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V500 SERVICE MANUAL - Vulcan On

1. 46 6 1 1 Entering And Exiting The Test Mode 46 O O CA 47 6 13 Mest ND I e 47 og TEBA In E E 48 6 1 5 48 5 48 BAT ERA ere ne dr EA C eiat eat Cate ER 48 6 2 Vulcan Check Out BOX 49 6 3 Load Cell Evaluation Tests d a eee da ane en ananas die 50 6 3 1 Leakage Test Procedure 44e 50 6 3 2 lare NESE PROCS CUE 51 6 3 3 Resistance Test Procedure sans nina 53 6 4 V500 Meter ETTOFCOGBS eee in 54 GAT Err ee conc cedente cete ecu Decr 54 July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CONTENTS 0341 2 54 As me t 55 OA ABIRE 55 925 NEMO 56 EPS A BEI pt ev er 56 OZE LEO nn ht ind tfe 57 O KT O O 57 pA U JEN OS PRE D ooo honba POS 58 ot mu LOM rc ilt 58 LEN a n AES 59 fade Modem Eaton a 59 BAS 60 6 5 System ee 61 6 5 1 No Indicator Display Or Function Lights 61 6 5 2 Unable To Enter Tare Or Calibration Numbers 62 6 5 3 Meter Reading Drifts Or Wanders With Time 62 6 5 4 Meter Reading Doe
2. If you need additional assistance parts or service give us a call at VULCAN CUSTOMER SERVICE 1 800 237 0022 HOURS 7 30 a m 9 00 p m PACIFIC TIME July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 7 CHAPTER APPENDIX July 2001 7 0 VULCAN ON BOARD SCALES 1 800 237 0022 STRESS TEK INC 2001 71 Doc 44 10031 001 Rev C 72 CHAPTER 7 7 1 STARTING CALIBRATION NUMBERS LOAD CELL VULCODER STOCK V26 V23 V27 V24 V28 V25 V32 NO 1 LEAD 2 LEAD 4 LEAD 6 LEAD 3 LEAD 15 SUPER BEAM L01 L02 2050 2050 2050 2050 1540 15 SUPER BEAM IN MODULAR CENTER L01 L02 N A 4100 4100 4100 N A HANGER 17 SHEAR BEAM 2100 2100 SINGLE POINT 26 SUPER BEAM L08 L09 2050 2050 2050 2050 EN L18 L19 26 HEAVY DUTY 2460 2460 2460 2460 1845 SUPER BEAM 2 SHEAR PIN L25 L26 1895 1895 1895 1895 3 SHEAR PIN N A 3618 N A N A N A 58 10608 005 19 FIFTH WHEEL L04 105 N A 2050 2050 2050 N A L31 AIR SENSOR L20 L21 6150 6150 6150 6150 4615 L40 28 SHEAR BEAM L27 3660 3660 3660 3660 2745 EXTRA HD 4 TRUNNION L32 L33 8200 N A N A N A N A LOAD CELL NOTES 1 Vulcoder Stock No V29 Designed for 7 Pin Connectors use Cal Number 6150 July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 7 73 7 2 SYSTEM SPECIFICATIONS Load Cells Electrical Connector Voltage Required Material Operating
3. Corroded fuses or corroded or bad meter cable connections to the battery 2 Battery is low under 10 5 Volts 3 Damaged power or ground cable 4 Faulty meter What to Do 1 Using a voltmeter check the power at the back of the meter When the meter is turned on and off the power should not change more than 1 2 Volt Turn off the meter either by the key or truck battery switch for a few seconds and then turn on again If the meter still does not work proceed to step 2 2 Check the fuses for both negative and positive leads Use 2 amp fast blow fuses for 12 Vdc applications and 1 amp fast blow fuses for 24 Vdc applications for V500 systems July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 66 CHAPTER 6 Check that the power supply wires are attached correctly at the 12 or 24 Volt power source for V500 systems Check the wires are attached to the green connector at the back of the meter Check the battery connections for corrosion If a spare meter 1s available the guickest and easiest next step is to exchange 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 doesn t the old meter is faulty If you do not
4. Note The Check Out box 1 needed to properly zero the electronics Note If the Check Out box is not used then you may receive incorrect readings Disconnect the Check Out box Clean and re connect the load cell to the VSL Vulcoder The meter will display the load cell preload number The preload number should not exceed 12 000 16 to 12 000 Ib If the preload number is within 12 000 Ib to 12 000 Ib again using the Check Out box to re zero the meter test the next load cell in the same manner If the preload number is within specification for all load cells reconnect and secure all load cell leads Reset the current Cal Number then reset the current Tare weight Note If the preload number 1s out of specification clean the load cell connector and cable connector with cotton swabs and isopropyl alcohol and dry thoroughly with a hair dryer and DO NOT OVERHEAT the connector Check the electrical isolation of the load cell by performing the Leakage Test Section 6 3 1 Reconnect the lead to the load cell Reset Tare to 0 and repeat test for that load cell Check the Preload Number again to see if it is within the 12 000 Ib to 12 000 Ib range If the load cell 1 still out of range it may be faulty Perform the Resistance Test Section 6 3 3 If the load cell cannot be brought to Vulcan specifications contact your Vulcan dealer July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPT
5. 6 5 6 5 1 SYSTEM MALFUNCTIONS CONDITION No lndicator Display or Function Lights Possible Causes po cq ON ds Ur Power switch turned off Power to the meter has been disconnected Bad meter cable connections to the battery Battery 1s low under 10 5 Volts A fuse is blown in the power or ground cable Faulty power switch Reversed polarity Faulty meter What to Do l Check the power to the meter When the meter is turned on and off the power should not change more than 1 2 Volt at the back of the meter Turn off the meter either by the key or truck battery switch for a few seconds and then turn on again If the meter still does not work proceed to step 2 Check the fuses for both negative and positive leads Note Use only 2 amp fast blow fuses for 12 Vdc systems and 1 amp fast blow fuses for 24 Vdc systems Check that the power supply wires are attached correctly at the 12 Volt power source and to the green connector at the back of the meter Check the battery connections for corrosion If a spare meter is available the quickest and easiest next step is to exchange 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 doesn t the old meter is f
6. D Active Tare Number Final Cal Number July 2001 Yes No Yes No Yes No Yes No VULCAN ON BOARD SCALES 1 800 237 0022 STRESS TEK INC 2001 CHAPTER 7 Doc 44 10031 001 Rev C
7. If the Tare Number Channel and Weight Indicators are Flashing The Lock option is activated The UP and DOWN ARROW buttons have no effect Refer to Section 2 7 to deactivate the Lock feature To Return to Normal Operating Mode 5 Press and release the TARE button July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 4 29 4 2 3 Entering Tare Weight For A Typical 2 Channel Refuse System Weigh the entire empty truck with full fuel tanks and driver 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 Weigh the rear axle group of the empty truck This is the Rear Axle Tare weight Enter this number in the space provided below Tare weight of Rear Axle Group Channel B Subtract the Tare weight of the Rear Axle Group form the Tare weight of the entire truck and enter this number in the space provide below Tare weight of Front Axle Channel A Stop the empty truck on level ground 2 Press and release button The LED s by and LOCK are illuminated The flashing LED below the channel designation indicates which channel is selected In addition the unit of measurement either Ib or Kg is also flashing Use the CYCLE button to select channel or to advance to the next channel while remaining in the set Tare mode n O
8. Vulcoder Updating s sod dote tn An nn a cme baad ak 23 4 0 V500 CALIBRATION nona oaa anke onde pi ere eme nee 25 4 1 Weight Measuring ee 25 41 1 Gross Vehicle Weight e RID DIU 26 July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 2 CONTENTS 41 2 Net Payload Weight eene soka 26 42 Procedure For Entering Tare Weights ss 26 4 2 1 Entering Tare Weight For A Typical 2 Channel Truck amp Trailer System eati utet mt ae tmd imn t m Dd tus 26 4 2 2 Entering Tare Weight For A Typical Short Logger System 28 4 2 3 Entering Tare Weight For A Typical 2 Channel Refuse System 29 4 3 Procedure For Entering Starting Calibration Numbers 30 4 4 Fine Tuning The Calibration Number For Gross Vehicle Weight Method When Only One Channel Per Truck Or Trailer Is Used 31 4 5 Fine Tuning The Calibration Number For Gross Vehicle Weight And Net Payload Weight Methods When More Than One Channel Is Used Per Truck au ad edat ds 33 5 D MAINTENANCE 37 5 1 Driver s Daily Vehicle Inspection 37 9 2 Preventative Maintenance And Vulcan Torque Specifications 38 6 0 TROUBLESHOOTING 45 6 1 V500 Meter Test Procedures
9. and white from the back of the meter Measure the resistance between the green and white wire It should be greater than 1000 ohms This method can be used to check different sections of the VSL line to isolate the short circuit 4 Inspect and replace any connection or 2 wire VSL cable that may show signs of being pinched or crushed as this could cause either open circuits or shorted lines 5 To check for an open VSL line ohm the VSL Vulcoder line by disconnecting and twisting the green and white wires together at the back of the meter Disconnect each Vulcoder from the VSL Vulcoder line There should be no resistance detected when measuring between the green and white wires at the Vulcoder hook up point 6 To check for a bad Vulcoder disconnect each Vulcoder from the VSL line and power up the meter If the meter powers up connect one Vulcoder at a time and manually reseguence the Vulcoder before restarting the meter 7 Replace meter 6 5 6 CONDITION Meter Displays LO LO If the meter encounters a low voltage situation either on the power input lead or the VSL line the meter will display LO LO and then switch to 1 90 one meaning the input power is low and the 90 being the amount of voltage 9 0 Vdc being read by the meter If the meter displays LO LO and then switches to 2 0 two meaning the VSL line is low and the number being the amount of voltage being read by the meter Possible Causes For and 1 XX l
