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FS2   

Fork-sensed lift truck scale   

User’s and Installation Manual 

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The following documents are in this manual: Introduction ………………………………. 2 Parts List .............………………………... 3 Operating tips ……………………………. 4 How the System Works ……………........ 5 Installation ……………………………....... 6-8 Noise filter installation ……………………. 9 Internal Reeving Installation …………... 10 Coil cable installation …..………………... 11 Alternative Wiring Arrangement …………. 12 One time calibration ............................... 13 Easy operation....................…………...... 14 Maintenance …………………………....... 15 Technical Notes ………………………...... 16 Parameter Sheet “F“ Scale……….......... 17 Parameter Sheet “A” Scale..................... 18 Accuracy ……………………………….…. 19/20 Warranty ………………………………........ 21

Rev: Nov 07

FS2 - Fork Sensed Lift Truck Scale Manual

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Introduction

Unlike any lift truck scale the FS2 has these desirable features:

• Instant installation avoids costly labour and equipment down-time.

• Immediate results since the system has been pre-calibrated at

factory • Weighs low and high weights accurately • Storing system when not using the lift truck for weighing

avoids scale damage • Versatile usage for a forklift fleet • If scale is damaged, then readily replace module. • Maintains lift truck capacity – no need to derate

FS2 Parts List

QTY Part Number Description

1 AWT05-506078 Weigh Point Service Parts Digital Indicator 12VDC

2 AWT05-506079 Weigh Point Service Parts 4K Load cell w/button

2 AWT05-506080 Weigh Point Service Parts Toe End Load cell

1 AWT05-506081 Weigh Point Service Parts Coil Cable Connection Steel Shield

1 AWT05-506082 Weigh Point Service Parts Inter-Fork Cable Connection Steel Shield

1 AWT05-506083 Weigh Point Service Parts Coil Cable Only

1 AWT05-506084 Weigh Point Service Parts Coil Cable w/Connector

1 AWT05-506085 Weigh Point Service Parts REEVING CABLE

1 AWT05-506088 Weigh Point Service Parts End Junction Box

1 AWT05-506089 Weigh Point Service Parts Inter-Fork Cable With Connector

1 AWT05-506090 Weigh Point Service Parts Fork Connector for Coil Cable

2 AWT05-506091 Weigh Point Service Parts Fork Connector for Inter-Fork

1 AWT05-506092 Weigh Point Service Parts Load cell Trim Card

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Scale operating tips These suggestions will optimize the accuracy. Only use the fork upright connector system for demo use, calibration & for system test. ⇒ Place load against fork heel, avoid overhanging load beyond the fork’s toes ⇒ Keep the load centered and maintain a wide spread between the two forks. ⇒ Avoid pressing the zero button between loads, the scale should track zero

without intervention. ⇒ Keep the mast perpendicular

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Compression loadcells are placed within the forks of the lift truck. Each of the four sensors sends out a signal that varies with the downward pressure exerted by the load bearing fork cover. Based on this signal, the weight computer calculates and displays the weight on the forks. The system can provide you with piece counting (optional) from entire totes of product, simply by entering a sample weight. All required functions and more, are handled by the display/processor. The loadcell’s high sensitivity leads to excellent accurate, 100% +/- 15 lbs. (A legal for trade system available shortly provides even greater accuracy). The forks rugged design allows you to install or remove the system easily in the event that standard forks are required. The system can also be used as a standard platform scale utilizing the forks removed from the truck. Should the system be frequently shut down, upon start up, the true weight and pre-set settings such as lb. or kg. will be saved. The system is resistant to water, most chemicals and saline atmospheres. Our customized kits can include options such as a label printer or an interface to a portable computer. We have the skills to develop custom software if required by your application.

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Quick Installation for Short Term Use

The system is provided precalibrated and can be operational in minutes – simply use the coil cable and portable battery for either trial use or portable operations. • The FS2 is designed to weigh pallets or crates that transverse both forks.

Do not weigh directly upon forks or you may introduce a weight reading error.

• Connect cable between forks, tighten connectors • Connect coil cable from display to one of the forks, strain relief cable on

fork hook with tie wrap. • Mount display in cab placing coil cable over the mast and tie-wrap at the

mast top. • Initially, use rechargeable battery to test out system. Later you may

hard-wire display into truck’s electrics. • Inspect all cables and tie down where necessary to ensure no snagging

occurs. • The scale is precalibrated at factory, however calibration procedures are

provided.

