Holtgreven Truck Scale Resources User Manual

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Page 1

PT300 Weighing System

Users Manual

Intercomp Co.

3839 County Road 116

Medina, MN 55340 U.S.A.

763-476-2531 800-328-3336

Fax: 763-476-2613

www.intercompcompany.com

Manual #: 700028-G

Page 1 of 44

Page 2

Table of Contents

INTRODUCTION ............................................................................................................................................................................4

Weights and Measures............................................................................................................................................................... 4

SPECIFICATIONS ..........................................................................................................................................................................5

ONTROLS

LECTRICAL

ERFORMANCE

NVIRONMENTAL

HYSICAL

ADIO (OPTIONAL

PTIONAL EQUIPMENT

SCALE OPERATIONS .................................................................................................................................................................... 8

PERATIONAL OVERVIEW

ISPLAY DESCRIPTION

ONTROLS

ON / OFF .................................................................................................................................................................................. 9

PRINT / ACCUMULATE........................................................................................................................................................... 9

LOCAL / TOTAL .....................................................................................................................................................................10

ZERO.......................................................................................................................................................................................10

OTALIZING SETUP

ERIAL OUTPUT SETUP

On-Demand .............................................................................................................................................................................12

Continuous ..............................................................................................................................................................................12

Data Format ............................................................................................................................................................................13

Accumulating Print..................................................................................................................................................................13

SING ACCUMULATED TOTAL

Accumulating Print Axle .........................................................................................................................................................13

Accumulating Print Standard .................................................................................................................................................. 14

CCUMULATING PROCEDURE

EIGHING PROCEDURES

ABLE 1: WEIGHING COMBINATIONS

YPICAL SCALE LAYOUTS

......................................................................................................................................................................................5

.................................................................................................................................................................................... 5

................................................................................................................................................................................ 5

...........................................................................................................................................................................5

........................................................................................................................................................................................6

).......................................................................................................................................................................... 6

...................................................................................................................................................................7

.............................................................................................................................................................. 8

...................................................................................................................................................................8

......................................................................................................................................................................................9

.......................................................................................................................................................................11

.................................................................................................................................................................12

......................................................................................................................................................13

:...................................................................................................................................................... 15

............................................................................................................................................................... 17

........................................................................................................................................... 18

............................................................................................................................................................ 19

MODE MENU .................................................................................................................................................................................20

ODE MENU

ETTING THE MODE MENU PARAMETERS

CABLED SCALE USAGE ............................................................................................................................................................. 24

OTALIZING/PRINTING IN CURRENT LOOP MODE

Example of Master/Slave designations....................................................................................................................................24

OTALIZING

RINTING

ATA INTERFACE

CALIBRATION ..............................................................................................................................................................................27

ROCEDURE: CALIBRATION (VERIFICATION

Check front/back load cell balance ......................................................................................................................................... 27

Scale Span Calibration............................................................................................................................................................28

ROCEDURE: CALIBRATION (ADJUSTMENT

Calibration Enable Jumper .....................................................................................................................................................30

ALIBRATION MENU

ETTING THE CALIBRATION PARAMETERS

Multiple Graduation Break Points .......................................................................................................................................... 32

EIGHT CALIBRATION

Corner Calibration (Both load cells) ...................................................................................................................................34

Corner Calibration (Single load cell) ..................................................................................................................................35

................................................................................................................................................................................. 20

.....................................................................................................................................21

.........................................................................................................................24

.................................................................................................................................................................................. 25

......................................................................................................................................................................................25

..........................................................................................................................................................................26

) ................................................................................................................................27

) .................................................................................................................................29

.....................................................................................................................................................................31

....................................................................................................................................32

.................................................................................................................................................................34

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Page 3

Span Calibration ..................................................................................................................................................................... 36

TROUBLESHOOTING ................................................................................................................................................................. 38

ROBLEM TABLE

RROR MESSAGES

IAGNOSTIC TESTS AND VOLTAGE MEASUREMENTS

Charger voltage.......................................................................................................................................................................40

Lamp........................................................................................................................................................................................ 40

Keys .........................................................................................................................................................................................40

Power down shutoff ................................................................................................................................................................. 40

Load Cells ...............................................................................................................................................................................40

Step Entries .............................................................................................................................................................................42

CONNECTOR ................................................................................................................................................................................43

HOW TO REACH INTERCOMP SERVICE .............................................................................................................................. 44

...........................................................................................................................................................................38

........................................................................................................................................................................39

..................................................................................................................... 40

"This document is the property of Intercomp Co. It contains material and information that is confidential and protected under federal and/or state trade secret, unfair competition, and copyright law. Any reproduction, use or disclosure without written permission from Intercomp Co. is prohibited".