10. and protection from possible damage Fixed body trucks Make sure body springs are intact and bolt locks are in place Tipper type trucks Check the load cell bearing pads Make sure they are not worn out and properly aligned and greased Make sure bolt locks are in place hinge pins are not bent and body guides are intact PREVENTIVE MAINTENANCE AND VULCAN TORQUE SPECIFICATIONS The following simple but important preventive maintenance steps must be performed periodically For example after the first 500 miles then monthly 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 L Check load cell connectors refer to location B shown on Figures 5 D through 5 L 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 VSL 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 VSL Vulcoder connectors If a connector i
11. have a spare meter disconnect then reconnect the green power plug on the back of the meter If the meter doesn t work then check the power source battery meter power cable or fuses If the power sources check out then the meter is faulty Possible Causes For 2 X pep VSL line orange cable is pinched or shorted VSL line incorrectly wired Damaged VSL plug or receptacle Faulty meter What to Do l Using a voltmeter check the voltage at the back of the meter when the meter is turned on and off the power should not change more than 1 2 Volt Turn off the meter either by the key or truck battery switch for a few seconds and then turn on again If the meter still shows the error proceed to step 2 Check the fuses for both negative and positive leads Use 2 amp fast blow fuses for 12 Vdc applications and 1 amp fast blow fuses for 24 Vdc applications Blown fuses could indicate a shorted VSL line Isolate the short by disconnecting sections of the VSL line and checking for proper meter operation Another way to check for a shorted line is to disconnect the green and white from the back of the meter Measure the resistance between the green and white wire It should be greater than 1000 ohms This method can be used to check different sections of the VSL line to isolate the short circuit Inspect and replace any connection or 2 wire VSL cable that may show signs of being pinched or crushed as this could cause e
12. n OR Use the UP or DOWN ARROW buttons to increase or decrease the Cal Number to the above recorded Cal Number for each channel If the Cal Number is flashing The Lock option is activated The UP and DOWN ARROW buttons have no effect Refer to Section 2 7 to deactivate the Lock feature To Exit the Calibration Mode Press the CAL button until the CAL LED is no longer illuminated The CAL button may need to be pressed once or twice for this to occur July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 4 31 4 4 FINE TUNING THE CALIBRATION NUMBER FOR GROSS VEHICLE WEIGHT METHOD WHEN ONLY ONE CHANNEL PER TRUCK OR TRAILER IS USED V500 600 WEIGHT 45000 LBE MA PLATFORM SCALE Figure 4 A Calibration GVW One Channel Used To properly calibrate a V500 system all channels used need to be calibrated Adjusting the Cal Number or Cal Weight adjusts the system sensitivity as compared to a certified platform scale The Cal Number is a reference number that is used to help the user keep track of the system calibration The Cal Weight displays the full weight for a particular channel and is used to aid the user in properly adjusting the system calibration by verifying any adjustments made to the Cal Number This feature however cannot be used in all applications because of certain system configurations At least 50
13. of segment on off conditions which might produce and error in the display There are several patterns which are run If seeing any deviation from this pattern contact you Vulcan dealer ORES Pressthe TARE or CAL button to exit from test 3 6 1 5 TEST 4 Test 4 displays the Vulcoder program version number EE Press the CYCLE button to change to a different channel 6 1 6 TEST 5 Test 5 displays the load cell offsets This function will only appear if you have at least one Vulcoder manufactured after May 2001 n OR Use the UP or DOWN ARROW buttons to change the load cell being read E Press the CYCLE button to change to a different channel 6 1 7 TEST6 Test 6 activates the meter demonstration mode n OR Use the UP or DOWN ARROW buttons to start the demo mode July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 6 49 6 2 VULCAN CHECK OUT BOX The Vulcan Check Out Box can be used to check load cells and the electronics It works as an extension to bring load cell connector pins to the side of truck where readings can be conveniently made It can also simulate an applied load to the VSL Vulcoder The Check Out Box is an optional equipment item for the Leakage and Resistance Tests Section 6 3 1 and 6 3 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 11 Vdc at the back of the meter when the
14. system Possible Causes 1 More than one VSL Vulcoder is attached at the same time 2 Line noise 3 Faulty VSL RF Vulcoder What to Do 1 Ensure that the RF Remote Vulcoder is the only Vulcoder attached to the remote meter 2 Verify if affected channel is still seguenced and manually seguence section 2 2 1 3 Replace VSL RF Vulcoder July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 60 CHAPTER 6 6 4 13 Err 13 Indicates too many Vulcoders on the transmit side were detected in an RF Radio Frequency Remote System For example a V600 Meter on the transmit side may have up to five standard Vulcoders and an RF Remote Transmit Vulcoder attached If the receive side is a V500 Meter it can only have three standard Vulcoders on the transmit side Therefore the 4 channel V500 Meter cannot read all of the 6 channels of the V600 Meter Possible Causes 1 Too many VSL Vulcoders attached to the VSL line 2 Faulty VSL Vulcoder What to Do 1 Verify the number of VSL Vulcoders attached to system The V500 Meter is limited to three standard Vulcoders and one RF Remote Receive Vulcoder The V600 Meter is limited to five standard Vulcoders and one RF Remote Receive Vulcoder 2 Verify sequencing manually sequence if necessary section 2 2 1 3 Replace VSL Vulcoder July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 6 61
15. to 10 before connecting the terminal block to the back of the meter July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 2 15 CHAPTER 2 0 V500 PROGRAM MENU SYSTEM SETUP 2 1 ENTERING THE PROGRAM MENU The V500 Meter program menu enables the user to e Program Sequence PS Assigns the proper sequence to the Vulcoders in the system Section 2 2 e Program Code PC By selecting a program code the user tells the meter what channels and combination of channels to display Section 2 3 e Program Units PU Selects the units of measure either pounds or kilograms Section 2 4 e Program Graduation PG Selects the graduation for displaying weight Section 2 5 e Program Cycle Time PCt Selects the channel cycle time Section 2 6 e Program Lock PL The lock must be in the Off position to adjust the Tare or Calibration settings for the scale Turning the lock to the On position will prevent changes to the system s calibration Section 2 7 To Enter the Meter Program Menu E Press the PWR MENU button to turn on the meter After the meter has completed its start up routine and is running press the PWR MENU button to enter the program menu Press the CYCLE button to go through the different program modes Note If the PWR MENU button is held too long the meter display will display all 8 s and the meter will turn off 2 2 SEQUENCING CHANNEL
16. 0 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 5 41 Typical Single Point Mounting Nc INBOARD 1 000 1 400 LB FT 2 PLACES 300 350 LB FT 6 PLACES Figure 5 F Typical Holland 5th Wheel Mounting 1 000 1 400 LB FT 4 PLACES Figure 5 G July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 42 CHAPTER 5 Typical Rear Hinge Mounting Tipping Body 650 890 lb ft 2 and bend lock tabs ZERK FITTING lubricate the pillow block via the zerk fitting Figure 5 H Typical Front 8 Middle Mountings Tipping Body 400 500 Ib ft 4 Figure 5 J July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 5 43 Typical Rear Mounting Fixed Body 650 890 Ib ft 2 400 500 Ib ft 4 Figure 5 K Typical Front amp Middle Mountings Fixed Body Tighten to compress the spring 1 4 1 000 1 400 Ib ft 2 Bend the tabs back July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 44 CHAPTER 5 July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 6 45 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
17. 0 Ib of weight must be applied to the specific channel before the Cal Weight function is operable Listed is a calibration procedure for the Gross Vehicle Weight Method Note Each channel in use must be properly calibrated ex A B C and D If additional assistance is needed to fine tune your scale system please follow the instructions shown in Section 7 3 Assistance in Fine Tuning Your Scale System July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 32 CHAPTER 4 Calibration Procedure Fully load the truck close to the legal limit Weigh each channel individually and record the weight Channel A Loaded weight Channel B Loaded weight Channel C Loaded weight Channel D Loaded weight Park on level ground Press the CYCLE button until the desired channel A B C or D and the LED by LOCK is displayed E Press the CAL button once to enter the Cal Number mode n OR Use the UP or DOWN ARROW buttons to increase or decrease the Cal Number Press the CAL button again to enter the Cal Weight mode The units of measure Ib or kg LED will be flashing n OR Use UP DOWN Arrow buttons to adjust the displayed weight to match the actual loaded platform reading This will automatically adjust your Cal Number You must exit the Calibration mode to save your new Calibration To Exit the Calibration Mode Press the CAL button until the CAL LED is no longer ill
18. 1f there 1 at least one SMT Vulcoder attached to the system Test 6 activates the meter demonstration mode 6 1 1 ENTERING AND EXITING THE TEST MODE The Test Mode may only be entered during the power up sequence To enter the Test Mode E Press the PWR MENU button to turn on the meter E Press the PWR MENU button while the software version number is being displayed The software version will be displayed as rx xx for example r2 01 gt Press the CYCLE button to select tESt 1 tESt 2 tESt 3 tESt 4 tESt 5 or tESt 6 n OR M Use the UP or DOWN ARROW buttons to begin the selected test Press the PWR MENU button while tESt 1 tESt 2 tESt 3 tESt 4 tE St 5 or tESt 6 is being displayed to exit from the Test Mode July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 6 47 6 1 2 TESTI1 Test 1 the keyboard test can be used to determine whether all of the keys on the keyboard are operating properly n OR Press either the UP DOWN ARROW buttons to begin the selected test 0 will be displayed indicating that no keys are being pushed a 2 or a 3 may be seen momentarily before releasing the arrow key as you start the test The keys are labeled 1 through 6 with 1 being the PWR MENU key and 6 being the CYCLE button Press each button one at a time the co
