breaker If both the old meter and the new meter do not work the problem is most likely in the power source battery meter power cable or fuses If the new meter works but the old one does not the old meter is faulty January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 6 41 If you do not have a spare meter disconnect then reconnect the green power plug on the back of the meter If the meter does not work then check the power source battery meter power cable or fuses If the power sources check out then the meter is faulty 6 4 2 Unable To Enter Tare or Calibration Numbers Possible Causes 1 Meter may have dirty button connections 2 Faulty buttons What to Do 1 Check to see if any buttons are defective You need to be on Channel A or B but not A B A Press and hold Tare button to display Tare Reference Number If it does not then the Tare button is faulty Refer to the maintenance section 5 3 page 27 B Press the Up b
9. any reason you must clean the load cell connector and cable connector with cotton swabs and isopropyl alcohol dry with a hair dryer DO NOT OVERHEAT and replace the O ring before reconnecting 3 Check the torque on load cell cap screws monthly New trucks must be checked once a week for 2 weeks Vulcan On Board Scales recommended torque values are shown on Figures 5 C through 5 F and general torque values shown below As a method of monitoring changes in fastener torque Vulcan On Board Scales recommends applying torque stripes to all fasteners see Section 5 1 step 2 Torque Specifications 5 8 3 4 7 8 1 1 1 8 lb ft 210 240 400 500 400 590 650 890 1000 1400 January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 24 CHAPTER 5 4 Vulcan load cells are plated for increased rust protection Certain minimum maintenance will be necessary to claim warranty of load cells Annually apply a high quality paint to the load cells bearing pads and mounting brackets For environments where high concentrations of salts are used on road surfaces undercoating is recommended 3M Universal Rubberized Undercoating 3M P N 8883 Spray undercoating when load cells are connected to electronics and fully assembled with bearing pads and brackets See Vulcan Load Cell Maintenance document 44 20006 001 for further details 5 Fill unused holes in load cells with grease to protect against rust Never grea
10. mechanical work or maintenance done to the vehicle changed bridge beam bunk etc Has there been any electrical work or maintenance done to the vehicle battery work generator alternator problems added accessories jump start Has there been any recent maintenance of the scale system parts exchanged etc Has anything else happened to the rig such as an accident SYMPTOMS Does the problem occur on Channel A or B or both Does the meter drift up and or down fast or slow or both Is the problem intermittent constant or both Does problem occur on flat road or off road or both January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 46 CHAPTER 6 Does it occur in wet or dry weather or both Does it occur at morning at night or both Does it occur when empty loaded or both INSPECTION Has the same platform scale been used to check scale accuracy Is the power cable connected directly to the battery Have you checked fuses in both power and ground wires Are you using Vulcan yellow fuse holders Are you using Vulcan orange cable or trailer light cable Is there mud or ice build up between the load cell pads and vehicle frame Is there any contact on top of the load cell mounting cap screw heads January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 6 47 6 6 TROUBLESHOOTING ASSISTANCE AND REPLACEMENT PARTS If y
11. 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 50 CHAPTER 7 7 2 IDENTIFY V200 VULCODERS The Vulcoder s Serial number is stamped on the case Use the serial number to identify its part number Use the table in Section 7 1 to find the starting calibration number for each channel Example Vulcoder serial number 96451C used with Tandem Center Hanger load cells in the Ibs mode Vulcoder part number would be V04 Calibration number for that Channel would be 3900 SERIAL NUMBER PART NUMBER RANGE 1 mv V 2 mv V 3mv V 7 pin use Cal Number of 6150 2790 January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 7 51 7 3 FINE TUNING YOUR SCALE SYSTEM 1 Using the Cycle button lock the meter on Channel A B and be sure that Tare is not flashing 2 Fine tuning Complete a row of information each time using the same certified scale Do this six times filling in rows 1 through 6 Channel A Cal Number 2050 Channel B Cal Number 2050 3 When you have entered six certified scale weights call Vulcan Customer Service at 1 800 237 0022 to determine your fine tuned Cal numbers Enter the new Cal numbers in the meter Channel A New Cal Number Channel B New Cal Number 4 Confirmation Complete a row of information for six more certified scale weights January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 4
