EDBRO TRAILER INCLINOMETER

Transcription

1 EDBRO TRAILER INCLINOMETER TINC01 (12V AND 24V VERSIONS) Installatin & Operating Instructins E5541 rev 5 (Sept 2015) Edbr PLC Nelsn Street, Bltn BL3 2JJ UK Tel: +44 (0) Fax: +44 (0) pstmaster@edbr.cm Web:

2 WARNING! Befre using this prduct please read and fully understand the instructins prvided. This Edbr plc prduct is t be used fr guidance purpses ONLY and must nt be relied upn t prevent an accident ccurring. Edbr plc r its representatives accept n respnsibility fr direct r indirect damage r injury whilst using this prduct. SAFETY IS THE SOLE RESPONSIBILITY OF THE OPERATOR Page 1

3 INTRODUCTION Vehicle Over turning is a majr safety issue within the Transprt Industry. The Edbr Inclinmeter is a cst effective slutin that warns the driver when a ptentially unsafe cnditin ccurs during tipping. The inclinmeter is supplied in kit frm cmplete with Tractr Cable, Suzi Cable, Trailer Cable, Cut-Off Valve and Sensr Unit and shuld be installed by a cmpetent engineer. The unit is supplied t suit either a 12V r 24VDC circuit. The vltage dictates which slenid is supplied in the kit. SYSTEM OPERATION The inclinmeter is intended t measure the angle f the vehicle chassis and alert the driver t an unsafe angle prir t tipping. Chassis angle is displayed n the Display unit LCD screen up t 8 degrees left r right (factry set t 5º) An alarm limit is set n the cntrl unit which will cause an audi alarm t trigger and the tipper cut-ff valve t activate when the chassis angle meets r exceeds the set alarm. This actin puts the tipper valve int the hld psitin. TO OPERATE: Switch n the Inclinmeter - EDBRO INCLINOMETER will be displayed fllwed by the sftware versin number and then the current set alarm angle. If the chassis angle is belw the set alarm limit then the chassis angle and directin f lean will be displayed n the LCD. The angle is displayed in whle degrees I.e. 1,2,3 and s n up t the pint where the alarm limit is reached. The system will bleep t the number f degrees indicated n the LCD. e.g. 3 bleep = 3 degrees. The vlume f these bleeps can be cntrlled via the vlume dial n the frnt f the cntrl unit. If at any pint during tipping (r prir t tipping when the unit is switched n) the set alarm angle limit is reached r exceeded then the system will g int alarm. An audi/visual alarm will sund in the cab and DANGER UNSAFE VEHICLE ANGLE and VEHICLE OVERTURN RISK will be displayed n the LCD screen. The tipper cut-ff valve will activate preventing the tipper bdy frm being raised. At this pint the peratr shuld CAREFULLY LOWER THE TIPPER BODY DOWN ONTO THE CHASSIS then mve the vehicle t level grund befre re-attempting t tip. DO NOT MOVE THE VEHICLE WITH THE TIPPER BODY RAISED. Once tipping is cmpleted the Inclinmeter shuld be switched ff. Page 2

4 Cntents f the Inclinmeter kit 1 x Inclinmeter Cntrl Unit (Serial N: ) 1 x Sensr Unit (Serial N: ) 1 x Data Cnnectin Unit c/w cable lm 1 x Valve Unit 1 x Suzi Cable 2 x Suzi Cnnectr 1 x Trailer Cable 1 x Sensr Cver 2 x Cntrl Unit munting bracket 2 x Grip Knb 1 x Override Key 1 x Trailer label 4 x 2.9 x 9.5 ST screw 8 x M4 x 20 pzipan head screw 8 x M4 Washer 8 x M4 Nylck Nut 8 x M5 x 20 Hex Blt 8 x M5 Washer 8 x M5 Nylck Nut 1 x Quick ref. guide 1 x Instructin Manual 60 x Black Cable Ties 4 x M5 x 50 Hex Blt* 4 x 25mm spacer* 4 x Rubber washer* * Only required when munting sensr t rearward facing crss member. Page 3