19. 31 001 Rev C STRESS TEK INC 2001 24 CHAPTER 3 July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 4 25 CHAPTER 4 0 V500 CALIBRATION Calibration is fine tuning a system to maximum accuracy in reference to a specific certified platform scale It is important to calibrate the scales for high accuracy to achieve the maximum hauling payload Calibration consists of setting the appropriate Tare weight and Calibration number for each channel It is important that conditions remain as constant as possible throughout the calibration process Inaccuracies may result from differences in fuel load ice or mud build up number of people in the vehicle 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 continuous questionable readings or if meter readings repeatably do not closely match the certified platform scale weights 4 1 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 In addition to these methods Vulcan Scales can be used to determine Axle Weight on certain on board scale configurations Important Notice for Front Loader Refuse Truck Operators To avoid weight measurement errors the forks must be in the down position and the body lift cylinder pressure mus
20. 4 10031 001 Rev C STRESS TEK INC 2001 58 CHAPTER 6 6 49 Err 09 Indicates the meter has found multiple rear VSL Vulcoders Possible Causes l More than one rear VSL Vulcoder is attached at the same time During sequencing or powering up the meter 2 Line noise 3 Faulty VSL Vulcoder What to Do 1 System needs to be manually sequenced Be sure that on two or more channel systems there is at least one rear VSL Vulcoder 2 See electronics installation section for proper installation procedure section 1 5 Verify that there is only one Vulcoder installed as a rear Vulcoder 6 4 10 Err 10 Communication error between the meter and the VSL Vulcoder The VSL Vulcoder is in a locked state Possible Causes 1 Faulty VSL Vulcoder What to Do 1 Run Test 2 from the V500 Meter Test Procedures section 6 1 3 2 Replace VSL Vulcoder July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 6 59 6 4 11 Err 11 The meter watchdog system is not running Possible Causes 1 New or recently repaired meter What to Do 1 Turn the meter off and then on to cycle power in system 25 If Err 11 is still displayed replace meter NOTE The following error codes should only appear if the system is using special application RF Vulcoders 6 4 12 Err 12 Indicates that more than one Vulcoder has been detected in an RF Radio Freguency remote receive
21. CONTENTS V500 OWNER S MANUAL Table of Contents 1 0 VULCAN SINGLE LINE VSL TECHNOLOGY V500 ELECTRONICS SYSTEM 1 1 Load Cells And Air Sensors nnne 8 1 2 VSLVUJEODBIS aceto e dita zd UL THUS AR CHR RO a dl okn 9 1 3 V500 Met r citate em md ea O Calta dada ted 9 1 4 Explanation of Meter Channels eee nene 10 T 5 Electronics 11 2 0 V500 PROGRAM MENU SYSTEM SETUP eene 15 2 1 Entering The Program 2d hot ha oto toad Rs es pr rb nr nb cl a 15 2 2 Sequencing 6hasrinels esce ad 15 2 2 1 Manual Sequencing s nada Nara du ne Rae 16 2 8 Setting Tbe Display Coded ee una 16 2 4 Setting The Units Eb or K9 duo sn ace dieu aR o bay 18 2 9 etg die GTA SIZE ie te eren te teen tob eee te teen do VE er 19 2 0 Setting The Channel Cycle Time 19 2 7 Setting The Lock Tare and Cal Lockout eee 20 2 8 Exiting The Program Mernu esee NA 20 3 0 V500 METER OPERATION 2 Hiero eredi ee nace e oed eee ene 21 3 4 Turning The Meter On And iii 21 3 2 Changing Display Intensity ss cede 21 3 3 Locking The Meter On A Particular Channel 22 3 4 Displaying are WIG chine immense 23 3 5 Displaying Calibration Numbers 23 3 6
22. Calibration GVW and Net Payload More than One Channel Used on 2 channel logger system July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 3A CHAPTER 4 Calibration Procedure 1 Fully load the truck close to the legal limit 2 Lock the meter on the two channels being calibrated Example 3 Weigh the loaded truck using a certified platform scale Record the weight shown on the certified scale and the weight as shown on the V500 Meter a Weight Shown on Certified Scale truck fully loaded Example 56 240 Ib Certified Scale truck fully loaded b Weight Shown on the V500 Meter truck fully loaded for channels selected Example A B Example 55 000 Ib V500 Meter truck fully loaded 4 Dump the payload 5 Weigh the empty truck on the same certified platform scale Record the weight shown on the certified scale and the weight as shown the V500 Meter for the channels selected Example A B a Weight Shown on Certified Scale truck empty Example 35 000 Ib Certified Scale truck empty b Weight Shown on V500 Meter truck empty for channels selected Example A B Example 35 000 Ib V500 Meter truck empty July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 4 35 10 11 Calculate the Net weight for both the Certified Scale Readings P and the V500 Meter reading V b
23. Check the black cables between the load cells and the VSL Vulcoder If the cabling is damaged the VSL Vulcoder needs to be repaired or replaced Contact your Vulcan dealer 5 Perform the Leakage Tare and Resistance Tests refer to Sections 6 3 1 through 6 3 3 6 5 5 CONDITION Meter Stops Powering Up After Displaying All Digits Possible Causes 1 Voltage to meter is below 10 5 Volts 2 Broken power wire or bad connection between the meter and the power source 3 Shorted VSL Vulcoder line 4 Vulcoder setup data is corrupted 5 Vulcoder does not have any load cells connected 6 Faulty Vulcoder 7 Faulty meter 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 2 System Specifications If the voltage is below 10 5 Vdc the problem could be in the power source battery meter power cable and or fuses July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 6 65 2 Verify at least one load cell is connected to the VSL Vulcoder 3 Check fuses for both negative and positive leads Note Use only 2 amp fast blow fuses for 12 Vdc systems and 1 amp fast blow fuses for 24 Vdc systems Blown fuses could indicate a shorted VSL line Isolate the short by disconnecting sections of the VSL line and checking for proper meter operation Another way to check for a shorted line is to disconnect the green
24. ER 6 6 3 3 Required Equipment Optional Equipment 53 RESISTANCE TEST PROCEDURE Digital Multi Meter with Conductivity Scale 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 or a Vulcan Check Out Box Refer to acceptable resistance ranges as shown below MULTI METER g a WHITE BLACK GREEN RED o o LOAD CELL Figure 6 C Resistance Test Pins A to D BtoC Terminal Color Code Red to Black Green to White Note For Center Hanger Load Cells Red to Black i CHECK OUT BOX OR MULTI METER LOAD CELL Acceptable Resistance Range 349 to 400 Ohms 349 to 352 Ohms 349 to 450 Ohms For Air Sensors contact factory for specifications 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 July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 54 CHAPTER 6 6 4 V500 METER ERROR CODES 6 4 1 Err01 Indicates the V
25. Ib 100 kg make a note of it Then clean and reconnect the left load cell Note For Vulcoders manufactured after May 2001 the meter will alternate between displaying an Err 1 and the reference number of the load cell cable that is disconnected Use Test 5 to display one load cell at a time section 6 1 6 If any one of the load cells wanders more than 200 Ib 100 kg perform the Leakage and Resistance test refer to Section 6 3 1 and 6 3 3 If both of the load cells wander more than 200 Ib 100 kg then the VSL Vulcoder may be faulty and needs to be checked refer to Section 6 3 4 VSL Vulcoder Check Out Procedure If four load cells are connected per VSL Vulcoder follow steps 5c through 5f C July 2001 For VSL 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 Ib 100 kg make a note of it Disconnect the right front load cell and reconnect right 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 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 k
26. K TRAILER V vsL VULCODER CONNECTOR Figure 1 C Example VSL Short Logger System Truck 2 channels Trailer not shown 2 channels July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 1 y 6 EACH M V500 METER L LOAD CELL V VSL VULCODER Figure 1 D Example VSL Refuse System With 6 Load Cells Truck 2 channels July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 8 CHAPTER 1 1 1 LOAD CELLS AND AIR SENSORS Vulcan load cells and air sensors are machined from solid blocks of high strength steel The Strain gages are bonded inside the load cell or air 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 This signal voltage is measured by the VSL Vulcoder and then used to determine weight Example Vulcan Super Beam Load Cell Calibration Circuit All wiring is routed internally through long holes drilled from each end of the load cell Patented shear section design provides maximum strength and high accuracy Environmentally sealed connector All internal cavities Strain gages Weld down are sealed with a bonded to shear bearing pad chemical a