Page 3 of 44

Page 4

Introduction

Weights and Measures

The PT300 meets or exceeds class IIII standards for 400 division accuracy from 0 lb to 20,000 lb. The certification was completed by the National Type Evaluation Program (NTEP); in accordance with the National Institute of Standards and Technology (NIST) Handbook 44. A NTEP Certificate of Conformance Number 90-106P was issued under the National Conference of Weights and Measures.

This operations manual describes the Intercomp Model PT300 platform specifications, detailed operating procedures, and calibration.

This manual is separated into several sections, each containing information on a different aspects of the scale. The specifications outline the design parameters for the scale. The detailed operation section outlines the correct use of the scale for most applications. The calibration section explains how to set the platform's adjustments.

Caution: Your PT300 scale is covered by a one year warranty and should be referred to the factory for maintenance within the warranty period. Attempts to make any extensive repairs within the warranty period may invalidate the warranty. If repairs are needed after the warranty period, only qualified technicians should attempt such repairs.

PT300 Users manual

Rev G, Feb 2011

Features

lb or kg programmable readout. Ability to display total weight. Accumulating total function. Auto zero tracking automatically corrects zero-weight display shifts. 5½ digit, 1 inch LCD readout, with automatic back lighting. 5-15 VDC and 120 VAC 60 Hz power sources standard. RFI/EMI protection. Low battery detection with automatic shutoff to protect batteries. Built-in self-diagnostics to check: Load cells, Memory, Display, AD converter, and Power supply. Weigh pads manufactured from high strength aluminum alloys.

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Page 5

PT300 Users manual

Specifications

Controls

General On/Off, Print/Accumulate, Local/Total, Zero Display 5 1/2 digit, 1 inch liquid crystal display (LCD), with automatic back

lighting.

Indicators: local weight, total weight, accumulated total weight

Electrical

Rev G, Feb 2011

Power source required

Charging Voltage 10 - 15 V DC. Batteries

Charging Current 50 mA. Charging Time 16 hours if the batteries are discharged. Battery endurance Radio off: 400 hours with alkaline or NiMH

Filtering Adjustable averaging up to 30 seconds. Auto-Zero Satisfies all HB-44 requirements.

5 - 15 VDC at battery input, 100-240 VAC when using charger

4-AA size NiCd, NiMH, or alkaline cells.

150 hours of continuous use with Ni-Cads Radio on: 300 hours with alkaline or NiMH 125 hours of continuous use with Ni-Cads

NOTE: For special setups that require a scale wireless ‘host’, that scale’s battery life is 40 hours (alkaline).

Performance

Speed 4 display updates per second Accuracy Calibration interval

± 1% of reading or ± display graduation, whichever is greater.

Twelve months recommended

Environmental

Humidity 10 to 95% Non-Condensing. Temperature Operating: -28 C to +65 C. / -20 F to +150 F. Storage: -40 C to +75 C. / -40 F to +170 F. EMI/RFI Meets Mil Spec 461

Page 5 of 44

Page 6

Physical

WARNING:

where the equipment should be used at distances greater than 20cm from

PT300 Users manual

Rev G, Feb 2011

Dimensions (PT300):

Weight (PT300): 37 lb / 16.8 kg Dimensions (PT300DW): Overall: 3 x 26 x 20 in. / 76 x 660 x 508 mm

Weight (PT300DW): 49 lb / 22 kg

Overall: 3 x 16 x 20 in. / 76 x 406 x 508 mm Pad: 12 x 12 in. / 305 x 305 mm

Pad: 22 x 14 in. / 559 x 356 mm

Radio (optional)

Radio frequency ISM 2.4GHz, 802.15.4 License requirements None. Pre-approved US/FCC, CAN/IC,

Range 200’ / 60m indoor, 300’ / 90m line of sight

the human body (with the exception of hands, wrists, feet, and ankles. Operation at distances less than 20cm is strictly prohibited.

