Weighing System CALIBRATOR ZURF

Transcription

1 Weighing System CALIBRATOR ZURF

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3 Content First necessary steps p. 2 General information p. 3 Fault CALIBRATUR ZURF p. 5 Fault Adjusting actuator p. 7 Fault Trend actuator p. 8 Fault The weight p. 9 Fault Actual load p. 10 Connection diagram p. 11 Connection box p. 12 Error messages p. 13

4 FIRST STEPS when checking the weighing system and the CALIBRATOR ZURF A: Check the power supply The tractor battery should preserve minimum 12 V with actuator in use. The connection between the tractor battery and CALIBRATOR ZURF must be stable. B: Check the plug connections between the spreader and the Calibrator The plugs must be absolutely clean and without rust Can be cleaned and protected with contact spray. C: Do a Full Calibration D: Calibrate the Actuator

5 General information FRONT FRAME / CHASSIS: Check that there are no foreign bodies (stones etc.) jammed between front frame and chassis. There must be free space all the way round. FRONT FRAME / CHASSIS: Check that there is an absolute parallellity between front frame and chassis all over the height of the frame. PARALLEL BEARING Check that the bearing ring is horizontal and parallel with the blade springs. Bearing ring must be completely tightened. BLADE SPRINGS: Check that both blade springs are horizontal and perpendicular to the front frame. The blade springs must not be bended and they must be absolutely tightened. The direction arrow of the load cell must be downwards. LOAD CELL, 6T: Check that the load cell is completely tightened by: 2 x M16 Unbraco and 4 x M12 bolts. If retightening the load cell or carrying bolt the weight must be recalibrated. LINK PINS: If the link pins are mounted in the lower position be sure that the lift arms do not collide with the parallel bearing rings from min. to max lifting height.

6 LOAD CELL BOX: The connection box is mounted under the spreader. Water must absolutely NOT penetrate into the box and cables may NOT be corroded. PLUG CONNECTIONS: Plugs must be absolutely clean. Can be cleaned and protected with BOGBALLE contact spray. SETTING POINTER: The connection rod of the setting pointer must be mounted / adjusted in such a way, that the shutters of the spreader are closed - when the setting pointer is placed on the scale number 0. (approx. 0,5 mm. opening) The adjustment is made on the connection rod. ROD CONNECTION: As standard the connection rod is mounted in standard position (Ø10 mm.) In case very large quantities being used on metres' spread width, a +40% / -40% connection rod (Ø12 mm.) can be used as option. Same connection rod is used for very small quantities (Ø8 mm.).

7 FAULT - CALIBRATOR ZURF CALIBRATOR ZURF turns off and on again without pressing ON / OFF. The system is unstable and opens/closes unprovoked. CHECK: That the tractor battery preserves minimum 12 V with actuator in use. That the connection between the tractor battery and CALIBRATOR ZURF is stable. That there is a direct connection from the +12V cable as well as the earth cable From the battery to CALIBRATOR ZURF (Both + and must be directly connected to the battery) That all cable connections have minimum the same quadrant as the CALIBRATOR ZURF +12V power supply cable. That the plug connections between CALIBRATOR ZURF and the spreader are intact without short circuits and with clean plugs without corrosion. If all of the above is ok: o Disconnect the calibrator from the spreader, run a wet finger over the pins in the AMP-connector (male). o While doing this check if the weighing value flickers rapidly up and down o If yes - go to the next page o If no the CALIBRATOR should be replaced/repaired ON THE CALIBRATOR Press Menu Test Power Supply The values mentioned are the limiting values. If the values of the CALIBRATOR are beyond these values the component in question should be checked/changed. Power supply U-Battery : 12V - 15V Tractor battery FSI-Speed : 3,0V 8V Impulse sensor FSI-Pto : 1,2V 8V Pto sensor Temperature: CALIBRATOR ZURF I-Actuator U-Battery Potentiometer FSI Speed FSI-Pto SI Mode SI Tank SI Start/Stop SI Impl Temperature [ENTER]: will freeze the values ENTER Freeze On/Off ESC