27. On Board Scale System consists of e Load Cells or Air Sensors to sense load or air pressure e VSL Vulcoders to convert the signals from the sensors to weight and communicate with the meter e V500 Meter to display the weights and run the scale system The number of VSL Vulcoders needed depends on the number of channels required The number and type of load cells needed depends on the truck s configuration such as length type of suspension load capacity etc Only one V500 Meter is required per truck The new Vulcan Single Line VSL technology is a revolutionary way that the V500 Meter communicates with each VSL Vulcoder VSL technology uses a single 2 wire cable to provide the communications between the meter and VSL Vulcoders The single 2 wire communication cable sends power and set up data to each VSL Vulcoder while receiving weight data from each VSL Vulcoder VSL VULCODER VSL VULCODER OR AIR SENSOR LOAD CELL VULCAN SINGLE LINE VSL AIR SENSOR Figure 1 A VSL Single Line VSL LUN July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 6 CHAPTER 1 4 Channel System Example M vsoo METER L LOAD CELL _ TRUCK TRAILER VULCODER CONNECTOR Figure 1 B Example VSL Long Logger System Truck 1 channel Trailer 1 channel L 4 EACH lt V500 METER L LOAD CELL TRUC
28. R A Enter the Tare weight of the Rear Axle Group as Channel B using the UP or DOWN ARROW buttons to increase or decrease the displayed Tare weight to match the actual Tare weight for each channel If the Tare Weight Channel and Weight Indicators are Flashing The Lock option is activated The UP and DOWN ARROW buttons have no effect Refer to Section 2 7 to deactivate the Lock feature To Return to Normal Operating Mode 2 Press and release the button July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 30 CHAPTER 4 4 3 PROCEDURE FOR ENTERING STARTING CALIBRATION NUMBERS To properly calibrate a V500 system all channels in use need to be calibrated Listed below is a procedure for entering the starting calibration numbers The starting calibration numbers must be entered for each channel Stop the empty truck on level ground Look up Cal Numbers for all active channels in Section 7 1 Starting Channel A Cal Number Starting Channel B Cal Number Starting Channel C Cal Number Starting Channel D Cal Number Press the PWR MENU button to turn on meter Press and release the CAL button The LED by LOCK and CAL are illuminated The flashing LED below the channel designation indicates which channel s is selected Press the CYCLE button to select a channel or to advance to the next desired channel A B C or D to enter calibration numbers
29. RESS TEK INC 2001 18 CHAPTER 2 A Press the CYCLE button until the PROGRAM CODE PC is displayed Example n OR Use the UP DOWN ARROW buttons to select the desired channel display code shown above Press the CYCLE button to store the display code information The meter will then advance to the next programming function 2 4 SETTING THE UNITS LB OR KG The V500 Meter allows the user to display the weight in either pounds or kilograms The LED illuminated by either pounds or kilograms shows the unit of measurement selected To change the unit of measurement refer to the procedure below Press the CYCLE button until the PROGRAM UNITS PU appears on the display The LED light by Ib or Kg will be flashing indicating the unit of measurement selected 0111 i LI Ib kg n OR v Use the UP or DOWN ARROW buttons to switch between Ib and kg Press the CYCLE button to store units selected The meter will then advance to the next programming function July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 2 19 2 5 SETTING THE GRAD SIZE The grad or graduation size for the V500 Meter allows the meter to display the weight in either 10 20 50 100 or 200 Ib or kg increments The procedure to change the grad size is listed below T Press the CYCLE button until the PROGRAM GRAD PG is displayed Use the UP or DOWN ARROW buttons to select the des
30. S The V500 electronics makes it possible for a truck to haul various types of Vulcan VSL equipped trailers with plug in and go ease To do this the VSL Vulcoders need to be assigned their position channel A B C or D in the scale system Once the Vulcoder has been assigned its position it will remember it and the process of seguencing does not need to be repeated unless the position of the Vulcoder changes Seguencing is the process in which the meter determines the order of each VSL Vulcoder or groups of load cells For example on a long logger the meter reads the Front VSL Vulcoder and assigns it as channel A and then reads the next VSL Vulcoder as a Rear and assigns this VSL Vulcoder as channel B July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 16 CHAPTER 2 After entering the Program Menu the first mode displayed will be Program Sequence PS If a combination of F and appears on the display then the meter has detected the VSL Vulcoders For example PS FrFr would indicate that four Vulcoders were detected where indicates front VSL Vulcoder and indicates a rear VSL Vulcoder The associated channel indicators will also be illuminated Note On new installations the system will attempt to automatically sequence the Vulcoders If the attempt is not successful i e more than one Front or Rear Vulcoder is hooked up when the meter is turned on a
31. S TEK INC 2001 56 CHAPTER 6 6 45 Err 05 Indicates the VSL Vulcoder has a hardware problem Possible Causes 1 VSL Vulcoder hardware component is damaged What to do 1 Press the PWR MENU button to turn the meter off and then press PWR MENU again to turn it on This may reset the meter and eliminate the error 2 Inspect VSL Vulcoder Communication line for cut or broken wires 3 Run Test 2 from the V500 Meter Test Procedures section 6 1 3 4 VSL Vulcoder is damaged replace VSL Vulcoder 6 4 6 Err 06 Indicates the VSL Vulcoder is processing an under ranged signal An under ranged signal means that the load cell output is less than the minimum that the VSL Vulcoder will accept Possible Causes 1 There is moisture in a load cell connector 2 One of the VSL Vulcoder to load cell cables has been damaged 3 No load cells are connected to the VSL Vulcoder 4 A load cell is faulty What to Do 1 Check to see that the load cells are properly connected to the VSL Vulcoder 2 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 Note For Vulcoders manufactured after May 2001 the meter will alternate between displaying an Err 1 and the reference number of the load cell cable that is disconnected Use Test 5 to display one load cell at a time section 6 1 6 3 Perform the Leakage Test re
32. SL Vulcoder is processing an over ranged signal An over ranged signal means that the load cell output is greater than the maximum that the VSL Vulcoder will accept Possible Causes 1 The load cells are being over loaded 2 There is moisture in a load cell connector 3 A load cell is not connected to the VSL Vulcoder cable 4 One of the VSL Vulcoder to load cell cables has been damaged 5 A load cell has a large Preload Number 6 A load cell 1s faulty What to Do 1 Ensure the load cell is plugged into the VSL Vulcoder cable 2 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 3 Perform the Leakage Test refer to Section 6 3 1 4 Perform the Tare Test refer to Section 6 3 2 5 Check mounting of the load cell per Section 5 2 Preventive Maintenance and Vulcan Torgue Specifications 6 4 2 Err 02 Indicates 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 l Check and reset the Cal Numbers and Tare weight July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 6 55 6 4 3 Err 03 Indicates the meter is not receiving a weight from the VSL Vulcoder Possible Causes 1 New Installation 2 Communication pro
33. TRESS TEK INC 2001 CHAPTER 5 37 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 DRIVERS DAILY VEHICLE INSPECTION l Check load cells mounting brackets and fasteners Make sure they are secure 2 If torgue stripes have been applied make sure they are properly aligned To apply a torgue 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 3 Check and remove any build up of mud ice or other debris that may obstruct the load cell s deflection under load Refer to the drawing below and Section A in Figures 5 C through 5 L NO CONTACT ON TOP OF LOAD PATH LOAD PATH LOAD PATH THE MOUNTING CAP SCREW HEADS O E 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 July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 38 5 2 CHAPTER 5 Check the system Make sure the meter powers up after it has been turned on digits are legible and the system functions normally Check all wiring for condition no cracks or splits security chaffing
34. Temp System Accuracy VSL Vulcoder Environment Operating Temp 4 Wire Cable Black 2 Wire Cable Orange Connectors Voltage Input Voltage Output V500 Meter Display Cycle Speed Graduation Display Range Voltage Required Current Draw Protection Hookup Operating Temp Weight Installation July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 STRESS TEK INC 2001 350 Ohms nominal impedance 4 pin bulkhead military type 5 0 1 Vdc High grade alloy steel 40 to 140 degrees F Typical error less than 1 Full Scale of actual weight under normal operating temperature range and normal loading conditions Environmentally sealed electronics 40 to 140 degrees F Custom shielded 4 conductor polyurethane jacket with drain Custom polyurethane jacket 4 pin military type 10 Vdc 5 Vdc 5 1 Vdc LED Variable brightness Variable cycle speed 1 9 seconds 10 20 50 100 or 200 Ib or kg 99 999 to 999 999 10 5 29 Vdc SAto2A External and internal fuse amp diode protected Screw type quick release terminal block on rear panel 40 to 180 degrees F 1 5 Ibs Power cables fuses mounting bracket and thumbscrews provided Doc 44 10031 001 Rev C 74 CHAPTER 7 7 3 ASSISTANCE IN FINE TUNING YOUR SCALE SYSTEM Primarily for Two Channels On One Truck Application Only 1 Lock the meter on the channels to be fine tuned Example A B 2 Fin
35. Test Leakage Test Specifications Measure 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 6 3 2 TARE TEST PROCEDURE Required Equipment Vulcan Check Out Box The Tare Test checks each load cell for a high Preload Number caused by mechanical damage or moisture Park the empty truck on level ground Use the CYCLE button to lock the meter on the Channel where the load cells will be tested or D Record the current Tare weight The Tare weight is the weight displayed when the vehicle is empty Current Tare Weight Press and release the TARE button The LED s by TARE and LOCK are illuminated July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 52 CHAPTER 6 n OR v Use the UP or DOWN ARROW buttons to change the display to read zero a Press and release the TARE button again Press and release the CAL button The LED s by CAL and LOCK are illuminated Record the current Cal Number Current Cal Number n OR M Change the Cal Number using the UP and DOWN ARROW buttons to display 2050 E Press and release the CAL button again Disconnect one load cell from the VSL Vulcoder of the channel to be tested Plug that one lead into the connector on the Check Out box Make sure the load switch is pointing away from the red dot