12. 4 10015 001 Rev A STRESS TEK INC 52 CHAPTER 7 X Call Vulcan Customer Service again at 1 800 237 0022 to confirm the system calibration Final Calibration Channel A Cal Number Final Calibration Channel B Cal Number Final Calibration Numbers set Date January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 7 D3 7 4 SYSTEM SPECIFICATIONS Load Cells Electrical Connector Voltage Reguired Material Operating Temp System Accuracy Vulcoder Environment Operating Temp 4 Wire Cable Black 2 Wire Cable Orange Connectors Voltage Input Required Voltage Output Required Signal Input Range Meter Display Cycle Speed Graduation Display Range Voltage Required Current Draw Protection Hookup Operating Temp Weight Installation January 2004 350 Ohms nominal impedance 4 pin bulkhead military type 7 5 5 Vdc High grade alloy steel 40 to 140 degrees F Typical error less than 1 Full Scale of actual weight for operating temperature range and normal loading conditions Environmentally sealed electronics 40 to 180 degrees F Custom shielded 4 conductor polyurethane jacket with drain wire 5 ft lengths standard Custom polyurethane jacket 45 ft length 4 pin military type 12 3 to 16 0 Vdc 7 5 5 Vdc 1 to 3 mV V Automatically backlit liquid crystal display Variable cycle s
13. CONTENTS tt V200 SERVICE MANUAL Table of Contents 1 0 VULCAN V200 ON BOARD SCALE SYSTEM REESEN 3 1 1 Load Cells And Pressure Sensors ssneseeeeseesnernrrresserenrnnnnnnsserernrnnnnnenserennne 4 Wee EV 0016 TEE E A A E ee caren 5 137 EE 5 1 4 Electronic nstalatoN eege ee 7 2 0 METER OPERATION an ki mena on OOo aan k o tr nt 9 2 1 Turning The Meter ONE Stiet eet det AE o ooo chads 9 2 2 Locking The Meter On A Particular Channel ssssssesseeseseeennnnnnnesseerenrnnnnrnsseernne 9 2 3 Displaying Tare WN Ee EE 9 2 4 Displaying Calibration Numbers 9 3 0 WEIGHT MEASURING METHODS eeee nene nene nenene en ena n eee nen AAA KAM AKA NAKA MAE 11 3 1 Gross Vehicle Weight 5x53 as A a ota a ota Ca A iat s as ota on 11 3 2 Net Payload Melde Seed ee edd ts edd er 11 4 0 CALIBRATION AND SYSTEM SET UP seen 13 4 1 Procedure For Entering Starting Calibration Numbers 13 4 2 Procedure For Entering Tare Weights AEN 14 4 3 Calibration Procedure For Gross Vehicle Weight Meibodes 16 4 4 Verifying Tare Weights 33 coe scr recs sn erred san ca iets deve vedencdhycdevndyet acres 17 4 5 Keeping Records a care he aneta ad oka ee fag Roda ddd ee een 19 5 0 MAINTENANCE S cccccaccceeseuteceecetecatenabecscenndowbeeseecteccncneteedaanecccesd 21 5 1 Drivers Daily Vehicle Inspection et du 21 5 2 Preventive Maintenance And Vulcan Torque Specifications 23 5 3 Meter Button Replacement And Ceanmg eee 27 5 3 1 Disassemble
14. DISASSEMBLE PROCEDURE 1 First remove meter from truck 2 Remove defective or dirty button using a small screwdriver Place the blade under the lip of the button and gently pry up Note It is not necessary to disassemble meter to remove buttons 3 Lift out metal dome switch from switch base as shown in Figure 5 G Caution Care must be taken not to drop the switch dome inside the meter If the switch dome does get inside it will have to be removed before the meter is plugged into the power source 4 Clean out any dirt that may be in the switch base Clean the center contact This can be done by lightly scraping or by using a pencil eraser January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 28 CHAPTER 5 5 3 2 RE ASSEMBLE PROCEDURE 1 Place the silver and gold switch dome in the switch base with the gold side towards the meter and the silver raised dome facing out 2 Snap the new plastic button into position by using a small screwdriver place the blade against the lip of the button and gently press in The taper surface face needs to be installed as shown in Figure 5 G 3 Re install the meter turn it on an check the function of the buttons NOTE If button starts sticking disassemble the switch as described Clean both the center contact in the base and switch dome Re assemble January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK
15. INC CHAPTER 6 A CHAPTER 6 0 TROUBLESHOOTING In general troubleshooting is a systematic process of testing and eliminating potential problem sources until the one that is causing the problem is found The problem can then be fixed by repairing or replacing the faulty part With a little knowledge and by following a step by step procedure most of the problems that you may encounter will be easy to diagnose and cure In this section you will find guidelines on how to troubleshoot the system some characteristics of a properly functioning system and where to look when certain problems occur Occasionally someone has a problem that is not described here Do not panic By approaching the problem systematically you will be able to eliminate potential sources of trouble until you find the one that is causing the problem The following section covers an explanation of Load Cell Evaluation Test Procedures and Vulcan Error Codes If a problem occurs and no Error Codes appear use the V200 Meter to isolate the problem to either Channel A or B January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 30 CHAPTER 6 6 1 VULCAN CHECK OUT BOX The Vulcan Check Out Box works as an extension to bring connector pins to the side of truck where readings can be conveniently made and it can also simulate an applied load to the Vulcoder The Check Out Box is required equipment for the Vulcoder Check Out