This equipment has been approved for mobile applications

EUR/CE

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Page 7

PT300 Users manual

Rev G, Feb 2011

Optional Equipment

PDA with Vehicle Weigh Software and Wireless Node (140661)

Laptop computer with Vehicle Weigh Software and Wireless Node (140667)

PT20 CPU (100540) PT20 CPU Wireless Node (140659)

Charger and Cable (100480)

120/220V plug in transformer with internationals plugs, cable and PT connection.

2 scale carrying case (100047) 4 scale carrying case (100048) 6 scale carrying case (100049)

Interconnecting cable for 2 scales, 15 ft (101029) Interconnecting cable for 4 scales (101032)

15, 25, 15 ft. spacing.

Interconnecting cable for 6 scales (101035)

15, 25, 15, 25, 15 ft. spacing.

Interconnecting/Charging Cable for 2 scales, 120/220V, international plugs (101030) Interconnecting/Charging Cable for 4 scales, 120/220V, international plugs (101033) Interconnecting/Charging Cable for 6 scales, 120/220V, international plugs (101036)

PT300 Dummy pad (100088)

Cast aluminum replica.

PT300DW Ramp (100072)

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PT300 Users manual

Rev G, Feb 2011

Scale Operations

Operational Overview

The control panel for the weighing platform is in the front section of the pad, along with the electronics of the system. The control panel has a liquid crystal display (LCD) screen and several control switches.

Display Description

The display is a Liquid Crystal Display unit, providing one line of 5 1/2 digits. The screen shows the weights read from the pad. The TOTAL icon indicates measurement mode as in the table below the PT300 display. Information displayed includes indicators for both “lb” and “kg”, a segment bar to show battery charge level, error conditions and set-point indicators when set-point thresholds are reached. The display contains an automatic backlight for use in low-light conditions.

Mode status Setting

TOTAL not lit Local

TOTAL lit Total

TOTAL flashing Accumulated Total

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Page 9

Controls

2000

20002000

2000

5500

55005500

5500

P-03

P-03P-03

P-03

5 seconds

for 2 seconds

displayed for 1

ON / OFF

Press and hold this key to apply power to the weighing system electronics. Make sure to hold this key until the display responds (up to 1 second). When power is first applied, the weighing system rapidly performs self-tests of the pad and the internal electronics. When the tests have completed successfully, the system begins weighing. If a problem is detected, the screen displays an error message. If the PT300 is powered up, press this button to turn the scale off. The PT300 retains the setup information, and calibration in a special memory device (non-volatile memory) that is not affected by power loss or battery condition.

PT300 Users manual

Rev G, Feb 2011

PRINT / ACCUMULATE

Press this button to print. When using the accumulated total function: press the PRINT / ACCUMULATE button to add the total to the accumulated total. See section titled “Using Accumulated Total”.

New accumulated total = total weight (all scales in system) + old accumulated total

Once a successful accumulation has a occurred, the scale will automatically toggle it’s display to show the current weight, accumulated total, and number of accumulations.

current weight displayed for

Note: The scale will not accumulate and will display the error message “Ac current weight is negative, zero, or if the weight is in motion. These Protections are added to ensure that only valid readings are accumulated into the total. Also, after a successful accumulation, ALL scales in the system must return to zero before you accumulate the next

total accumulated weight displayed

total number of accumulations

Ac.Err

Err” if the

AcAc

ErrErr

Page 9 of 44

Page 10

PT300 Users manual

Rev G, Feb 2011

weight. If you attempt to accumulate the next weight before allowing the scale(s) to return to zero, the error message “Ac

The accumulated total weight can be viewed only on the scale you are accumulating from. After the PRINT/ACCUMULATE button is first pushed; the display will show “Ac. X” as the system will accumulate the next reading and send it to print. (X will show the number of accumulations this session) Once a successful accumulation has occurred, pressing the LOCAL/TOTAL button will cycle the display to show number of accumulations, current local weight, current total weight on all scales, and the accumulated total. When the local weight, current total weight, or accumulated total is displayed, the total icon will be lit up, flashing, or off. (as shown in the display description).

Ac.Err

Err” will be displayed.