36. al 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 truck such as an accident July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 6 69 SYMPTOMS Does the problem occur on Channel A B C D or all Does the meter drift up and or down fast or slow or both Is the problem intermittent constant or both Does the problem occur on flat road or off road or both 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 July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 70 CHAPTER 6 6 7 TROUBLESHOOTING ASSISTANCE AND REPLACEMENT PARTS
37. atically selects the display code depending on how many VSL Vulcoders are communicating with the meter at power up The meter display code allows the user to display a combination of one or more of the available channels Refer to the list of display codes on the next page July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 2 17 Table of Display Codes The first number in the display code refers to the number of channels in the system Displayed Channels Code VS Vendor common ete number of VSL Vulcoders communicating with the meter Consists of the following special grouping codes 3c1 3c2 3c3 3c4 that can be quickly selected using the CYCLE button without going into the Program Menu In normal operation press and hold the CYCLE button down then use the UP or DOWN arrow buttons to select the grou Consists of the following special grouping codes 4 1 4c2 4c3 4c4 403 that can be quickly selected using the CYCLE button without going into the Program Menu In normal operation press and hold the CYCLE button down then use the UP or DOWN arrow keys to select the group desired gt gt UV uw wW ala a U A US PAB C Do S 45 A B D ABD 46 A Figure 2 B Display Codes V500 Meter July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C ST
38. ation For vehicle combinations with one to four channels of weight sensing The V500 Meter provides a high visibility display and the ability to easily read different trailers The V500 Meter uses VSL technology to power and communicate with VSL Vulcoders on a single 2 wire cable The meter requests weight information from the different Vulcoders It then displays individual channel weights and total weight as requested by the operator The weight can be displayed in pounds or kilograms The meter also transfers all setup and calibration information for up to four independent channels A B C and D into the VSL Vulcoder where it is stored Figure 1 G V500 Meter July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 10 CHAPTER 1 1 4 EXPLANATION OF METER CHANNELS The V500 Meter can display information on up to four channels A B C and D There is a VSL Vulcoder for each channel The number of channels is based on the number of load cells and their grouping For example a trailer could have as many as four load cells per channel The display code tells the meter what channels to scan For more information on how to select the meter display code refer to Section 2 3 Set Display Code Refuse or Logging Truck Applications Typically a refuse or logging truck application usually requires o
39. aulty If you do not have a spare meter disconnect and then reconnect the green power plug on the back of the meter If the meter doesn t work then check the power source battery meter power cable or fuses If the power sources check out then the meter is faulty July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 62 CHAPTER 6 6 5 2 CONDITION Unable To Enter Tare Or Calibration Numbers Possible Causes 1 Meter may be in the Driver Lockout mode which does not allow the Tare weight Cal Number or Cal weight to be changed 2 Faulty meter What to Do 1 The Lock feature may be enabled see Section 2 7 Setting The Lock 2 Unplug the green connector at the back of the meter for few seconds re plug it in and try to enter the Tare or Cal Numbers again 3 Faulty meter Call your Vulcan dealer for meter replacement The meter contains no user serviceable parts 6 5 3 CONDITION Meter Reading Drifts Or Wanders With Time Possible Causes 1 Voltage to meter 1s less than 10 5 Volts Voltage out of the VSL Vulcoder is less than the Voltage Output required as stated in Section 7 2 System Specifications 3 Moisture in a load cell connector 4 Damaged cable between VSL Vulcoder and load cell 5 Bad connection on green connector broken wire or cable between meter and the VSL Vulcoder 6 Faulty load cell What to Do 1 Using a voltmeter check th
40. blem between Meter VSL Vulcoder 3c Dirty or worn truck to trailer connectors 4 Cables have been disconnected or damaged 5 Green and white leads reversed on VSL Vulcoder line 6 Multiple front or rear Vulcoders for one channel 7 Faulty VSL Vulcoder What to Do 2 Verify if affected channel is still sequenced manually sequence if necessary section 2 2 1 2 Reconnect any cables that have become disconnected 3 Clean any dirt mud or ice out of 4 pin truck to trailer connectors 4 Inspect VSL Vulcoder Communication line for cut or broken wires and proper connection of the green and white wires To check for an open VSL line ohm the VSL Vulcoder line by twisting the green and white wires together at the back of the meter and disconnect each Vulcoder from the VSL Vulcoder line There should be no resistance detected when measuring between the green and white wires at the Vulcoder hook up point 5 Inspect truck to trailer connecting plug and receptacles for good connection Spread and clean pins in receptacle and plug 1f needed 6 Run Test 2 from the V500 Meter Test Procedures section 6 1 3 7 VSL Vulcoder is damaged replace VSL Vulcoder 6 4 4 Err 04 Indicates the VSL Vulcoder is not calibrated Possible Causes 1 Cal or Tare Numbers are not entered What to Do 1 Check and reset the Cal Numbers and Tare weight July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRES
41. ditional 1 8 of a turn more with channel lock pliers The additional tightening is necessary to compress the O ring This prevents 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 the single 2 wire orange VSL Vulcoder cable from the meter in the cab to the last VSL Vulcoder in the system Be sure to route the cable to the meter and do not trim any excess wire off at the meter Trim off the excess cable to approximately 1 2 of extra orange cable at the location of the VSL Vulcoder splice to allow for the splice Note On a truck to trailer connection these wires may be routed using the existing truck to 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 If using the separate connector for the best and most reliable connection connect each color wire to two pin connections For example connect the green wire to the top two pins of a 4 pin truck to trailer connector and the white wires to the bottom two pins Connect the first VSL Vulcoder in the system to the 2 wire cable by splicing each color coded wire from the communication cable and the VSL Vulcoder cable refer to Figure 1 J When using the Vulcan supplied 3M connector do not strip the insulation from each wire Be sure to insert wires c
42. e tuning Complete a row of information each time using the same certified scale Do this six times filling in rows 1 through 6 Set the Cal Number for each channel being fine tuned to that shown in section 7 1 NEN Truck Fully Loaded Truck Empty Meter Displa Platform Meter Displa Platform 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 Cal Number Channel Cal Number Channel Cal Number Channel Cal Number July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 7 75 4 Confirmation Complete a row on information for six more certified scale weights I t icc Truck Fully Loaded Truck Empty Meter Display Meter Display 5 Call Vulcan Customer Service again at 1 800 237 0022 to confirm the system calibration Channel Final Cal Number Channel Final Cal Number Channel Final Cal Number Channel Final Cal Number Date Final Calibration Numbers were set July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 76 7 4 KEEPING RECORDS Channel A Channel A Active Tare Number Final Cal Number Channel B Channel B Active Tare Number Final Cal Number Channel C Channel C Active Tare Number Final Cal Number Channel D Channel
43. e voltage at the back of the meter Refer to the required meter voltages in Section 7 2 System Specifications 2 Check the black 4 wire cabling between the load cells and the VSL Vulcoder If the cabling is damaged contact your Vulcan dealer for VSL Vulcoder repair or repair kit 3 Measure the voltage between pins A and D of the VSL Vulcoder connector If it measures less than 5 Volts make sure the VSL Vulcoder cable is securely attached to the meter green plug and the length of the orange cable from the VSL Vulcoder to the meter isn t longer than 100 ft Also check any truck trailer connectors in the VSL 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 the system for one day to see if the problem is fixed If the problem is not fixed continue to step 5 July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 6 63 5 two load cells are connected per VSL Vulcoder follow steps 5a and 5b a 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