16. Procedure Section 6 2 4 and is an optional equipment item for the Leakage and Resistance Tests Section 6 2 1 and 6 2 3 Before using the Check Out Box make sure the meter fuses are good Use a multi meter to ensure there is a minimum of 12 Vdc at the back of the meter Make sure the green plug is plugged in and the meter is turned on If there are any error messages displayed refer to Section 6 3 V200 Meter Error Codes O ge H 99 CONNECTOR oo NZ TO VULCODER OFF ON LOAD SWITCH 04 RED DOT WHITE BLACK CHECK OUT o PI RED BOX CONNECTOR TO LOAD CELL CABLE gt 4 FEET Figure 6 A Vulcan Check Out Box To order a Check Out Box P N 56 10425 001 contact your Vulcan dealer January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 6 31 6 2 LOAD CELL EVALUATION TESTS The tests listed below will help identify and locate any problem you may encounter with your Vulcan Scale System Leakage Test Tare Test Resistance Test Vulcoder Check Out Test 6 2 1 LEAKAGE TEST PROCEDURE Required Equipment Multi meter Isopropyl Alcohol Cotton Swabs Hair Dryer Optional Equipment Vulcan Check Out Box The Leakage Test Procedure detects the presence of moisture that could cause erratic meter readings The way to measure leakage is to use a digital multi meter that has a conductivity scale Electrical isolation is mea
17. ather shear web Weld down resistant elastomer measures bearing pad weight change Figure 1 B Vulcan Super Beam Load Cell Covered by one or more of the following patents US Patent RE 35 301 4 459 863 Canadian Patent 1 245 677 January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 1 1 2 VULCODERS The primary functions of the Vulcoder are to supply the load cells with power and to relay the load cells output to the meter The Vulcoder receives a 12 Vdc input from the meter and supplies the load cells with 7 5 Vdc 5 Vdc When weight is applied the voltage output of the load cells change The Vulcoder then reads the change in voltage from the load cells and converts it from an analog to a digital signal This signal is then relayed to the meter and displayed as weight 12 Vdc 1 3 METER WEIGHT Lb Kg V200 METER Figure 1 C Vulcan Electronics Diagram 12 Vdc 7 5 Vdc 5 Vdc ANALOG DIGITAL OUTPUT E CONVERTER mV V ANALOG LOAD CELLS DIGITAL VULCODER SIGNAL The V200 meter s primary functions are to supply the Vulcoder with 12 Vdc and to read the digital signal transmitted from the Vulcoder The meter reads the digital signal makes calculations and displays a weight in pounds or kilograms The V200 meter is shown on the following page together with a description of the meter b
18. can On Board Scales are installed on all types of vehicles including hook lifts logging trucks flatbed trailers chip trailers and many other commercial vehicles requiring scales Total truck payload weights and gross vehicle weights can be measured using the Vulcan On Board Scale System Typically a scale system has either four or six load cells two Vulcoders and one meter per truck The number of load cells required depends on the truck s length and the load capacity Vulcan Scale System Load Cells Vulcoders Meter Figure 1 A Typical Long Logger System January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 4 CHAPTER 1 1 1 LOAD CELLS Vulcan load cells and pressure sensors are machined from solid blocks of high strength steel The Strain gages are bonded inside the load cell or pressure sensor to sense extremely small dimensional changes in the material A strain gage is a precision electrical resistance element When force is applied to these sensors the strain gages stretch or compress causing a change in output signal voltage Example Vulcan Super Beam Load Cell Calibration Circuit All wiring is routed internally through long holes drilled from each end of the load cell Shear section provides maximum strength and high accuracy Environmentally sealed connector All internal cavities Strain gage are sealed with a bonded to chemical and we
19. d hold the Tare button to display Tare Reference Number Use the Up or Down Arrow buttons to change the value displayed so when the Tare button is released it matches the Empty Trailer Weight Note When Tare button is held down the number displayed is not the Tare Weight 8 IMPORTANT Leave the meter on for a minimum of 3 minutes after changing the Tare Weight so the new values will be recorded into permanent memory Starting the truck turning the ignition switch during this time will cause the meter to reset and return to a previous setting January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 16 4 3 CHAPTER 4 CALIBRATION PROCEDURE FOR GROSS VEHICLE WEIGHT METHODS Fully load the truck close to the legal limit Weigh the loaded truck and then the loaded trailer using same certified scale write them here a Channel A Loaded Weight Loaded truck b Channel B Loaded Weight Loaded trailer Park on level ground Lock meter on Channel A using the Cycle button to display weight If displayed weight does not match Channel A Loaded Weight in Step 2 correct as follows a Press and hold Cal button down to display Cal Number b Use the Up or Down button to increase or decrease the Cal Number until the value displayed when the Cal button is released matches Channel A loaded truck weight above Lock meter on Channel B using the Cycle button to display weight If disp