8 If the CALIBRATOR is ok as described above: Connect the AMP-plug between CALIBRATOR and spreader again Check the voltages in the connection box between the load cell and the wire net of actuator All measurings with the minus wire on the green wire: + (Brown) = 5,0 volts ± 0,2 +sign (White) = 2.5 volts ± 0,2 -sign (Yellow) = 2.5 volts ± 0,2 A. Brown: If there are not 5 volts, disconnect the wire (brown) to the load cell, and measure again. If there are now 5 volts there are faults in the load cell. B. Brown: If the 5 volts are shown, the voltage in the CALIBRATOR is checked by switching over to the test picture "Power supply" (See page 1). If 5 volts are shown - there are faults in the wire net of the spreader. If 5 volts are not shown - there are faults in the CALIBRATOR. C. White/Yellow: If there are 5 volts on the brown wire, but not 2,5 volts on the white and yellow wires (+sign / sign) - there are faults in load cell or in the wire net of the spreader. D. Disconnect the two wires to the CALIBRATOR (+sign / sign), and measure on the two wires coming from the load cell (+sign / sign). If there are still not 2,5 volts - there are faults in the load cell. If there are 2,5 volts - there are faults in the spreader's wire net

9 FAULT Adjusting Actuator Adjusting actuator is unstable and moves forward and backwards. Adjusting actuator is not placed at the correct scale e.g. scale 4.5 during manual calibration. CHECK: That Set pos, Eff pos and position of the handle correspond to each other. That the actuator is calibrated correctly. Complete the Actuator calibration under all circumstances. That all moving parts are moving easily and without corrosion. That the plug connections between CALIBRATOR ZURF and the spreader are intact without short circuits and with clean plugs without corrosion. That there is a minimum 12 V power supply with actuator in use That 11A is not exceeded with actuator in use If you still have the fault after you have gone through all of the above you need to change the actuator. If all of the above is ok move on to trouble shooting the load cell ON THE CALIBRATOR Press Menu Test Adj. Actuator The values mentioned are the limiting values. If the values of the CALIBRATOR are beyond these values the component in question should be checked/changed. Adj. Actuator [+ / -] Required scale Curser step 0,25 Curser and actuator position are changed by [+ / -] Actuator scale Expected position Actual response from actuator set pos : 0,00 9,00 Set scale eff pos : 0,00 9,00 Registrated scale deviation : -0,1 +0,1 Deviation between set/eff current : 0,00 3,00 battery voltage: 12,00 15,00 Battery power motor status : OK Actual status set pos eff pos deviation pot-meter current battery voltage motor status 0,01 0,01 1,214 0,01 13,72 OK ESC Exit

10 FAULT Trend actuator Trend actuator does not change position when activated CHECK: That CALIBRATOR ZURF has been switched off and on again after mounting of Trend Actuator. That PTO-shaft does not rotate. That PTO sensor is intact and mounted correctly regarding to mechanical and electrical use. That the system is not blocked as a result of corrosion or damage. That all cables are mounted correctly in the connection box and that there there is no water/moist in the box. That the response from the actuator is correct regarding to the actual position. If you still have the fault after you have gone through all of the above you need to change the actuator. ON THE CALIBRATOR Press Menu Test TB-Actuator The PTO must be stopped during the test at it can damage the transmission of the spreader Trend Act. Test [+ / -] Required Actuator position Curser and actuator positions are changed by [+ / -] Normal Trend Actuator position Expected position Actual response from actuator Position Status Normal Ok Warning! Do NOT turn on PTO during this test! + ENTER ESC Move to TREND Stop Move to normal Exit -

11 FAULT The Weight The weight is unstable and moves from 10 kg up till 200 kg The weight is out of calibration and moves from 0 kg to 9999 kg CHECK That various limiting values are observed. If this is not the fact a Full Calibration must be completed. Alternatively Factory Setting can be chosen. Factory Setting tells whether the calibration is defect or wrongly calibrated. That the plug connections between CALIBRATOR ZURF and the spreader are intact without short circuits and with clean plugs without corrosion. The connection box mounted on the spreader is free of water/moist or corrosion. That there is no damage of the parallel weighing. That there are no foreign bodies between the front frame and the spreader chassis. Notice! The weighing system is a Kg system, where 1 Kg corresponds to 0,01%. Therefore the weight can vary +/- 5 Kg within 5 10 minutes, which is considered acceptable. For longer terms the weight can vary up to 20 Kg. If all of the above is ok and if you have a weight simulator: o Disconnect the CALIBRATOR from the spreader. Connect a weight simulator to the CALIBRATOR. o Do a full calibration. o If the CALIBRATOR shows correct weight you need to change the load cell ON THE CALIBRATOR Press Menu Test Load Cell status The Weighing system test picture informs about CALIBRATOR ZURF and the load cell(s). Subsequently only the essential limiting values are mentioned. Follow instructions TEST/FAULT finding. Load Cell Status (zsa) : point value full scale : Max. Calib. weight (zsa) zero scale a/d: full scale a/d: (da) diff a/d: (zsk) : 0 10 Value empty hopper in kg (zsk) zero scale kg: 0 full scale : Max. Calib. weight in kg full scale kg: 500 (dk) diff kg: 500 (av) actuel a/d: (d) av zas: (f) da/dk: Result : Actual hopper contents Zsk + d/f = kg: 0 [ENTER]: Will Freeze the values ENTER Freeze On/Off ESC