44. een installed the Vulcoders must have either the wire loop cut or uncut Cutting the loop wire will designate the Vulcoder as a Front Vulcoder refer to Figure 1 K and not cutting the Vulcoder designates the Vulcoder as a Rear Vulcoder refer to Figure 1 L Following this procedure will enable the meter to properly assign channels For example on a 2 channel system with the truck having a Front Vulcoder and the trailer having a Rear Vulcoder the meter will seguence the Front Vulcoder as channel A and the Rear Vulcoder as channel B LOAD CELL lt CUT N p SL 29 B CABLE ORANGE AN NY CABLE MA Ld LOAD CELL Figure 1 K Front VSL Vulcoder Configuration July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 1 13 10 LOAD CELL BLACK ae CABLE ORANGE 1 LOAD CELL Figure 1 L Rear VSL Vulcoder Configuration WARNING If installing the meter in a vehicle with a positive ground electrical system the meter chassis mounting bracket and mounting fasteners MUST be electrically isolated from the vehicle chassis Find a suitable location for the meter and install the mounting bracket Secure the VSL Vulcoder cable so it does not obstruct other in cab equipment and strain relieve Unplug the terminal block from the back of the meter strip the wires a
45. fer to Section 6 3 1 4 Perform the Tare Test refer to Section 6 3 2 5 Check mounting of the load cell per Section 5 2 Preventive Maintenance and Vulcan Torque Specifications July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 6 57 6 4 7 Err 07 Indicates that a new VSL Vulcoder has been detected or multiple VSL Vulcoders with the same channel designation have been found Possible Causes 1 Multiple VSL Vulcoders with the same channel ID have been found 2 Line Noise 3 Faulty VSL Vulcoder What to Do 1 System needs to be manually sequenced Be sure that on two or more channel systems there is at least one rear VSL Vulcoder and it is the last VSL Vulcoder in the system 2 Turn the meter off and then on to cycle power in system 3 Replace faulty VSL Vulcoder 6 48 08 Indicates the meter has found multiple front VSL Vulcoders Possible Causes 1 More than one front VSL Vulcoder is attached at the same time During seguencing or powering up the meter 2 Line noise 3 Faulty VSL Vulcoder What to Do 1 System needs to be manually seguenced Be sure that on two or more channel systems there is at least one front VSL Vulcoder 2 See electronics installation section for proper installation procedure section 1 5 Verify that there is only one Vulcoder installed as a front Vulcoder July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 4
46. g make a note of it If any one of the load cells wanders more than 200 Ib 100 kg perform the Leakage and Resistance tests refer to Sections 6 3 1 and 6 3 3 If all the load cells wander more than 200 Ib 100 kg then the VSL Vulcoder may be faulty and needs to be checked refer to Section 6 3 4 VSL Vulcoder Check Out Procedure Note For Vulcoders manufactured after May 2001 the meter will alternate between displaying an Err 1 and the reference number of the load cell cable that is disconnected Use Test 5 to display one load cell at a time section 6 1 6 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 64 CHAPTER 6 6 5 4 CONDITION Meter Reading Does Not Change When Truck is Being Loaded Possible Causes Voltage to meter is below 10 5 Volts Mud or ice build up under the load cells Calibration Number on the meter 1s set too low Faulty load cell Broken wire or a bad connection between the load cell and VSL Vulcoder Meter display is locked DATE O What to Do 1 Using a voltmeter check the power at the meter s green plug on the back of the meter Refer to Section 7 2 System Specifications If the voltage is below 10 5 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 Verify that the Cal Number is reasonable 4
47. ged Below is a procedure to turn Lock feature or off gt Press the CYCLE button until the PROGRAM LOCK PL OFF or PL On is displayed n OR M Use the UP or DOWN ARROW buttons to activate or deactivate the Driver Lock feature mec LI OFF Driver Lockout deactivated 0 M PL On Driver Lockout activated U L Press the CYCLE button to store the lock information The meter will then advance to the next programming function 2 8 EXITING THE PROGRAM MENU To Exit the Meter Program Menu Press the PWR MENU button to exit from the program menu at any time to return to the normal operating mode Note If the PWR MENU button is held too long the meter will display all 8 s and the meter will turn off July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 3 21 CHAPTER 3 0 V500 METER OPERATION 3 1 TURNING THE METER ON AND OFF Figure 3 A V500 Meter To Turn the Meter On E Press the PWR MENU button for less than 2 seconds To Turn the Meter Off E Press and hold the PWR MENU button until the meter display goes blank 3 2 CHANGING DISPLAY INTENSITY There are four levels of display intensity to choose from To Increase the Display Intensity B Press the UP ARROW button while in the normal operat
48. ing fuel eguipment personnel and payload In order to use the Gross Vehicle weight method the Tare weight for each channel must be entered The Tare weight is the weight of the empty truck with fuel eguipment 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 will also increase For a 2 channel system A and B the total Gross Vehicle weight is displayed on Channel A B For a 4 channel system the total Gross Vehicle weight is displayed as Channel A B C D 4 1 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 for each channel The weight displayed at all times is the Net Payload weight 4 2 PROCEDURE FOR ENTERING TARE WEIGHTS GROSS VEHICLE amp NET PAYLOAD WEIGHT METHODS To properly calibrate a V500 system all channels in use need to be calibrated Listed below is a procedure for entering the Tare weights The Tare weights must be entered for each channel IMPORTANT The truck and trailer must not be in a twist or turn while entering the Tare weights 4 2 1 X Entering Tare Weight For A Typical 2 Channel Truck amp Trailer System Weigh the entire empty truck with full fuel tanks and driver b
49. ing mode To Decrease the Display Intensity v Press the DOWN ARROW button while in the normal operating mode Note Leaving the meter on and not pressing any other meter keys will save the current display intensity Upon the next power up the meter will start up where the intensity was last set July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 22 CHAPTER 3 3 3 LOCKING THE METER ON A PARTICULAR CHANNEL The illuminated LED light below the channel designation indicates the channel or group of channels currently being displayed The meter will automatically cycle through the channels and groups of channels as determined by the display code setting If two or more LED s are illuminated this represents the sum of the weights on those channels For example if A and B are both illuminated the meter is displaying the total weight on A and B A B To Lock on a Channel When the desired channel or group of channels is being displayed press the CYCLE button to stop the automatic advance The LED by LOCK is turned on and the meter is locked on that particular channel s LI O CAL O TARE A B c e LOCK og To Unlock the Channel Press the CYCLE button again The LOCK LED will be turned off and the meter will continue to cycle through the channels oa HP gt CAL TARE A LOCK JD S Note Leaving the meter on and not pressing an
50. ired the Grad Size The Grad Size settings are 10 20 50 100 and 200 Press the CYCLE button to store the grad size selected The meter will then advance to the next programming function 2 6 SETTING THE CHANNEL CYCLE TIME The V500 system allows the user to change the Cycle Time or the amount of time a channel is displayed The user can adjust this Cycle Time from a minimum of 1 second up to a maximum of 9 seconds To change the Cycle Time refer to the procedure shown below Press the CYCLE button until the PROGRAM CYCLE TIME PCt appears on the display Ore 2 Pree m To Increase the Cvcle Time Press the UP ARROW button to increase the Cycle Time Maximum Cycle Time is 9 seconds Release the UP ARROW button when the desired Cycle Time is reached To Decrease the Cvcle Time Press the DOWN ARROW button to decrease the Cycle Time Minimum Cycle Time is 1 second Release the DOWN ARROW button when the desired Cycle Time is reached Press the CYCLE button to store the Cycle Time selected The meter will then advance to the next programming function July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 20 CHAPTER 2 2 7 SETTING THE LOCK TARE AND CAL LOCKOUT The Lock option prevents drivers or other unauthorized personnel from accidentally changing the calibration settings on the scale system If the Lock is the Tare and Calibration values cannot be chan
51. ither open circuits or shorted lines To check for an open VSL line ohm the VSL Vulcoder line by disconnecting and twisting the green and white wires together at the back of the meter Disconnect each Vulcoder from the VSL Vulcoder line Measure the resistance at these connection points There should be no resistance detected when measuring between the green and white wires at the Vulcoder hook up point July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 6 67 5 To check for a bad Vulcoder disconnect each Vulcoder from the VSL line and power up the meter If the meter powers up connect one Vulcoder at a time and manually reseguence Section 3 4 1 the Vulcoder before restarting the meter 6 Replace meter July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 68 CHAPTER 6 6 6 TROUBLESHOOTING WORKSHEET If you need assistance this will help us find 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 If not whose Channel C load cells If not whose Channel D 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 cutting welding mechanic
52. lly 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 grease the inside of the connector 6 Check welds on load cell brackets IMPORTANT If a weld repair 1 required remove the load cell CAUTION Do not exceed 140 degrees Fahrenheit 60 C on the load cell Arcing on the body of the load cell voids the manufacturer s warranty and may seriously damage the load cells structural integrity The load cell must NOT be installed if this occurs i Tipper Trucks Keep bearing surfaces greased preferably with a Moly Disulfide type of grease 8 Check and grease the rear hinge pin pillow block assembly 9 Check all wiring for condition routing and protection 10 Check meter for secure mounting and strain relief of wires 11 Check system for functionality 12 Review and address any driver concerns Typical Western Logger Mounting 650 890 Ib ft 3 places 1 000 1 400 Ib ft 2 places Figure 5 C New Hutch Center Hanger Mounting July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 40 CHAPTER 5 Ib ft 480 500 Ib ft laces 350 470 Ib ft Figure 5 D Typical Hutch or Transpro Center Hanger Mounting 480 500 Ib ft Torgue arm 500 550 Ib ft Figure 5 E July 2001 VULCAN ON BOARD SCALES 1 80