20. de definitions possible causes and procedures to correct the system malfunction 6 3 1 Err 1 Indicates that the Vulcoder is processing an over ranged signal An over ranged signal means that the load cell output is greater than the maximum that the Vulcoder will accept Err 1 is displayed briefly when the meter is first turned on and clears after the meter and Vulcoder get in synch Possible Causes 1 The load cells are being over loaded 2 There is moisture in a load cell connector 3 One of the Vulcoder to load cell cables has been damaged 4 A load cell is faulty S A load cell has a large Preload Number What to Do 1 Check and verify that the Cal Number is reasonable Refer to Section 7 1 Starting Calibration Numbers 2 Perform Tare Test refer to Section 6 2 2 3 Check the load cells Check by disconnecting one load cell at a time When the faulty load cell has been disconnected the meter will read a number instead of the error code 4 Check mounting of the load cell per Section 5 2 Preventative Maintenance and Vulcan Torque Specifications Figures 5 C to 5 F January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 38 CHAPTER 6 6 3 2 Err 2 Indicates that the reading to be displayed is beyond the limitations of the meter s display Possible Causes l Cal Number set too high 2 Tare Weight set too high What to Do 1 Check and reset Cal
21. efer to Section 6 2 4 Vulcoder Check Out Procedure If four load cells are connected per Vulcoder follow steps 5c and 5f January 2004 For Vulcoders with 4 load cells disconnect the cables to all the load cells except the right front load cell Watch the meter display a number for a period of 5 minutes If it wanders more than 200 1b 100 kg make a note of it Disconnect right front load cell and reconnect right rear load cell Watch the meter display for 5 minutes If it wanders more than 200 lb 100 kg make a note of it Disconnect the right rear load cell and reconnect the left rear load cell Watch the meter display for 5 minutes If it wanders more than 200 Ib 100 kg make a note of it Disconnect the left rear load cell and reconnect the left front load cell Watch the meter display for 5 minutes If it wanders more than 200 Ib 100 kg make a note of it VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 44 CHAPTER 6 If any one of the load cells wanders more than 200 1b 100 kg perform the Leakage and Resistance tests refer to Sections 6 2 1 and 6 2 3 If all of the load cells wander more than 200 1b 100 kg then the Vulcoder is faulty and needs to be checked refer to Section 6 2 4 Vulcoder Check Out Procedure 6 4 4 Meter Reading Does Not Change When Truck Is Being Loaded Possible Causes 1 Voltage to meter is below 12 3 Vdc 2 Mud or ice bu
22. gs clean the connector with isopropyl alcohol and dry with a hair dryer Reconnect the load cells 6 3 4 Err 4 Same as Err 1 6 3 5 Err 5 This error code is not used 6 3 6 Err 6 Indicates a malfunctioning Vulcoder circuit Err 6 may also appear briefly as an over ranged signal comes within range Possible Causes 1 Moisture problem at load cell connector 22 Faulty Vulcoder What To Do 1 Perform checks on page 38 section 6 4 3 Note When both load cells are disconnected from the Vulcoder the meter does not necessarily display an error message Often the meter will display a steady number e g 79100 or it may display a number that jumps around January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 40 CHAPTER 6 6 4 SYSTEM MALFUNCTIONS 6 4 1 No Indicator Display or Functioning Lights Possible Causes 1 Power switch turned off E Power to the meter has been disconnected 3 Bad meter cable connections to the battery 4 Battery is low under 11 Volts 5 A fuse is blown in the power or ground cable 6 Meter s internal circuit breaker is blown T7 Faulty power switch 8 Faulty meter 9 Reversed polarity What to Do 1 Check the power to the meter When the meter is turned on and off the power must not change more than 5 Vdc If the meter still does not work proceed to step 2 2 Check the fuses for both negative and positive leads
23. he meter powers up after it has been turned on digits are legible and the system functions normally T Check all wiring for condition no cracks or splits security chaffing and protection from possible damage January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 5 A 5 2 PREVENTIVE MAINTENANCE AND VULCAN TORQUE SPECIFICATIONS The following simple but important preventive maintenance steps must be performed periodically after 500 miles monthly afterwards or more frequently if needed 1 Look for mud ice buildup or other debris between the load cell and bracket Refer to location A shown on Figures 5 C through 5 F 2 Check load cell connectors refer to location B shown on Figures 5 C through 5 F make sure they are finger tight plus an additional 1 8 of a turn with channel lock pliers The additional tightening is necessary to prevent scale errors which can occur from moisture entering into the load cell connector Do not grease or lubricate inside the Vulcan load cell connector or Vulcoder connector These components are highly sensitive to foreign substances and inaccurate readings will occur if these components are contaminated Your manufacturer s warranty does not cover the failure of Vulcan components due to contamination use of grease or other conductive substance in either the Vulcan load cell connectors or Vulcoder connectors If a connector is opened for