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Other than the mounting of the Display/processor unit, and establishing a power supply, there is no other highly technical installation required. The following steps should be taken to connect the system to lift truck power, and install wiring from the cab mounted display to the loadcells. Reeving cable installation 1. Remove standard forks from the truck and install the Weigh Point forks in the same manner and position as the factory forks. 2. Both cables from forks and reeving cable junction with 4 position terminal strip. 3. Install pulley and bracket for each stage of the truck. The best place is to follow hydraulic hoses. 4. Utilize the kellem and springs supplied to keep the cable taunt and squarely guided over sheave. The diagram shows reeving for the first stage. If practical instead of installing the pulleys and bracketry provided it is recommended to order the lift truck with an additional hose grouping. In this arrangement remove the vinyl hose sheaving and feed the cable directly through the hydraulic hose provided with the extra hose group package. Coil cable installation 1. Remove standard forks form the truck and install the Weigh Point forks in the same man-

ner and position as the factory forks. 2. Begin installation by mounting the junction box to the carriage. Holes can be drilled and

tapped so that the box can be bolted directly to the carriage or the box can be first bolted to a mounting plate which itself is mounted to the carriage. The location of the junction box should be such that the coil cable can travel in the direction of the carriage upward movement. Make certain allowance is made for sideshifter movement.

3. The fork cables should be secured to the carriage hidden from the possible damage. Avoid pinching or pulling of the cables. Square steel tubing can be tack welded to the carriage to secure and protect the forks cables.

Lift the carriage to maximum height slowly to ensure that the coil cable is long enough. Check all movements ( lift, tilt etc. ) to be certain the newly mounted cables do not interfere and are free from potential damage.

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Installation and Wiring Physical Installation The WP9202 indicator can be located wherever convenient. It is not advisable to locate the indicator where it would be exposed to direct sunlight, excessive mechani-cal abuse or moisture. Power requirements Find out the voltage of your lift truck’s electrical system. Our system requires 12 VDC, advise truck’s voltage is 24, 36 or 48 VDC, a power supply will be added to the kit for voltage conversion. The kit will also run from a rechargeable battery as an alternative to using your trucks power. The Weigh Point system requires “clean power”. To assure no contamination by stray frequencies always install the provided noise suppressor. This will prevent problems both presently and future interference. * Diagram on pg. 6 Wiring Connect the cable from reeving or coil cable to rear indicator’s terminal strip.

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Red +12

Black _

connect

connect

Blue +12

Black -

Red + FILTER

to Battery - to Battery +

Noise Filter Installation

The Weigh Point system requires “clean power”. To assure no contamination by stray frequencies always install the provided noise suppressor. This will prevent interference problems.

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FS2 – Internal Reeving Installation

Only 1st stage & Reeving shown. This arrangement is then repeated for 2nd and 3rd stage trucks.

Technical Support 1-800-268-7400 Reeving @ back of carriage

Reeving @ front of carriage

Loadcells Mounted in chains

Braided Strain Relief

Cable to indica-tor

Spring

Pulley &

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Coil Cable Installation

Indicator in cab

Mounted Junction box with bracket.

View from front of lift truck

View from cab

Interior of junction box with wiring to terminal strip

Red to Red Black to Black White to White Green to Green

Coil Cable

Loadcell cables to junction

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Alternative Wiring Arrangements for Fork Assemblies

Above dwg “A” denotes coil cable for tests, calibration or short term weighing. For permanent coil cable installation do not use upright’s connector system

“A”

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Button Position for Calibrating

The indicator is programmed at factory with default parameter setting. To change parameters see parameter sheet (page 16/17) After installation, your next step is to do “one time calibration” . This procedure must performed with forks at selected weigh height. This height should be used consistently for weighing to assure best accu-racy.

Your Weigh Point System is custom programmed to work with you lift truck by these simple steps: 1) Slide the switch behind the rear inspection plate. (CAL ) 2) With key [1] depressed turn indicator on. See F1 displayed. Raise your forks off the ground, Ramp F1 to F15 with [5] to go forward, or [4] to go backwards. 3) With F15 displayed and no weight on forks press key [2] then press key [3] 4) Lift known load and press key [4] or [5] to display F16 5) With F16 displayed press [2]. Proceed with entering known weight using keys [4] (shift) and key [5] (ramp) numbers. 6) Press [3] to set weight 7) Move slide Switch at rear of indicator to reset system.

1 2 3 4 5

One Time Calibration

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Button Position for Operation

Your Weigh Point System is custom programmed to work with you lift truck by these simple steps:

WEIGHING: Raise load and read displayed weight.

ACCUMULATION: Each raised load can be accumulated by pressing [5] Notice the display will briefly display the accumulated weight.