12 FAULT Actual load The actual load does not equal difference in hopper contents CHECK: A Full calibration must be completed. Alternatively Factory Setting is chosen. Follow the instructions in TEST Load Cell status ON THE CALIBRATOR Press Menu Test Load Check It is possible to check the weighing function e.g. by the weight of one person. When the test is started the load test must be completed within 60 seconds. Load Check step 1 of 3 Countdown 60 sec Hopper contents before loading Hopper contents during loading Difference in hopper contents = load weight before 500 kg weight now 580 kg difference 80 kg ENTER Start countdown ESC Cancel

13 Connection diagram A E D F B C G H AL TEKNIK 6 Ton I AL POS PART A CALIBRATOR ZURF Fuse part w/ 8 Amp. fuse B ± 12 V (Min. 10 V Max. 14 V) Speed Sensor Induktiv C w/ Ferredic iron sensing AMP 22 pol Male D w/ bracket and lid AMP 22 pol Female E w/ Fix screw Connectionbox F w/ connections G Trend Actuator, LA 12 H PTO-sensor Reed w/ magnetic sensing I Load cell 6 Ton J Reg. Actuator, LA 32

14 Connection box Shield 1 W-Power (-) Green 2 AMP no. 6 Green Load cells W-Signal Shield (+) White 3 AMP no. 17 White W-Power (+) Brown 4 AMP no. 11 Brown PTO Trend / IC W-Signal (-) Yellow PTO-Signal (+) Brown PTO-Signal (-) Blue IC / Trend (-) White IC / Trend (+) Red IC / Trend-signal Black AMP no. 12 AMP no. 16 AMP no. 15 AMP no. 1 AMP no. 22 Yellow Brown White Green Yellow Tank Tank (+) Tank (-) Brown Tank-Signal Black Blue AMP no. 14 Pink AMP no. 3 Gray

15 ERROR MESSAGES on CALIBRATOR ZURF Display Observation Reasons What to do Power too low Battery power less than 8V Check the battery Power too high Battery power higher than 16V Check the conditions concerning the tractor generator. A bad - / ground connection may course extreme voltage in the Actuator timeout Actuator blocked and has not reach the expected position within 20 sec. There was a connection problem with the actuator detected. Please check the electrical installation There was a over current problem with the actuator detected. Please check the electrical installation There was an unexpected problem with the actuator detected. Please check the electrical and mechanical installation ZURF measures a potentiometer value outside the limits of: 0,7 < x < 9,2 [V]. 1. The actuator must be calibrated correctly 2. There might be a bad connection in the wire system. 3. Potentiometer can be defect The actuator has reached one of three limits: 9A in 5 sec. 13A i 500 m sec. 18A i 100 m sec. 1. The actuator is mechanical blocked wire system. 1. If this fault occurs when START is activated check that the mechanical system is not blocking and without corrosion.2. If this fault occurs when STOP is activated the actuator is not able to keep or find its intended position which in this case is scale 0. Make a actuator calibration. Calibrate the actuator once more. Try to redo the calibration 2-3 times. Check that the actuator is free movable and not stocked at any position. This is a fault that can not be further classified Calibrate the actuator once more. Try to redo the calibration 2-3 times. Use the Test programme for the actuator to get more information's

16 ERROR MESSAGES on CALIBRATOR ZURF Display Observation Reasons What to do There was a connection problem with the trend actuator detected. Please check the electrical installation ZURF has no contact to the Trend actuator (SHIFT). Turn OFF the ZURF and turn it ON again. Notice if the ZURF detects the Trend actuator doing the START- UP-TEST. In the START-UP-TEST the actuator is named TB- actuator The trend actuator is not in the expected position anymore.please check the electrical and mechanical installation A connection problem with the DS-actuator was detected. Please check the electrical installation Trend (TB) has been moved / pushed away from one of the two end positions.this might happen if the mechanical connections / adjustments are not mounted or done correctly.the message comes up when the actuator has been pushed away five times within 60 seconds. ZURF has no contact to the Trend actuator (DS). 1. Check the cables in the connection box 2. Check the pins in the 22 pin plug The mechanical parts must be readjusted properly. Turn OFF the ZURF and turn it ON again. Notice if the ZURF detects the Trend actuator doing the START- UP-TEST. In the START-UP-TEST the actuator is named DS- actuator The DS-actuator is not in the expected position anymore.please check the electrical and mechanical installation Trend (TB) has been moved / pushed away from one of the two end positions.this might happen if the mechanical connections / adjustments are not mounted or done correctly.the message comes up when the actuator has been pushed away five times within 60 seconds. 1. Check the cables in the connection box 2. Check the pins in the 22 pin plug The mechanical parts must be readjusted properly.