24. ild up under the load cells 3 Calibration Number on the meter is set too low 4 Faulty load cell 5 Broken wire or bad connection between the load cell and Vulcoder What to Do 1 Using a voltmeter check the power at the meter s green plug at the back of the meter Refer to Section 7 4 System Specifications If the voltage is below 12 Vdc the problem could be in the power source battery meter power cable and or fuses 2 Reset the meter by unplugging the green connection on the back of the meter for a few seconds 3 Refer to Section 7 1 Starting Calibration Numbers to verify that the Cal Number is within range 4 Check the black cables between the load cells and the Vulcoder If the cabling is damaged the Vulcoder needs to be repaired or replaced Contact your Vulcan dealer 5 Perform the Leakage Tare and Resistance Tests refer to Sections 6 2 1 through 6 2 3 January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 6 o B 6 5 TROUBLESHOOTING WORKSHEET Briefly describe your problem Do you have Vulcan electronics If not whose Do you have all Vulcan load cells If not whose Channel A load cells If not whose Channel B load cells HISTORY Were the scales put on a new vehicle or were they retrofitted How long have you had this system Has the system ever worked How long has the current driver been using the vehicle Has there been any
25. layed weight does not match Channel B Loaded Weight in Step 2 correct as follows a Press and hold Cal button down to display Cal Number b Use the Up or Down button to increase or decrease the Cal Number until the value displayed when the Cal button is released matches Channel B loaded truck weight above January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 4 17 V200 WEIGHT Mal 5000 Lo EEE PLATFORM SCALE Figure 4 A Truck Gross Weight Channel A in Relation to a Certified Platform Scale With in 1 of gross vehicle weight It is common for operators to calibrate better than 1 If additional assistance is needed to fine tune your scale system please follow the instructions shown in Section 7 3 Fine Tuning Your Scale System 4 4 VERIFYING TARE WEIGHTS 1 Unload truck 2 Park on level ground 3 Lock meter on Channel A using the Cycle button to display Tare Weight If displayed Tare Weight matches 400 1b Channel A Tare Weight originally set into meter you have successfully calibrated this channel Go to Step 4 If displayed Tare Weight does not match 400 Ib Channel A Tare Weight originally set into meter continue to fine tune the calibration by repeating the process beginning at Section 4 3 January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 18 CHAPTER 4
26. ls from Vulcoder on the channel being tested While depressing the Tare button use the Up or Down Arrow buttons to make the display read zero The display must read zero while the Tare button is depressed Release the Tare button With all load cells disconnected on the channel being tested plug a Vulcoder lead into the Check Out Box load switch OFF The meter display must read zero 200 Ib If the Tare Reference Number is not zeroed the cabling is damaged Move the load switch to ONT indicted by the red dot The V200 meter must display 38 200 Ib 200 Ib Check all leads If any Vulcoder lead does not perform as stated above the black Vulcoder cable is damaged and must be inspected and repaired If all Vulcoder leads do not perform as stated above all have been damaged or the Vulcoder needs to be replaced Contact your Vulcan dealer for repair or replacement of damaged Vulcoder lead 6 3 V200 METER ERROR CODES The V200 Meter is equipped with a self diagnostic program Should a malfunction occur the meter will display an error code This error code can be used to isolate and identify a problem with the Vulcan Scale System If an error code is displayed on the screen while the meter is locked on Channel A B use the Cycle button to isolate the problem to either Channel A or Channel B January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 6 A Listed below are the error co
27. nuous questionable readings or if meter readings repeatably do not closely match the certified platform scale weights The Vulcan Scale System can be calibrated for Gross Vehicle Weight and Net Payload Weight The Net Payload Weight displays only the weight of the payload and the Gross Vehicle Weight displays the weight of both the truck and its payload 4 1 PROCEDURE FOR ENTERING STARTING CALIBRATION NUMBERS 1 Stop the empty truck on level ground 2 Turn on the meter Wait for system initialization 3 Look up Cal Numbers for Channel A and B in Section 7 1 Starting Calibration Numbers and write them in the space provided below Starting Channel A Cal Number Starting Channel B Cal Number 4 Lock meter on Channel A using the Cycle button January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 14 CHAPTER 4 5 Press and hold Cal button to display Cal Number setting If setting does not match starting Channel A Cal Number in Step 3 correct the Cal Number with the Up or Down Arrow buttons Note Holding down the Up or Down Arrow buttons will accelerate the number change 6 Lock the meter on Channel B using the Cycle button T7 Press and hold Cal button to display Cal Number setting If setting does not match starting Channel B Cal Number in Step 3 correct the Cal Number with the Up or Down Arrow buttons Note Holding down the Up or Down Arrow buttons will accelerate the number