53. n Error code will be displayed 1 e Err 03 Err 07 Err 08 or Err 09 If this happens the system will have to be Manually Seguenced 2 2 1 MANUAL SEQUENCING Manually disconnect all trailer VSL Vulcoders as shown in figure 2 A and confirm that if the truck has two Vulcoders that one is set up as a Front and one as a Rear per installation instructions section 1 5 TRAILER DISCONNECTED TE Figure 2 A Disconnected Trailer With the meter in the Program Sequence PS mode press and release the CAL button to start the sequencing mode The meter will find and sequence the truck Vulcoders in a few seconds and will display their front F or rear r designators Manually connect each trailer starting with the most forward trailer connection As each connection is made the meter will verify each connection with either an indicating a front VSL Vulcoder or an r indicating a rear VSL Vulcoder If the PS appears on the display no VSL Vulcoders are detected Press the CYCLE button to store the seguencing information The meter will then advance to the next programming function 2 3 SETTING THE DISPLAY CODE The number of VSL Vulcoders connected to the Vulcan system corresponds to the number of channels The first number in the display code 1s the number of channels The next two numbers or letters determine how the channels will be displayed When code 000 is selected the meter autom
54. nd connect the VSL Vulcoder wires to the terminal block refer to Figures 1 M and 1 N Secure the power cable so it does not obstruct other in cab equipment strain relieve the power cable and cut to length Strip the wires and make all wire connections to the terminal block refer to Figures 1 M and 1 N Do not plug the terminal block into the meter at this time Disassemble the positive fuse holder red wire Apply grease to the positive connector at the battery post to inhibit corrosion Connect fused power leads directly to battery posts 12 or 24 Vdc Refer to Section 7 2 System Specifications Do not connect the power cable to a power source activated by the key switch power should be supplied at all times July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 14 CHAPTER 1 STRIPPING WIRES FOR METER 1 4 TWIST TIGHTLY DO NOT SOLDER Be careful that stray wires DO NOT contact adjacent terminals Figure 1 M Stripping Wires for the Meter Stress Tek Inc Kent WA U S A o 1 Eune Jus O 12Vdc only 2A fast blow fuses in power leads 24Vdc only 1A fast blow fuses in power leads screws 0 1 0 Do not remove POWER POWER GREEN lt WHITE A VSL VULCODER POWER lt 7 COMMUNICATION CABLE CABLE COMM LINK Figure 1 N Wire Connections to the Meter 11 Review steps 1
55. nd weather web measures resistant elastomer small deflections caused by weight on the load cell Figure 1 E 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 July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 1 gt 1 2 VSL VULCODERS The VSL Vulcoder is specifically designed to be used with the V500 Meter The functions of the VSL Vulcoder are to supply power to the load cells or air sensors and receive the analog voltage signal from the load cells or air sensors A computer inside the VSL Vulcoder then calculates the weight based on the calibration values the Tare Weight and the Cal number for that particular channel which are stored in its memory When the meter reguests weight from a channel the proper VSL Vulcoder will respond and send the weight information back to the meter All VSL Vulcoders connect to the same single 2 wire cable Any VSL eguipped trailer can be plugged into any truck with a V500 meter and be immediately identified and read properly POWER amp 2 WAY COMMUNICATIONS TO OTHER 10 5 29 Vdc WEIGHTIbkg A AS S VSL VULCODER VSL VULCODER VOOR MEIER DA ER STORES DATA STORES DATA LOAD CELL LOAD CELL LOAD CELL LOAD CELL Figure 1 F V500 Vulcan Electronics System Diagram Shown 1 3 V500 METER Applic
56. nly one or two meter channels A or A and B Channel A usually represents the truck or front load cells regardless of the number of load cells connected to the VSL Vulcoder Channel B usually represents the trailer or rear load cells The total weight for both the front and rear load cells is represented on Channel A B LOAD CELL LOAD CELL VSL VULCODER VULCODER LOAD CELL LOAD CELL CHANNEL A CHANNEL B LOAD CELL LOAD CELL LOAD CELL VSL VULCODER VSL VULCODER LOAD CELL LOAD CELL LOAD CELL CHANNEL A CHANNEL B Figure 1 H Vulcan 4 and 6 Cell System Configurations July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 1 11 1 5 ELECTRONICS INSTALLATION Tape the VSL Vulcoder connectors prior to routing the cabling to avoid contamination Mount the VSL Vulcoders on the inside of the truck frame rail or next to a structural member The VSL Vulcoder mounting surface must be in an area protected from road and hauling debris Route the black cable to the load cells Do not trim the black cable to length Important Check the connectors to make sure they are clean and dry Do not get moisture contact cleaner or any other substance inside of the connectors Check the load cell connector coming from the VSL Vulcoder for an O ring Attach the black cable connectors to the bulkhead connectors on the load cells Make sure they are finger tight plus an ad
57. ompletely into the connector and check their position by looking through the translucent connector body Crimp the connector cap down flush with the top edge of the connector body ensuring a good connection Tape the connection and all of the wires with the orange insulation stripped off to help seal and prevent wire chaffing that can cause a wire to short Wire tie the splice so that the connection is strain relieved Find a suitable location for each additional VSL Vulcoder needed in the system Connect additional VSL Vulcoders in the system to the 2 wire cable by splicing each color coded wire from the communication cable and the VSL Vulcoder cable refer to Figure 1 J When using the Vulcan supplied 3M connector do not strip the insulation from each wire Be sure to insert wires completely into the connector and check their position by looking through the translucent connector body Then crimp the connector cap down flush with the top edge of the connector body ensuring a good connection Tape the connection and all of the wires with the orange insulation stripped off to help seal and prevent wire chaffing that can cause a wire to short Wire tie the splice so that the connection is strain relieved July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 12 CHAPTER 1 lt GREEN WHITE ORANGE CABLE Figure 1 J VSL Vulcoder Communication Connection 8 Once all of the Vulcoders have b
58. oth front and rear axles using a certified platform scale This is the truck s Tare Weight Enter this number in the space provided For the Net Payload Weight Method the Tare weight must be set to zero Note If your truck will be hauling different trailers weigh the entire empty truck with the trailer disconnected and with full fuel tanks and driver both front and rear axles using a certified platform scale July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 4 27 Tare weight of entire empty truck Weigh the entire empty trailer s all axles This is the trailer s Tare weight Enter this number in the space provided Tare weight of entire empty trailer Stop the empty truck and trailer on level ground a Press and release the TARE button The LED s by TARE and LOCK are illuminated The flashing LED below the channel designation indicates which channel is selected In addition the unit of measurement either Ib or Kg is also flashing Use CYCLE button to select channel to advance to the next channel while remaining in the set Tare mode n OR D Use the UP or DOWN ARROW buttons to increase or decrease the displayed Tare weight to match the actual Tare weight for each channel If the Tare Number Channel and Weight Indicators are Flashing The Lock option is activated The UP and DOWN ARROW buttons have no effect Refer to Section 2 7 to deac
59. 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 solve 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 vou 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 V500 Test Procedures Load Cell Evaluation Test Procedures and Vulcan Error Codes If a problem occurs and no Error Codes appear use the V500 Meter to isolate the problem to the appropriate channel July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 46 CHAPTER 6 6 1 V500 METER TEST PROCEDURES Six diagnostic tests are available for the Vulcan V500 Meter These can perform a thorough test of the display keyboard and the VSL communications The tests are called Test 1 which performs the keyboard test Test 2 which performs the VSL communications test Test 3 which performs the LED display test Test 4 which displays the Vulcoder software version number Test 5 which displays the load cell offsets Note This test will only appear
60. rresponding number should be displayed This indicates proper button functioning M Press the UP and DOWN ARROW buttons at the same time to exit from test 1 6 1 3 TEST2 Test 2 the communications test can be used to determine if the electronics are communicating properly n OR Use the UP or DOWN ARROW buttons to begin the selected communications test The channel LED s indicate which channel you are presently looking at A Press the CYCLE button to change to a different channel The display will show in the left most position and you should see a number on the right hand side which will be counting up As you press the UP or DOWN arrow keys you will cycle through the various readings listed below n Number of transmission attempts e Number of communication errors t Number of time outs detected Some errors are inherent in any communication system and the VSL system is designed to recover from most error conditions If the error rate becomes excessive greater than 1 of the total transmissions contact your Vulcan dealer ORBA Pressthe TARE or CAL button to exit from test 2 July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 48 CHAPTER 6 6 1 4 TEST3 Test 3 can be used to determine if the LED display is operating properly n OR Use UP or DOWN ARROW buttons to begin the selected LED display test This tests all the combinations