RETAINED ACCUMULATION: is displayed by pressing [4]

CANCEL ACCUMULATION TOTAL: by pressing [4] followed by quickly pressing [2] while accumula-tion total is displayed. Standard Setup The tare button is deactivated so that accumulation is available. The accumulation is set with parame-ter A7 @3 (page 12)

Easy Operation – WP9202

1 2 3 4 5

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Performance of the Fork-Sensed lift truck scale is generally non deteriorating, however, there are factors that do affect accuracy and reliability and there are preventative maintenance procedures that can be performed by skilled mechanics or technicians. The facility should have available a known weight ( 200 to 1000 lbs ) that can be lifted regularly to confirm the accuracy of the scale. Calibration of the scale is constant and will not degrade unless the carriage assembly has been damaged to cause significant misalignment. Do not recalibrate until the mechanical conditions are corrected. Most common problems involve damage to the reeving cable and to the coil cable. The damaged cable can be completely replaced or sometimes replaced in part by splicing. Prevention of damage begins with adequate secured and protected cables. For example it is often beneficial to bolt a protection plate between the forks, on the front of the carriage. Weekly: Inspect cables for damage such as cuts or crushing. Ensure fork covers are tight (tighten the bolts) Ensure all dirt and dust are cleaned from display membrane (use only a soft cloth moistened with a non-abrasive cleaner for this procedure). Monthly Remove fork covers, inspect loadcells and ensure tight.

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TECH NOTES

PRODUCT Fork-Sensed Forklift Scale FOCUS Weight signal transmission signals from the sensors to the display The reeved wiring system is preferred to carry the sensor signal to the cab mounted digital display, this tech note discusses 3 methods, the Cascade 6:1 system is sel-dom utilized but currently available. Wired systems Three ways applicable to Weigh Point are: 1. Normally reeved system 2. Coil cable system 3. Wire reel system (Cascade 6:1 typical) 1. An appealing arrangement is to have the wire cable track alongside the lift-ing chains similarly to the route followed by reeved hydraulic hoses. In fact, the scale cable is sometimes installed into hydraulic hoses to provide additional protec-tion. Tension springs can be installed to keep the wire properly tensioned on the pulley. 2. Some customers opt for the coil cable system as it is universally adaptable, easy to install and readily serviced. The disadvantage of the coil cable is its prone-ness to damage if snagged and severed in certain harsh environments (commonly the damage is at the junction box end which permits shortening at the damaged section and re-use) 3. Wire reel systems must be of the brushless type such as manufactured by Cas-cade Hydraulics and designated as the 6:1 take-up reel. This system replaces the external hydraulic hose reel with the unit that incorporates both hydraulic hoses and a 4-wire electrical coil that provides a continuous connection to the display regard-less of the position of the carriage. Brush type systems are unsuitable.

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Code: Name: Description: Code/Value:

F1

Full Scale Full Scale Number of Division x Value of Division

5000 1000 1500 2000 2500 3000 4000 5000 6000 8000 10000 15000 20000 30000

F2 Division Minimum difference between two weighing reading

1 2 5 10 20 50

F3 Decimal Pt. Decimal point position 0 , 0.0, 0.00, 0.000, 0.0000, 0.00000

F4 Overload Limit Display will show “_ _OL_ _” if the reading is greater than the value

100%F.S 110%FsS

F5 Zero Tracking Display maintain zero while the reading is less than this selection and stable

0.5d 1d 3d 5d OFF

F6 Zero Range The range of zero-setting operation is enabled

2%F.S 100%F.S

F7 Motion Band The MOT LED light out and the weighting operation (I.e. zero, tare) is enable while motive reading, is not exceeded the limit of this selection

1d 3d 5d 10d

F8 Digital Filter L– light, M-middle, H-heavy. Select heavier, the reading is stable but slower

L M H

F9 Calibration Unit Select unit at calibration. You should use “lb.” weights if you select “lb.”. Select unit at calibration. You should use “kg.” weights if you select “kg.”.

F10 Communication Mode 0-standard RS-232 output 1-printout 0 1

F12 Print Ticket Print ticket Mode: 0-Print “GROSS, NET,TARE” 1-Print displayed weight

0 1

F15 Zero Calibration Show internal codes at zero (no load on platform) and wait for MOT LED light out, press SET key to save zero calibration value.

F16 Span Calibration Enter the value of current test weights on platform via direction keys and wait for MOT LED light out, press SET key to save span calibration value. See appendix A if display show EER 1

F17 Manual Zero Calibration Check or re-establish zero calibration value.

F18 Manual Span Calibration Check or re-establish span calibration value.

Parameter Sheet “F” scale

To change these settings, place in calibration mode (see page 14) System Serial No. ____________ Indicator s/n _________________ Loadcell Type ____________________ Loadcell S/N _________________ Date ___________________________

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“A” Scale Typical Settings

1. When the power is ON, press key [1] and hold, then slide the switch behind the rear inspection plate. The display shows A1 2. Ramp A1 to A8 with keys [5[ to go forward, or key [4] to go backwards, 3. Press key [2], shows value to change value use key [4] or [5] 4. To save/accept displayed data press key [3]

Code Name Description Code/Value

A1 Baud Rate Set baud rate of the RS232 serial communication when F10 is 0

1200 2400 4800 9600

A2 Communication Model “c” = continuous mode “d” = command mode

C d

A3 Data bits and parity 8N:8 data bits with no parity bit and 1 stop bit 7O: 7 data bits with odd parity bit and 1 stop bit 7E: 7 data bits with even parity bit and 1 stop bit

8 N 7O 7E

A4 Disable the lb/kg “0” - disable the lb/kg key “1” = enable the lb/kb key

0 1

A5 ID no. enable “0” = disable the ID no. “1” = enable the ID no.