28. of the Vulcoder connector If it measures less than 7 5 Vdc 5 Vdc make sure the Vulcoder cable is securely attached to the meter green plug and the length of the orange cable from the Vulcoder to the meter is not longer than 100 ft Also check any truck trailer connectors in the Vulcoder signal cable 4 Before proceeding clean the load cell connector and cable connector with isopropyl alcohol and cotton swabs then dry with a hair dryer Do not overheat Reconnect and operate system for one day to see if the problem is fixed If the problem is not fixed continue to step 5 January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 6 43 5 If two load cells are connected per Vulcoder follow steps 5a and 5b Disconnect the cable to the right load cell Watch the meter display the number for a period of 5 minutes If it wanders more than 200 Ib 100 kg make a note of it Then clean and reconnect the right load cell Disconnect the cable to the left load cell Watch the meter display the number for period of 5 minutes If it wanders more than 200 Ib 100 kg make a note of it Then clean and reconnect the left load cell If any one of the load cells wanders more than 200 1b 100 kg perform the Leakage and Resistance tests refer to Sections 6 2 1 and 6 2 3 If both of the load cells wander more than 200 Ib 100 kg then the Vulcoder is faulty and needs to be checked r
29. or a Vulcan Check Out Box Refer to acceptable resistance ranges as shown below OR u MULTI METER e MULTI METER 00 Doo O O J WHITE BLACK goo 2 GREEN RED E Q oj CHECK OUT BOX LOAD CELL o ON n LOAD CELL Figure 6 C Resistance Test Pins Terminal Acceptable Color Code Resistance Range AtoD Red to Black 349 to 400 Ohms BtoC Green to White 349 to 352 Ohms Pin B Green to Pin A Red should be the same number as Pin B Green to Pin D Black within 1 Ohm Pin C White to Pin A Red should be the same number as Pin C White to Pin D Black within 1 Ohm If the load cell cannot be brought to Vulcan specifications contact your Vulcan dealer January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 36 CHAPTER 6 6 2 4 VULCODER CHECK OUT PROCEDURE Reguired Eguipment Vulcan V200 Meter Vulcan Check Out Box Using the Cycle button lock the meter on the Channel that the Vulcoder will be tested on either Channel A or B Refer to section 7 2 to identify V200 Vulcoders Set the Calibration Number to 2050 on the channel being tested for 2 mV V Vulcoders set to 4100 for 3 mV V Vulcoders set to 6150 Set the Tare Reference Number for that channel to zero using the following procedure Disconnect all load cel
30. osion Review steps to 7 before connecting terminal block to back of meter STRIPPING WIRES FOR METER 1 4 TWIST TIGHTLY DO NOT SOLDER Be careful that stray wires DO NOT contact adjacent terminals Figure 1 E Stripping Wires for Meter Stress Tek Inc Renton WA ul H CT mu device pursuant to Subpart J of Part 15 of FCC ules mg m Caution Use only 3 amp fuse in both power leads O V200 METER BACK VIEW Ki VULCODER CABLE ORANGE CABLE POWER CABLE GREY Figure 1 F Wire Connections to Meter January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 2 CHAPTER 2 0 METER OPERATION 2 1 2 2 2 3 2 4 TURNING THE METER ON This can be done by pressing the Power button on the meter LOCKING THE METER ON A PARTICULAR CHANNEL To lock the meter on a particular channel press the Cycle button until the channel light is displayed Press the Cycle button again the meter is now locked on a specific channel Channel Designations for Figures 2 A and 2 B Channel A Represents the truck or front load cells regardless of whether it is a four or a six cell configuration Channel B Represents the trailer or rear load cells Channel A B Represents the total weight from the front and rear load cells DISPLAYING TARE WEIGHT Lock the meter on Channel A or B The Tare Weight is the displayed reading when the vehicle is empty For setting the Tare Weight refer to Chap
31. ou need additional assistance parts or service give us a call at VULCAN CUSTOMER SERVICE 1 800 237 0022 HOURS 7 30 a m 5 00 p m PACIFIC TIME January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 7 CHAPTER APPENDIX January 2004 Ts 0 VULCAN ON BOARD SCALES 1 800 237 0022 STRESS TEK INC 48 Doc 44 10015 001 Rev A CHAPTER 7 49 7 1 STARTING CALIBRATION NUMBERS LOAD CELL VULCODER ES Fee p a Kg 15 SUPER BEAM E L02 ETS ET wann ETS 15 SUPER BEAM IN MODULAR CENTER L01 L02 2050 930 4100 1860 6150 2790 2050 930 HANGER 17 SHEAR BEAM L03 SINGLE POINT 2100 955n r 4200 1910 6300 2865 2100 955 26 SUPER BEAM L08 L09 2050 930 4100 1860 6150 2790 2050 930 L18 L19 26 HEAVY DUTY L11 3075 1395n r 6150 2790 9225 4185 3075 1395 SUPER BEAM 19 FIFTH WHEEL L04 LOS 2050 930n r 4100 1860 6150 2790 N R L31 AIR SENSOR L20 L21 6150 2790 6150 2790 6150 2790 61502790 28 SHEAR BEAM L27 3650 1660n r 7300 3320 N R N R EXTRA HD 4 TRUNNION L32 L33 N R N R N R 8200 LOAD CELL Factory recommended Vulcoder for this load cell n r Not recommended for this load cell NOTES 1 Final Cal Number should be within 200 counts of Starting Cal Number If not troubleshoot the system for possible mechanical or electrical problem 2 Vulcoder Stock No V02 Designed for 7 Pin Connectors use Cal Number 6150 January