AcAc

ErrErr

LOCAL / TOTAL

The local weight is the weight on that scale only. The total weight is the weight on all of the scales in your system. Pressing the LOCAL / TOTAL button toggles between local weight and total weight. The indicator bars (as shown in the display description) will show whether the scale is displaying the local or total weight.

Note: If the system is not setup correctly, the “error” icon and message “t0t displayed when trying to view the total weight. See section titled “Totalizing Setup”.

t0t” will be

t0tt0t

ZERO

Sets the weighing system to read zero pounds or kilograms. If pressed while a pad holds weight, that weight becomes the zero condition for the pad. This can be useful to cancel the weight of any weighing fixtures, such as tail cones or wheel chocks. When the weight is removed, a negative weight displays until the system is re-zeroed. This switch is used any time the scale shows a non-zero value with no weight on the pads.

Note: This system contains a feature called Auto Zero Tracking (AZT), which corrects for slight zero changes during normal operation. An example of a zero change could be a buildup of dirt on the pads.

Another function of the zero key is to clear the accumulated total. Press and hold the ZERO key until the display reads “CLr

accumulated total and the accumulation number. All other scales you have connected will also be zeroed through the interconnect cables. This allows you to zero your entire system with one key press.

CLr.tttt“ and release the ZERO key. This will reset the

CLrCLr

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Page 11

PT300 Users manual

---04

---04---04

---04

01---

01---01---

01---

scale ID#

Rev G, Feb 2011

Totalizing Setup

This section covers configuring a scale set for either self-totalizing or connection to a PC/PDA for advanced display features. For accumulating multiple weights on a scale or scale set, see the “Using Accumulated Total” section. In ‘self-totalizing’ mode, the LOCAL/TOTAL button works to switch between weight on that particular scale (LOCAL) and the total weight of connected scales (TOTAL). If the system is not setup correctly, the “error icon” and message

“t0t

t0t “will be displayed when trying to view the total weight.

t0tt0t

1. To enter into totalizing setup: Simultaneously press the LOCAL/TOTAL and ZERO buttons.

2. Message “SCid displayed with 3 dashes following it. This is the scale number (ID). Use the LOCAL/TOTAL button to increment and the ZERO button decrement the number. When the desired number is displayed, press the PRINT/ACCUMULATE.

3. Message “SCLS will show three dashes and then a number. This number is the total number of scales in the system. Use the LOCAL/TOTAL button to increment and the ZERO button decrement the number. When the desired number is displayed, press the PRINT/ACCUMULATE button. The maximum number of scales is 32.

4. If the scale# is ‘1’, the display will ask if the scale is the “HOSt PRINT/ACCUMULATE button. Use the LOCAL/TOTAL or the ZERO button to toggle the

display “Yes “yes” if the scale network consists of scales only. If your system uses an external device such as a PDA or PC to view the weights, this setting should be set to “no” since the external host controls the network. Press the PRINT/ACCUMULATE button to save the setting.

Example 1 of correct scale settings: 4 pad system with PDA or PC: Scale ID Number of Scales *Host setting

SCid” will be displayed. Press PRINT/ACCUMULATE button. A number will be

SCidSCid

SCLS” will be displayed. Press the PRINT/ACCUMULATE button. The display

SCLSSCLS

total # of scales

(only displayed on scale #1)

HOSt”. Press the

HOStHOSt

Yes” or “no

YesYes

no”. A ‘Host’ controls the scale network, and this setting should be set to

nono

Scale #1:

Scale #2:

Scale #3:

Scale #4:

[01---

01---] [---

01---01---

[00002222---

---] [---

------

[00003333---

---] [---

------

[00004444---

---] [---

------

---04

04] [ no

------

0404

---04

04]

------

0404

---04

04]

------

0404

---04

04]

------

0404

Page 11 of 44

no ]

nono

Page 12

PT300 Users manual

Example 2 of correct settings: 4 pad totalizing system using scales only: Scale ID Number of Scales *Host setting

Rev G, Feb 2011

Scale #1:

Scale #2:

Scale #3:

Scale #4:

* Host setting is only available when scale ID is set to ‘01’

[01---

01---] [---

01---01---

[00002222---

---] [---

------

[00003333---

---] [---

------

[00004444---

---] [---

------

---04

04] [ yes

------

0404

---04

04]

------

0404

---04

04]

------

0404

---04

04]

0404

------

yes ]

yesyes

Serial Output Setup

There are three different serial output modes for the PT300, “on-demand”, “continuous”, and “accumulating print”. The rest of this section provides more information on these modes.