0 1

A6 ID no. entry Pressing [4] and [5] key to input ID no. and pressing the [3] key to store and return to A6. Displaying Axxxxx. Prints ID flashing. No. column after ID no. being set (see APPe) 6-bit ID no. can be inputted

A7 Additional features 0 typical 1 counting feature 2 peakhold 3 accumulation 4 accumulation and peakhold

0 1 2 3 4

A8 Weight threshold Typically 100 For lbs. threshold

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Accuracy The 100% (+/- 15 lbs.) accuracy is based upon the lift truck’s capacity e.g. a 4000 lb. ca-pacity lift truck will provide a 20 lb. error possibility (0.5% of 4000 lbs.) In practice you will observe this error only with high weight loads. Weigh accuracy of low weight loads, ie. Up to 300 – 400 lbs. will only show a maximum 5 – 10 lb. error. Maintenance Performance of the FS2 scale is generally non-deteriorating, however, there are factors that do effect accuracy and reliability and there are preventative maintenance procedures that can be performed by skilled mechanics or technicians. The facility should have available, a known weight (200 to 1000 lbs.) that can be fitted regularly to confirm the accuracy of the scale. Inaccuracies of scale failure that develop will be the result of a fault such as damaged weigh sensing disk, cable or digital display. The calibration of a functioning scale will not deteriorate. Troubleshooting Although designed to operate similarly to a conventional floor scale, the FS2 works in a dy-namic environment and can occasionally fault like any other industrial system. There will be less incidents of failure if the fork covers are removed when utilizing the fork-lift for non-weighing usage, however the system will be reliable when permanently in-stalled. If the display is weighing incorrectly or displays an error code then it may be the result of a wiring fault. Red wire to black wire (excitation lines) can vary from 350 ohm to approx. 400 ohm. Green to white wire (signal lines) should be 350 ohm +/- 5 ohms. A short in the circuit is observable by connecting all lines to the ohmmeter probe and the other probe to the weigh sensing body. The ohmmeter is set on the megohm scale. Make certain no physical contact is made with the probes or a false reading will result. The meg test will show (infinity) or as though the probes were in a non-connected position.

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Removing a sensor cable from the circuit one at a time from the cover terminal strip (no need to physically remove sensor), simply disconnect the four lines from the jumper block will permit checking the display reading to see if fault is corrected by the removed sensor. Remove each of the four sensors until the faulty sensor is lo-cated. Check each connector for disconnected wire or a short between connector pins. Check the interconnecting cables for opens or shorts, use the ohm meter to facilitate these tests. Pull, twist and wiggle the cables whilst observing ohm meter for changes, which indi-cates an intermittent fault. Weigh sensors with fault need to be replaced. Electrically, each sensor has a 350 ohm impedance. The wiring of each sensor is as follows: Red + excitation Black - excitation Green + signal White - signal The sensors can be checked electrically to establish if the circuit is within specifica-tion. If the circuit fails the test then the sensor should be replaced (cut back the wires to a pigtail as a last attempt to get successful results before discarding sensor). An ohm meter with a meg-ohm scale is required. Join all four wires to the ohmmeter probe, the other probe to the body of the sensor. Set ohm meter to the meg scale. A bad sensor will display a reading. It should read infinity. Set ohmmeter to ohm scale and expect green to white wires to read 350 ohm. Ex-pect red to black wires to read under 400 ohm. Another handy check is required if the display readings are unstable. Remove the disc connection out of the circuit, one at a time until the reading stabilizes with removed sensor. The removed sensor can be considered the culprit. Wiring – all sensors are connected in parallel, ie all reds together, similarly black,

Warranty One year free replacement of faulty material and/or workmanship of the scale system. Cabling and batteries are not warranted. No other warranty liability is expressed or implied. 90 day warranty on all service parts. Precautionary procedures: To prevent voiding warranty

Weigh scales are measuring devices and require reasonable handling and care

Inspect cabling to ensure no snagging will occur. Note that damaged cables are

not covered by warranty.

Static buildup can easily destroy the microprocessor display. If static build up is suspected then take precautions such as use of grounding straps or chains, anti-marring tires are particularly responsible for static buildup

Periodic inspection and adjustment of the scale components is required for

scale longevity and safety.

Please note the precautionary notes are mandated as a condition of the product

warranty.