32. peed 1 9 seconds 100 Ib increments in Ib mode 50 kg in kg mode 99 900 to 320 000 Ib or kg 12 5 to 16 0 Vdc 150 mA to 350 mA Internal reverse polarity and external 3 amp quick blow fuses Screw type quick release terminal block on rear panel 20 to 160 degrees F 17 oz including bracket Power cables fuses mounting bracket and thumb screws provided VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 54 CHAPTER 7 NOTES January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC
33. se the inside of the connector 6 Check welds on load cell brackets IMPORTANT If a weld repair is required either remove the load cell or do not exceed 140 degrees Fahrenheit 60 degrees Celsius on the load cell Arcing on the body of the load cell may seriously damage the load cell s structural integrity and must NOT be installed if this occurs This also voids the manufacturer s warranty 7 Check all wiring for condition routing and protection 8 Check meter for secure mounting and strain relief of wires 9 Check system for functionality 10 Review and address any driver concerns January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 5 E Typical Western Logger Mounting 650 890 lb ft Figure 5 C Typical Hutch or Transpro Center Hanger Mounting 480 500 Ib ft Torque arm 300 350 lb ft Figure 5 D January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 26 CHAPTER 5 Typical Single Point Mounting INBOARD 1 000 1 400 LB FT 2 PLACES 210 240 LB FT 6 PLACES Figure 5 E Typical Holland 5th Wheel Mounting 1 000 1 400 LB FT 4 PLACES Figure 5 F January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 5 27 5 3 METER BUTTON REPLACEMENT AND CLEANING Switch Dome Silver Side Out Switch Button Figure 5 G 5 3 1
34. sured between any pin and an unpainted clean surface on the load cell or the connector body Electrical isolation must not exceed 2 0 nS nano siemans or be less than 500 Meg Ohms Refer to Figure 6 B for the Leakage Test equipment set up If a Vulcan Check Out Box is used it is important that the Vulcoder leads from the load cells of the channel being tested are disconnected For proper operation the power and signal leads from the load cell must have a very high resistance to the load cell body An electrical path between the wires and the body would indicate moisture in the cell or shorting to the body This would result in erratic fluctuating or even out of range weight displays If the load cell fails electrical isolation is greater than 2 0 nS or is less that 500 Meg Ohms check the inside of the load cell connector with a dry cotton swab to make sure it is clean and dry If not clean with isopropyl alcohol dry with a hair dryer and check the electrical isolation again January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 32 CHAPTER 6 Caution Do not touch the probes with your hands when making measurements This could cause an error in the meter reading A person s body can have 10 times the allowable conductivity of a load cell MULTI METER mm V d MULTI METER 2000 2000 Q WHITE BLACK ye A GREEN RED o el
35. ter 4 0 Calibration and System Set up DISPLAYING CALIBRATION NUMBERS Lock the meter on Channel A or B Press and hold the Cal button to display the Calibration Number For setting the Calibration Numbers refer to Chapter 4 0 Calibration and System Set up January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 10 CHAPTER 2 LOAD CELL LOAD CELL VULCODER LOAD CELL LOAD CELL CHANNEL A CHANNEL B VULCODER LOAD CELL LOAD CELL LOAD CELL VULCODER VULCODER LOAD CELL LOAD CELL LOAD CELL CHANNEL A CHANNEL B Figures 2 A and 2 B Vulcan 4 and 6 cell configurations January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 3 11 CHAPTER 3 0 WEIGHT MEASURING METHODS The Vulcan Scale System can be used to measure weight by two different methods These methods are Gross Vehicle Weight and Net Payload Weight 3 1 GROSS VEHICLE WEIGHT Gross Vehicle Weight Entire truck weight including fuel equipment personnel and payload In order to use the Gross Vehicle Weight method the Tare Weight for Channel A and Channel B must be entered The Tare Weight is the weight of the empty truck with fuel equipment personnel and no payload For example if the Tare Weight is 30 000 Ib the meter will display this weight before any payload has been loaded As the payload increases the weight displayed on the meter