5 INSTALLATION ADVICE IMPORTANT: CAREFULLY READ THIS INSTRUCTION MANUAL BEFORE STARTING THE INSTALLATION OF THE INCLINOMETER. Befre munting the Inclinmeter Cntrl Unit, fllwing pints shuld be taken int cnsideratin: Ensure the tipper bdy is empty. Park the tipper/ trailer in a straight line n firm level grund. Check fr any verhead bstructins befre raising the tipper bdy in particular verhead pwer lines Prp the tipper bdy fllwing manufacturer instructins befre underneath it. If the vehicle cab has t be tilted frward, ensure all heavy and lse bjects are remved frm the cab t avid any items falling thrugh the windscreen. The Inclinmeter needs t take pwer frm a 12v r 24vDC Ignitin switched feed (live when the ignitin is in the n psitin). We recmmend that pwer fr the Inclinmeter is picked up frm the fllwing: A fuse spare lcated in the vehicles fuse bx. This is ften marked Auxiliary r AUX. Or the vehicle cigarette lighter scket. Be sure t check that it is 12v r 24vDC ignitin switched. Any ther suitable 12v r 24vDC ignitin switched supply. We DO NOT recmmend cnnecting t the fllwing circuits:- The braking system (ABS, EBS) Engine management If yu are unsure always cnsult the vehicle manufacturer handbk. Ensure the Inclinmeter Cntrl Unit des nt bstruct items such as gear shift, brake handle, pedals, switches and ther cntrls. The cntrl unit must nt bstruct the driver s line f sight this can lead t MOT failure. When chsing the psitin fr the Inclinmeter bear in mind the hw easily the cables can be ruted and hidden behind the dashbard and facia panels. Page 4

6 INSTALLATION INSTRUCTIONS 1. Using the tw Cntrl Unit munting brackets, tw Grip Knbs and fur 2.9 x 9.5 ST screws munt the unit t a suitable lcatin in the cab. 2. Place the Data cnnectin unit behind the dash/fascia f the cab. The ideal psitin is behind the passenger ft well panel. Cnnect the cable marked POWER t the vehicle electrical supply. The BLUE lead is cnnected t the vehicles GROUND r 0v (n mst mdern vehicles the chassis is grund, always check with a vltage meter). The FUSED lead is cnnected t the vehicles 12v r 24v this shuld be an ignitin switched supply. 3. Cnnect the cable marked SENSOR t the sensr scket n the Inclinmeter cntrl unit. The sensr cable needs t be ruted thrugh the dash f the vehicle, thrugh the bulkhead t the exterir f the cab. The sensr cable is ruted thrugh the vehicle dash and exits thrugh cable gland in passenger ft well (ften fund n Scania vehicles). By remving the cver and the dash panel in the passenger ft well, the sensr cable can be ruted t the utside f the vehicle (sme DAF, Fden & ther vehicles) 4. Cnnect the cable marked VALVE r AUX * t the valve r AUX scket n the Inclinmeter cntrl Unit. The cable will be marked either VALVE r AUX depending n specificatin and ptinal accessries supplied with the kit. The valve cable needs t be ruted thrugh the dash and brught ut behind the PTO cntrl handle. 5. Cnnect the Valve Unit t the push fit terminals n the end f the valve lead. The leads t the Valve Unit can be cnnected up any way rund (the valve is nt plarised) 6. The Valve Unit has three prts, air in, air ut and exhaust. They are marked n the valve as IN, OUT and EXH. The valve needs t be cnnected t the PTO airline marked TIP r UP. If it is nt marked n the rear f the PTO cntrl the crrect air line can be fund by the fllwing prcedure: With the PTO in the HOLD psitin remve ne f the air lines frm the cnnectrs in the rear f the PTO cntrl, it is ften better t start with ne in the centre (remember which cnnectr yu remved the airline frm). With ne air line remved, engage the PTO cntrl, and then put the PTO cntrl int the TIP r UP psitin. If air escapes frm the rear f the PTO cntrl yu have fund the TIP r UP air line. If n air escapes r air escapes as sn as the air line is remved frm the cnnectr this is NOT the crrect airline. Re-cnnect the air line t the PTO cntrl and repeat the prcedure with ne f the ther air lines. Once yu have lcated the TIP r UP air line the valve unit needs t be cnnected s that it will interrupt it. Make sure the airflw passes thrugh the valve as marked n the valve bdy. Page 5