17 ERROR MESSAGES on CALIBRATOR ZURF Display Observation Reasons What to do The TREND function cannot be performed There is no contact to the PTO sensor! Please check the electrical installation of the PTO sensor The TREND function cannot be performed There was a short circuit detected with the PTO sensor!please check the electrical installation of the PTO sensor The TREND function cannot be performed Communication with the Trend actuator failed Please check electrical installation of the trend actuator The TREND function cannot be performed Communication with the DSactuator failed Please check electrical installation of the DS-actuator The PTO sensor might be missing. 1.The sensor might not be mounted correctly in the connection box 2. The Sensor might be defect The PTO sensor has a short-circuit 1. Short-circuit in the connection box 2. The sensor might be defect ZURF as no connection to the Trend actuator (SHIFT).1. The actuator might not be mounted correctly in the connection box ZURF as no connection to the Trend actuator (DS).1. The actuator might not be mounted correctly in the connection box. Check that the sensor is mounted correctly and that the sensor is not damaged Check that the sensor has a distance of 5 10 mm. to the magnet Check that the wires is mounted correctly in the connection box Check that the sensor is not damaged Turn OFF the ZURF and turn it ON again. Notice if the ZURF detects the Trend actuator doing the START- UP-TEST. In the START-UP-TEST the actuator is named TB- actuator 1. Check the cables in the connection box 2. Check the pins in the 22 pin plug Turn OFF the ZURF and turn it ON again. Notice if the ZURF detects the Trend actuator doing the START- UP-TEST. In the START-UP-TEST the actuator is named DS- actuator 1. Check the cables in the connection box 2. Check the pins in the 22 pin plug

18 ERROR MESSAGES on CALIBRATOR ZURF Display Observation Reasons What to do The TREND function cannot be completed Motion of the trend actuator failed due to timeout! The TREND function cannot be completed Motion of the trend actuator failed due to over current detection! The TREND function cannot be completed Motion of the trend actuator failed due to a severe internal electrical malfunction! The TREND function cannot be completed Motion of the DS-actuator failed due to timeout! The Trend (TB) actuator has been running for more than 10 sec. in one direction.1. The internal gear of the Trend actuator is defect. The current to the actuator (TB) has been higher than 2,5 A in 5 sec.1.the actuator is mechanically / physically overloaded. The Trend actuator (TB) is defect. Both end position and internal stop / switch are active at the same time. The Trend (DS) actuator has been running for more than 10 sec. in one direction.1. The internal gear of the Trend actuator is defect. The actuator must be changed Check the mechanic conditions concerning the TB actuator. The actuator must be changed The actuator must be changed

19 ERROR MESSAGES on CALIBRATOR ZURF Display Observation Reasons What to do The TREND function cannot be completed Motion of the DS-actuator failed due to over current detection! The TREND function cannot be completed Motion of the DS-actuator failed due to a severe internal electrical malfunction! The position of the trend actuator does not fit to the latest registered operation mode! You need to select your desired operation mode! The positions of the TB- and DSactuator do not fit to the latest registration operation mode! You need to select your required operation mode! The position of the trend actuator is undefined.please use the TREND dialog to fix this problem! The position of the DS-actuator is undefined.please use the TREND dialog to fix this problem! The current to the actuator (DS) has been higher than 2,5 A in 5 sec.1.the actuator is mechanically / physically overloaded. The Trend actuator (DS) is defect. Both end position and internal stop / switch are active at the same time. This information might occur when you have been testing the Trend actuator in the ZURF test program. This information might occur when you have been testing the Trend actuator in the ZURF test program. Trend (TB) has been moved / pushed away from one of the two end positions.this might happen if the mechanical connections / adjustments are not mounted or done correctly.the message comes up when the actuator has been pushed away five times within 60 seconds. Trend (DS) has been moved / pushed away from one of the two end positions.this might happen if the mechanical connections / adjustments are not mounted or done correctly.the message comes up when the actuator has been pushed away five times within 60 seconds. Check the mechanic conditions concerning the DS actuator. The actuator must be changed Bring back the actuator in the wanted position by choosing the Trend function on the CALIBRATOR ZURF Bring back the actuator in the wanted position by choosing the Trend function on the CALIBRATOR ZURF Readjust the mechanical Trend system. Readjust the mechanical Trend system.

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