To setup the serial output mode: Press the PRINT/ACCUMULATE and ZERO buttons simultaneously until the display shows “bbbb.LitE through the menu (12 times) until the display shows “Prt t

button once to display setting number. Set print mode to the number of the print mode wanted by using the LOCAL/TOTAL button to increment and the ZERO button decrement the number. .

Communication Mode Setting

On-Demand 0

Continuous 1

Accumulating Print Axle 2

Accumulating Print Standard 3

Note: For best results, only set one scale to ‘1, ‘2 or ‘3. This should also be the scale you are printing from. ‘0’ is the default setting.

Press the PRINT/ACCUMULATE button. Now the display will display “PbAUd PRINT/ACCUMULATE button to change the baud rate set, press the LOCAL/ TOTAL or the ZERO button to cycle through the baud rates available. The baud rates available are: 1200, 2400, 4800, 9600, 19200, 38400, 57600, and115200. When the desired baud rate is displayed, press the PRINT/ACCUMULATE button. The baud rate only needs to be set on the scale doing the printing. The settings are saved once PRINT/ACCUMLATE is pressed to advance the menu, and the scale can then be turned off to exit the Mode Menu.

LitE”, Press the PRINT/ ACCUMULATE button to scroll

LitELitE

Prt t”. Press the PRINT/ACCUMULATE

Prt tPrt t

PbAUd”. Press the

PbAUdPbAUd

On-Demand

The weight is transmitted every time the PRINT/ACCUMULATE key is pressed. Press PRINT/ACCUMULATE to print either the local or total weight (depending on the local/total setting of the scale). This is the default print mode.

Continuous

The PT300 automatically and continuously outputs the weight at a rate of about once per second.

Page 12 of 44

Page 13

PT300 Users manual

Rev G, Feb 2011

Data Format

When the serial output is set to either on-demand or continuous mode, the transmitted data is in the format shown below:

AAAAAAA BB<cr><lf>

Item Meaning ASCII Hex ASCII Decimal AAAAAAA weight BB units “lb” or “kg” <cr> carriage return 0D 13 <lf> linefeed 0A 10

The AAAAAAA field will vary in length depending on the length of the number and could contain a decimal point and/or a minus sign. The weight will either be local weight or total weight, depending on which mode you’re in.

Accumulating Print

See section titled “Using Accumulated Total” for both the Axle and the standard formats.

Using Accumulated Total

The PT300 platforms can be used separately, in pairs, or in groups to measure a support load or the total weight in one measuring procedure. To use the Accumulated Total feature, the scales need to be numbered correctly and the scale you intend to print from or display the accumulated total must have it’s print mode set to one of two ‘Accumulating Print’ modes. See the “Totalizing Setup” and “Serial Output Setup” sections for details.

Accumulating Print Axle

Press the PRINT/ACCUMULATE button to add the current total weight to the accumulated total weight. At the same time, a print ticket will be generated (assuming you have a printer in the system). The print ticket format is in respect to a vehicle’s individual wheels and axles or a standard weight accumulation mode.

For example wheel and axle, think of “WHL 1” as scale 1 and “AXL 1” as the total weight of scale 1 and scale 2. The following print ticket example is a 4 scale system:

PRINT / ACCUMULATE button has been pressed

PRINT / ACCUMULATE

button has been pressed

WHL 1: 7460 WHL 2: 7400 AXL 1: 14860 WHL 3: 10110 WHL 4: 10070 AXL 2: 20180 SUBTOTAL GRP 1: 35040 ACCUM TOTAL: 35040

WHL 1: 10110 WHL 2: 10070 AXL 1: 20180 WHL 3: 9800 WHL 4: 9500 AXL 2: 19300 SUBTOTAL GRP 2: 39480 ACCUM TOTAL: 74520

Page 13 of 44

Page 14

PT300 Users manual

scale

scales

this session

10110

1011010110

10110

this session

ACAC

2 2

39480

3948039480

39480

74520

7452074520

74520

Rev G, Feb 2011 Once a successful accumulation has occurred, press the LOCAL/TOTAL button to toggle the display through the current local weight, current total weight, accumulated total, and the number of accumulations that make up the total.