7 7. The Sensr Cable, which shuld nw be running frm the inside f the vehicle t the exterir, needs t be ruted under the cab t the Suzi cnnectin pint at the rear f the cab. On mst vehicles it can be ruted thugh a gland r electrical cver. Then fllwing the vehicles electrical cable lm t the rear f the cab. YOU MAY NEED TO TIP THE CAB AT THIS POINT The Sensr Cable shuld be secured t the vehicle s existing cable lm with cable ties. Ensure the cable is nt ruted such that it can be damaged r trapped when the cab is returned t the nrmal psitin and that the cable is kept away frm ht surfaces. 8. Munt ne f the Suzi Cnnectrs t the rear f the cab. Munt the Suzi using fur M4 x 20 PAN Screws, fur M4 Washers and fur M4 Nylck Nuts. D nt fix the Suzi bracket t any part f the cab that will mve when the cab is tilted. 9. Munt the secnd Suzi Cnnectr t a suitable lcatin n the Trailer using the fur M4 x 20 PAN screws, fur M4 Washers and fur M4 Nylck nuts. 10. Cnnect the trailer cable t the Suzi Cnnectr. See wiring diagram belw. Cable wiring clurs have changed in kits manufactured frm January Ensure the equipment is installed accrding t this amendment and retain this dcument with the Installatin and Operating Instructin Manual. Failure t cnnect the equipment crrectly may result in malfunctin f the equipment. TRACTOR SUZI CONNECTOR Wire Clurs 2015 nwards Serial# Befre 2015 Serial# BLACK (0v sensr) 2. BROWN (sensr) 3. GREEN (sensr grund) 4. NOT USED 5. RED (+v supply t sensr) 6. SCREEN 7. WHITE(NOT USED) 8. NOT USED 9. NOT USED 10. NOT USED 1. BLACK(0v sensr) 2. BROWN(sensr) 3. GREEN (sensr grund) 4. White (sensr buzzer signal) 5. RED (+v supply t sensr) 6. SCREEN 7. Grey (NOT USED) 8. NOT USED 9. NOT USED 10. NOT USED Page 6

8 TRAILER SUZI CONNECTOR Wire Clurs 2015 nwards Serial# Befre 2015 Serial# BLACK (0v fr sensr) 2. BROWN ( sensr utput) 3. GREEN (sensr grund) 4. NOT USED 5. RED (+v supply t sensr) 6. SCREEN 7. NOT USED 8. NOT USED 9. NOT USED 10. NOT USED 1. BLACK (0v fr sensr) 2. BROWN (sensr utput) 3. GREEN (sensr grund) 4. WHITE (sensr buzzer signal) 5. RED (+v supply t sensr) 6. SCREEN 7. NOT USED 8. NOT USED 9. NOT USED 10. NOT USED Example: Serial Number cde = mnth,mnth,year,year,i/d number,i/d number = December 2014 number 01 Nte: Internal sensr buzzer signal n lnger used n 2015 versins 11. Cnnect the Suzi cable t the trailer and tractr cnnectrs. Linking the trailer t the tractr. 12. Bring the trailer cable ut thrugh the cable gland in the side f the Suzi cnnectr and ruted dwn the length f the trailer t the rear mst crss member. Leave enugh lse cable at the rear f the trailer t cnnect the sensr unit. Secure cable using cable ties. 13. Install and calibrate the Sensr. The accuracy f the system depends n the sensr installatin being dne with precisin and accuracy. The Sensr shuld be attached t the middle f the rear mst crss member r the nearest ne accessible t the rear f the trailer. Cnnect all the cables tgether befre fitting the Sensr. Clean the tp f the crss member and place the Sensr n tp. Page 7

9 Switch n the Inclinmeter, and bserve the reading n the LCD display n the Cntrl Unit. An audible warning shuld als be heard frm the Cntrl Unit and Sensr. i.e. 1 beep = 1 degree, 2 beeps = 2 degrees.and s n. If the crss member is level then the display will shw a Zer, and n beep. Shuld the Inclinmeter shw that it is nt level, establish which way the trailer is leaning. (+ / -), and make a nte f the LCD reading. The Sensr is very sensitive and can fluctuate between tw numbers, s allw it enugh time t stabilise. Discnnect the Sensr, mark and drill a small hle in the crss member, with the Sensr being placed in the middle f the crss member. Secure the sensr t the crss member with ne blt which will allw the Sensr t be pivted t psitin. Recnnect the Sensr and switch the Inclinmeter n. The Sensr can nw be pivted until the previus reading is matched, again allwing fr the (+ / -). Mark and drill the remaining three hles, again test fr calibratin befre tightening all the blts, then finally applying a lcking slutin. Nte: If yu are fitting the Inclinmeter t multiple vehicles it may be wrth investing in a digital prtractr which can measure the exact angle f the vehicles chassis. Precisin munting f the sensr will result in increased accuracy f the Inclinmeter. 14. Munt the Sensr Cver ver the Sensr Unit using fur M5 x 40 HEX blts. Use Silicne sealant r ther waterprf sealant t make a waterprf seal between the Sensr Cver and the trailer crss member. Page 8