61. rtant that the VSL 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 If the load cell cannot be brought to Vulcan specifications contact your Vulcan dealer July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 6 51 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 O MULTI METER o 6 5 o 88 9 T Cr WHITE BLACK Q goo GREEN RED o o J CHECK OUT BOX LOAD CELL LOAD CELL Figure 6 B Leakage
62. s Not Change When Truck Is Being Loaded 64 6 5 5 Meter Stops Powering Up After Displaying All Digits 64 6 5 6 Meter Displays LO LO AAA 65 6 6 Troubleshooting Worksheet dee tole lel o no s menton 68 6 7 Troubleshooting Assistance And Replacement 70 7 0 Nn E 0116003 Doo 7 7 1 Starting Calibration non 72 7 2 Ds 73 7 3 Assistance In Fine Tuning Your Scale System Primarily For Two Channels One Truck Application Only 52 2 nc fod Deed dole ns nina he 74 7 4 Keeping Records tes 76 July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 4 CONTENTS July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 1 5 CHAPTER 1 0 VULCAN SINGLE LINE VSL TECHNOLOGY V500 ELECTRONICS SYSTEM Vulcan On Board Scales can be installed on all types of vehicles including hook lifts logging trucks flatbed trailers chip trailers front loaders rear loaders side loaders roll offs transfer trailers and many other commercial vehicles requiring scales Axle group weights payload weights gross vehicle weights and individual pick up and drop off weights can be measured using the Vulcan On Board Scale System The Vulcan
63. s opened for 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 Note In areas where salt is used on the roads wrap the threads of the load cell connector with plumber tape Teflon tape This will not allow salt to penetrate the threaded connection 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 L 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 3 4 7 8 I 1 1 8 1 1 4 Ib ft 400 500 400 590 650 890 1000 1400 1450 1780 July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 5 39 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 fu
64. system is running 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 4 V500 Meter Error Codes o o 98 CONNECTOR oo TO VULCODER OFF ON LOAD SWITCH RED DOT WHITE BLACK CHECK OUT GREEN RED BOX CONNECTOR TO LOAD CELL CABLE 4 FEET Figure 6 A Vulcan Check Out Box To order a Check Out Box P N 56 10425 001 contact your Vulcan dealer July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 50 CHAPTER 6 6 3 LOAD CELL EVALUATION TESTS The tests listed below will help identify and locate any problem you may encounter with your Vulcan load cells Leakage Test Tare Test Resistance Test 6 3 1 LEAKAGE TEST PROCEDURE Required Equipment Digital Multi Meter with Conductivity Scale 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 1s measured 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 setup If a Vulcan Check Out Box is used it is impo
65. t be relieved at the time of measuring for all methods The pressure relief valve should be engaged during weight measurements If the truck is not equipped with a pressure relief valve relieve the pressure manually In addition all packing should be done after the weight is recorded AXLE WEIGHT Vulcan Scales can be used to reduce overweight fines by measuring a vehicle s axle weight For some vehicle configurations such as many logging trucks and trailers the channel weights will be the axle group weight For other configurations the channel weight may not be the actual axle group weights because some of the load is being shared by other axles For short log and refuse trucks the scales can indicate a weight on an axle group that should not be exceeded in order to keep the truck legal Load the truck close to the legal maximum according to a certified platform scale The number displayed on the channel of the meter corresponding to the axle group represents an approximate rear axle group weight and may be used as a reference weight to avoid exceeding the legal limit This reference weight may be different from the weight shown on the certified platform scale display Note Channel does not represent the steering axle weight when fully loaded July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 26 CHAPTER 4 4 1 1 GROSS VEHICLE WEIGHT Gross Vehicle weight Entire truck weight includ
66. tivate the Lock feature To Return to Normal Operating Mode E Press and release the TARE button July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 28 CHAPTER 4 4 2 2 Entering Tare Weight For A Typical Short Logger System Weigh the entire empty truck with full fuel tanks and driver both front and rear axles using a certified platform scale This is the truck s Tare weight Enter this number in the space provided For the Net Payload weight method the Tare weight must be set to zero Tare weight of entire empty truck Divide the empty truck weight by 2 and enter is the space provided Tare Weight of entire empty truck divided by 2 Weigh the front axle group of the empty trailer Tare Weight of front axle group of the empty trailer Weigh the rear axle group of the empty trailer Tare Weight of rear axle group of the empty trailer Stop the empty truck and trailer on level ground E Press and release the TARE button The LED s by TARE and LOCK are illuminated The flashing LED below the channel designation indicates which channel is selected In addition the unit of measurement either Ib or Kg is also flashing E Use the CYCLE button to select a channel or to advance to the next channel while remaining in the set Tare mode n OR Use the UP or DOWN ARROW buttons to increase or decrease the displayed Tare Weight to match the actual Tare Weight for each channel
67. uminated Note The CAL button may need to be pressed more than once to fully exit the Calibration Mode July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 4 33 4 5 FINE TUNING THE CALIBRATION NUMBER FOR GROSS VEHICLE WEIGHT AND NET PAYLOAD WEIGHT METHODS WHEN MORE THAN ONE CHANNEL IS USED PER TRUCK OR TRAILER To properly calibrate a V500 system all channels used need to be calibrated Listed below is a calibration procedure for the Gross Vehicle Weight and Net Payload Weight Methods when more than one channel is used per truck or trailer If additional assistance is needed to fine tune your scale system please follow the instructions shown in Section 7 3 Assistance in Fine Tuning Your Scale System Note When fine tuning a trailer with the load cells positioned over an axle group refer to section 4 4 for fine tuning the Calibration number Truck Full Truck Empty V500 600 WEIGHT 500500 WEIGHT X 20000 LEE CHANNEL A CHANNEL B 1 CHANNEL A CHANNEL B LB LB 56240 35000 PLATFORM SCALE PLATFORM SCALE Figure 4 B Calibration GVW and Net Payload More than One Channel Used on 2 channel refuse system Truck Full Truck Empty V500 600 WEIGHT V500 600 WEIGHT gt 2000 188 CHANNEL CHANNEL 35000 15 ABE o A HBla muzom 7 X Led Sa E LB PLATFORM SCALE PLATFORM SCALE Figure 4 C
68. y other meter keys will save the current displayed channel s Upon the next power up the meter will start up where it was last set either locked on a channel s or in the cycling mode July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 CHAPTER 3 23 3 4 DISPLAYING TARE WEIGHT Lock the meter on Channel A or D The Tare weight is the displayed reading when the vehicle is empty For setting the Tare weight refer to Chapter 4 0 V500 Calibration 3 5 DISPLAYING CALIBRATION NUMBERS Lock the meter on Channel or D The LOCK LED will be illuminated Press and release the CAL button The CAL LED will be illuminated and the meter channel will flash CU JU ABCD LOCK e o 00 To View the Cal Number on Other Meter Channels E Press the CYCLE button until the meter is locked on the desired channel either A B C or D To Exit Displaving Cal Numbers Press and release the CAL button until the LED is no longer illuminated The CAL button may need to be pressed once or twice for this to occur 3 6 VULCODER UPDATING After adjustments have been made to the meter s set up tare or calibration values the meter will update the Vulcoders with the new information while displaying Note Do not power off the meter while it is updating the Vulcoders July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 100
69. y subtracting the truck empty weight from the truck fully loaded weight P Weight shown on Certified Scale truck fully loaded Weight shown on Certified Scale truck empty Example P 56 240 Ib 35 000 Ib 21 240 Ib V Weight shown on V500 Meter truck fully loaded Weight shown on V500 Meter truck empty Example V 55 000 Ib 35 000 Ib 20 000 Ib If the average difference between the certified scale and the meter is more than several hundred pounds you may want to adjust the Calibration Numbers If so proceed to Step 8 To determine the new Calibration Number for each Channel refer to the formula shown below New Channel Cal Number Old Channel Cal Number x P V Example Old Channel Number 2050 P 21 240 Ib Certified scale net weight V 20 000 Ib Vulcan scale net weight New Channel Number 2050 x 21 240 20 000 2177 The Calibration Number for Channel B is the same as the Calibration Number for Channel A Channel B New Cal Number Channel A New Cal Number Example Channel B New Cal Number 2177 Record the new Cal Numbers in Section 7 4 Keeping Records located in the Appendix Repeat this procedure for other channels if they do not directly represent axle group weights Example C and D July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C STRESS TEK INC 2001 36 CHAPTER 4 July 2001 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10031 001 Rev C S

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