Current local weight on this

to zero, the error message “Ac

Current total weight on all

Ac.Err

AcAc

Err” will be displayed.

ErrErr

Total weight of accumulations

Total number of accumulations

Ac.Err

AcAc

Err” if the

ErrErr

Accumulating Print Standard

A standard accumulation shows total weight of multiple items weighed on 1 or more scales. The following print ticket example is a 1 scale system after 3 items are weighed: (950lb, 1000lb, and 1500lb)

950 lb ACCUM TOTAL: 950 lb

PRINT/ACCUMULATE has been pressed

1000 lb ACCUM TOTAL: 1950 lb

1500 lb ACCUM TOTAL: 3450 lb

Page 14 of 44

Page 15

PT300 Users manual

scale

scales

this session

1500

15001500

1500

this session

ACAC

3 3

1500

15001500

1500

3450

34503450

3450

Rev G, Feb 2011

Once a successful accumulation has occurred, press the LOCAL/TOTAL button to toggle the display through the current local weight, current total weight, accumulated total, and the number of accumulations that make up the total.

Current local weight on this

to zero, the error message “Ac

The accumulated total weight can be viewed only on the scale you are accumulating from. After the PRINT/ACCUMULATE button is first pushed; the display will show “Ac

system will accumulate the next reading and send it to print. (X will show the number of accumulations this session) Once a successful accumulation has occurred, pressing the LOCAL/TOTAL button will cycle the display to show number of accumulations, current local weight, current total weight on all scales, and the accumulated total. When the local weight, current total weight, or accumulated total is displayed, the total icon will be lit up, flashing, or off. (as shown in the display description).

Note: In print-mode 3 it can accumulate either in local or total weight, but not when viewing the accumulated total.

To clear the accumulated total weight, press and hold the ZERO button until the display shows “CLr

CLr.tttt“.

CLrCLr

Current total weight on all

Ac.Err

AcAc

Err” will be displayed.

ErrErr

Total weight of accumulations

Total number of accumulations

Ac.Err

AcAc

Err” if the

ErrErr

Ac. X” as the

AcAc

Accumulating Procedure:

1. With your system setup correctly, decide which scale you will accumulate from. This can be

2. With the first group of items stable on the scales, press the PRINT/ACCUMULATE button. If

any scale, but once you choose, you must only accumulate with that scale until the weighing is complete. This scale needs to be set to your desired accumulate mode, 2 or 3 (See “Serial Output Setup”). If you are using a printer, select the scale directly connected to the printer.

you are using a printer, a print ticket with all weights will now be printed. The display will return to the setting that the accumulation was taken from. This first group’s weight will become the accumulated total, which can be seen on the display by pressing the LOCAL/TOTAL button as described in the previous section with the TOTAL icon flashing. Another accumulation can not be made in the standard mode if the scale is in the

Page 15 of 44

Page 16

PT300 Users manual

Rev G, Feb 2011

Accumulation Print mode. (TOTAL icon flashing). After accumulation, remove the first group of items from the scale(s).

3. With the next group of items stable on the scale(s), press the PRINT/ACCUMULATE button. This will add the total weight to the accumulated total. If you are using a printer, a print ticket with all weights will now be printed.

4. Repeat step 3 as needed. If the accumulated total becomes too large to display, the “diSP

diSP”

diSPdiSP

message and error icon will be displayed.

5. When finished, you may clear the accumulated total weight by pressing and holding the ZERO button until the display show “CLr

CLr.tttt“. The display will clear the accumulated total and the

CLrCLr

number of accumulations.

Note: The scale will not accumulate when the weight is negative, zero, or if the weight is in motion. A display message “Ac

Ac.Err

Err” with error icon will be displayed if any of those

AcAc

ErrErr

conditions are present. After a successful accumulation the scale must return to zero before you accumulate the next weight. If you attempt to accumulate the next weight

before allowing the scale to return to zero, a display message “Ac

Ac.Err

Err” with error icon will

AcAc

ErrErr

be displayed.