10 Fig A The frnt f the sensr must face twards the cab as in figure A. Occasinally it is nt pssible t munt the sensr directly t a rear crss member s that the frnt faces the cab. See figure B. Fig B If the sensr cannt be munted as shwn in fig A abve it must be munted as in fig B. Use the fur M5x50 Hex Blts, fur rubber washers & fur 25mm Steel Spacers. M5x50 Hex Blt, Rubber Washer & 25mm Steel Spacer. Page 9

11 Circuit Diagram Page 10

12 OPERATING INSTRUCTIONS Pwer Switch: The unit must be switched n t perate the tipper. 2. LCD Display: Displays maximum tipping angle at start up fllwed by the vehicle current angle and directin f camber. It als displays warning messages when it is unsafe t tip. The display is back lit fr day/night use. 3. Mde Buttn: Allws the peratr t set the maximum safe tipping angle in cnjunctin with the Override Key. 4. Vlume Cntrl: During tipping the unit will display the current angle f the vehicle and emit audible tnes which als indicate the angle. i.e. 1 bleep = 1 degree, 2 bleeps = 2 degrees and s n. During nrmal safe tipping, the vlume can be adjusted r even muted. If the vehicle angle exceeds the safe tipping angle the system will g int alarm mde where the vlume autmatically ges t full and can nt be adjusted r muted. 5. Pwer Scket: The pwer lead is cnnected t this scket. 6. Sensr Scket: The Sensr Scket has tw functins, the first is t cnnect the sensr lead, and the secnd is t set the cntrl unit t verride in cnjunctin with the verride key. 7. Valve r AUX Scket: The valve r AUX lead is cnnected t this scket. 8. Warning Indicatr: Green = OK t tip; Red Danger! Tipping stpped Page 11

13 Setting the maximum safe tipping angle The Inclinmeter is factry set t 5 maximum safe tipping angle. If the angle f the vehicle exceeds 5 in respect t the hrizntal plane it will alarm and prevent the tipper bdy frm being raised. Edbr recmmends that yu cntact yur trailer manufacturer t btain infrmatin n its maximum safe tilt limit. T set the maximum safe tipping angle f the inclinmeter: 1. Switch the pwer t the unit OFF. 2. Remve the lead marked SENSOR frm the sensr scket n the cntrl unit. 3. Insert the verride key int the sensr scket. 4. Push and hld the buttn marked MODE. 5. Keeping yur finger n the MODE buttn, switch the pwer t the unit ON. 6. When the unit pwers up it will display the current maximum safe tipping angle then it will flash OVERRIDE n the display. 7. Keeping the mde buttn depressed, remve the verride key. 8. The display will nw start t cunt up frm the minimum available angle t the maximum angle. 9. When the display reaches the desired angle, take yur finger ff the mde buttn. 10. Wait a cuple f secnds fr the unit t stre the angle setting and reset. 11. Turn the pwer t the unit OFF 12. Re-cnnect the sensr lead and switch the unit n. 13. When the unit pwers up, the new maximum safe tipping angle will be displayed mmentarily. NOTE: The Inclinmeter Cntrl Unit shuld NOT be set t 0 max tipping angle. This will cause the Inclinmeter t alarm as sn as it is switched n. The ability t set the max tipping angle t 0 is fr test purpses nly. Page 12