36. ulcoder one at a time The meter will display the load cell Preload Number The Preload Number should fall between 12 000 to 12 000 counts If the Preload Number exceeds 12 000 to 12 000 counts proceed with steps 6 a to 6 f a Clean the load cell connector and cable connector with cotton swabs and isopropyl alcohol b Dry thoroughly with a hair dryer DO NOT OVERHEAT c Check the electrical isolation by performing the Leakage Test Refer to Section 6 2 1 d Ifa Vulcan Check Out Box is available perform the Vulcoder Check Out Test Refer to Section 6 2 4 e Check the Preload Number again to see if it is within the 12 000 Ib to 12 000 Ib range If the load cell is still out of range it may be faulty Perform the Resistance Test Refer to Section 6 2 3 f Replace the O rings before re connecting 7 Measure the Preload Number of the remaining load cells one at a time 8 Reset the original Cal Number and Tare Weight If the load cell cannot be brought to Vulcan specifications contact your Vulcan dealer January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 6 o K 6 2 3 RESISTANCE TEST PROCEDURE Required Equipment Multi meter Optional Equipment Vulcan Check Out Box Please refer to drawing below in setting up the Resistance Test The resistance in the pins should correspond to the Vulcan specifications listed below This test can be conducted with a multi meter
37. utton The number displayed will increase If it does not then the Up button is faulty Check for a dirty or bad connection Refer to the maintenance section 5 3 page 27 C Press the Down button The number displayed will increase If it does not then check the Down button is faulty Check for a dirty or bad connection Refer to the maintenance section 5 3 page 27 D Press and hold Cal button to display Cal Number If it doesn t then the Cal button is faulty Refer to the maintenance section 5 3 page 27 January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 42 CHAPTER 6 6 4 3 Meter Reading Drifts or Wanders With Time Possible Causes 1 Voltage to meter or Vulcoder is less than 12 3 Vdc X Voltage out of the Vulcoder is less than the voltage output required as stated in Section 7 3 System Specifications 3 Moisture in a load cell connector 4 Damaged cable between Vulcoder and load cell 5 Bad connection on green connector or broken wire or cable between meter and the Vulcoder 6 Faulty load cell What to Do 1 Using a voltmeter check the voltage at the back of the meter Refer to the reguired meter voltages in Section 7 4 System Specifications 2 Check the black 4 wire cabling between the load cells and the Vulcoder If the cabling is damaged contact your Vulcan dealer for Vulcoder repair 3 Measure the voltage between pins A and D
38. utton functions January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 STRESS TEK INC Doc 44 10015 001 Rev A 6 CHAPTER 1 ON FF o stress tek Figure 1 D V200 Meter POWER BUTTON Turns the meter on and off UP DOWN ARROW BUTTONS Used to increase or decrease the Cal Number and Tare Number CYCLE BUTTON Used to view the weight on different channels CAL BUTTON Used to view and adjust the Cal Number for a particular channel TARE BUTTON Used to view and adjust the Tare Weight for a particular channel January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 1 1 4 ELECTRONICS INSTALLATION Tape Vulcoder connectors prior to routing cabling to avoid contamination Mount Vulcoders on inside of truck frame rail or next to a structural member Mounting surface must be in an area protected from road or hauling debris Route black cable to load cells Do not trim black cable to length Important Check connectors to make sure they are clean and dry Turn meter off while making any wire connections Do not get moisture contact cleaner or any other substance inside of connectors Check load cell connector coming from the Vulcoder for O ring Attach black cable connectors to bulkhead connectors on load cells Make sure they are finger tight plus an additional 1 8 of a turn with channel lock pliers The additional tightening is necessary to
39. will also increase The weight displayed on Channel A at all times is the Gross Truck Weight The weight displayed on Channel B at all times is the Gross Trailer Weight and the weight displayed on Channel A Bis the Total Gross Vehicle Weight truck and trailer 3 2 NET PAYLOAD WEIGHT Net Payload Weight Weight of the truck s payload only By using the Net Payload Weight method payload pickups are measured cumulatively Net Payload Weight can be measured when the truck s Tare Weight is set to zero If the Tare Weight for Channel A and Channel B are set to zero the weight displayed at all times during the route is the Net Payload Weight January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC 12 CHAPTER 3 January 2004 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10015 001 Rev A STRESS TEK INC CHAPTER 4 13 CHAPTER 4 0 CALIBRATION AND SYSTEM SET UP Calibration is fine tuning a system to maximum accuracy in reference to a specific certified platform scale It is important to calibrate for high accuracy in order to achieve the maximum possible payload It is also important that conditions remain as constant as possible throughout the calibration process Inaccuracies may result from differences in fuel load ice build up etc It may take 2 or 3 attempts at calibration to achieve the optimum setting Calibration should be done anytime a system is installed if there are conti
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