14 TROUBLESHOOTING Prblem Pssible Cause/Crrective Actin 1. There is n pwer t the Inclinmeter Cntrl Unit. The unit is pwered by ignitin feed frm the vehicle. The vehicle ignitin must be in the POWER ON psitin Check that all the leads t the Inclinmeter are in the crrect sckets, prperly cnnected and the pwer switch is in the ON psitin. The fuse t the inclinmeter may have blwn, check the 3A blade fuse lcated at the end f the pwer supply lead (usually under the vehicle dash where the pwer has been picked up), if this is intact check the 2A fuse which is munted in the Inclinmeter Cntrl Unit. 2. The Inclinmeter Cntrl Unit shws that it is safe t tip but tipper bdy will nt raise. Check that the lead marked valve r V is crrectly cnnected t the crrespnding scket n the Inclinmeter Cntrl Unit. Check that the Shut-Off Valve is installed crrectly. The valve is marked fr air IN and OUT. Als check that it is installed in the PTO airline marked TIP r UP. Occasinally excessive dirt and misture in the airline may cause the valve t stick. Try pushing the RED buttn n the valve t free the valve shuttle. If this fails the valve must be replaced. 3. The Inclinmeter Cntrl Unit is alarming but the vehicle seems t be n level grund. The unit will alarm if the chassis angle is greater than the maximum tipping angle set n the Inclinmeter Page 13

15 4. The Inclinmeter Cntrl Unit is alarming but the vehicle seems t be n level grund. If the Inclinmeter Cntrl Unit has been set at a lw angle f degrees i.e. <3 it may lk as if the vehicle is alarming n level grund. Try setting the inclinmeter at its maximum angle setting then read the angle that is displayed. ALWAYS REMEMBER TO SET THE INCLINOMETER BACK TO ITS ORIGINAL SETTING AFTER THIS TEST. Check that the Inclinmeter Cntrl Unit has NOT been set t 0 max tipping angle by mistake. This will cause the Inclinmeter t alarm as sn as it is switched n. The maximum tipping angle is displayed every time the unit is switched n. Nte: The ability t set the max tipping angle t 0 is fr test purpses nly. Check the fllwing cnnectins: All leads are crrectly cnnected t the Inclinmeter cntrl Unit. Bth sides f the suzi cable are cnnected crrectly. The sensr is crrectly cnnected t the trailer cable. On a new installatin check that the suzi cnnectr has been wired crrectly. The trailer, suzi, r tractr cable may have been damaged. Check that there is n cable damage frm the cntrl unit thrugh t the sensr. 5. The Inclinmeter behaves erratically when CB radi, cellular telephne r ther transmitting device is used in clse prximity t it. Occasinally pwerful transmitting devices r nn-legal CB radis/ transmitters may interfere with the Inclinmeter. FOR REASONS OF SAFETY DO NOT USE CELLULAR TELEPHONES, CB RADIOS, OR OTHER TRANSMITTING DEVICES DURING THE TIPPING PROCESS. The use f such devices nly serves t distract the peratr during the tipping prcess. Page 14

16 MAINTENANCE Prviding the installatin is dne crrectly, the Inclinmeter shuld require very little maintenance. Service The Inclinmeter cntrl unit, sensr and data cnnectin unit cntain n user serviceable parts. DO NOT OPEN THE UNIT. Fr service cntact Edbr Service n +44 (0) Cleaning The cntrl unit can be cleaned using a sft damp clth. DO NOT use detergents, abrasives, slvents r alchl. Prevent misture arund the pwer switch and cnnectrs. DO NOT allw liquid t enter the cntrl unit. If any liquid is spilt int the cntrl unit, it shuld nt be switched n and returned fr Repair, stating the cause f the defect. WARNING! DO NOT USE JET WASH OR HIGH PRESSURE HOSES ON THE FOLLOWING ITEMS: Suzi cnnectrs Suzi cable Sensr/Sensr Cver Althugh the Inclinmeter sensr and exterir cable cnnectins are IP68 rated (waterprf), high-pressure water jets will damage the sensr and electrical cnnectrs. Fuses The Inclinmeter system is fitted with tw fuses 1 x 3A Autmtive Blade Fuse (clur - purple) 1 x 2TA 20mm Fuse The 3A blade fuse is munted in a splash-prf fuse hlder n the pwer lead where the pwer is picked up. The 2TA fuse is munted in the tp f the cntrl unit. Page 15

17 TECHNICAL SPECIFICATIONS TINC01/12v TINC24V Display and Sensr Operating Vltage Nminal Operating Current 12 r 24v DC 400mA Measurement Range ± 8 (Factry set t ± 5 0 ) Sensr Operating Temperature -30 C t +55 C Reslutin 1 Slenid Valve Valve Operating Vltage 12vDC 24vDC Valve Operating Current Valve Operating pressure Valve Operating Temperature 170mA P.S.I 0 t +50 C Page 16

18 SERVICE RECORD Date Details Engineer Manufactured and tested. Installed at: Vehicle Reg: Page 17