Page 16 of 44

Page 17

PT300 Users manual

Rev G, Feb 2011

Weighing procedures

The PT300 platforms can be used separately, in pairs, or in groups of 4, 6, or more to measure a support load, wheel load, axle load, axle group load, or the total weight of a multi-axle truck in one measuring procedure.

Ideally, all wheels of a vehicle should be measured at the same time in order to avoid measuring errors due to the suspension system.

If you are not able to weigh the wheels of a tandem or triple axle simultaneously, the difference in height must be compensated for by using dummy plates (grids, wood or rubber plates) of the same height. The wheel load scales are put in front of the wheels of a vehicle, the driver then drives on the scales/plates and stops within the active weighing area. To avoid improper weighing which might be caused by wheel or axle load displacements, the vehicle brakes should be released before reading the weight values.

NOTES:

1. It is recommended to weigh the wheels of one axle at the same time.

2. The dummy plates can be omitted if the scales are embedded in recesses in the road surface

at the same levels as the road surface.

Please see tables on the following page

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Page 18

Table 1: Weighing Combinations

PT300 Users manual

Rev G, Feb 2011

Page 18 of 44

Page 19

Typical Scale Layouts

PT300 Users manual

Rev G, Feb 2011

Page 19 of 44

Page 20

PT300 Users manual

Rev G, Feb 2011

Mode Menu

To access the mode menu simultaneously press the PRINT/ACCUMULATE and ZERO buttons. The display will show “bbbb.LitE

scale is in the RUN position. (shorting pins 2 and 3(RUN)

At times it will be necessary to enter up to a five digit number. When this is necessary the current number will be displayed with the right most digit flashing. The flashing digit may be incremented by pressing the LOCAL/TOTAL button. To move one digit to the left, press the ZERO key. When you have finished entering a number press the PRINT/ ACCUMULATE button. The settings are saved once PRINT/ACCUMLATE is pressed to advance the menu, and the scale can then be turned off.

Step Function Note

bbbb.LitE

LitE

LitELitE

SEtP1

SEtP1SEtP1 SEtP2

SEtP2

SEtP2SEtP2

vEr

vEr.

vErvEr

AAAA. rt

rtrt

AAAA.tHrS

tHrS

tHrStHrS

A off

A offA off Prt t

Prt t

Prt tPrt t

Pbaud

PbaudPbaud

Units

UnitsUnits Proto

Proto

ProtoProto

iiii.baud

baud

baudbaud

radio

radioradio Rf CH

Rf CH

Rf CHRf CH

Rf.pan

pan

RfRf

panpan

Rf.eCp

eCp

RfRf

eCpeCp

Rf.def

def

RfRf

defdef

LitE”. If it doesn’t, go to Calibration Enable Jumper section and verify the

LitELitE

Default

Backlight

Set Point 1 0 to 199999

Set Point 2 0 to 199999

Firmware Version View only XXXXX

Average rate 1 to 120

Average threshold 1 to 10000

Auto off 000 = off, 1 to 240

Print Mode 0 = On-demand, 1 = Continuous,

Printer baud rate 1200, 2400, 4800, 9600, 19200,

Measurement units lb or kg lb

Protocol

Interface baud rate 9600 or 115200

Radio Enable Yes or no

Radio Channel 01 to 12

Radio Network ID 0 to 65534

Radio encryption enable Yes or no

Radio Encryption Key 0 to 65534

Restore Radio Defaults 0 or 3

Auto

Auto, on

on, oFF

AutoAuto

2 = Accumulating Total Axle, 3 = Accumulating Total Standard

or 38400, 57600, 115200

StAnd

StAnd, Lo Pr

StAndStAnd

oFF

onon

oFFoFF

Lo Pr, CCCC.L00P

Lo PrLo Pr

L00P, or none

L00PL00P

none

nonenone

Auto

AutoAuto

199999

199999199999

199999

199999199999

008

008008

200

200200

060

060060

0000

9600

96009600

Lo Pr

Lo PrLo Pr

9600

96009600

nono

1111

8000

80008000

nono

00000

0000000000

0000

Page 20 of 44

Page 21

PT300 Users manual

Rev G, Feb 2011

Setting the Mode Menu Parameters

1. Simultaneously press the PRINT/ACCUMULATE and ZERO buttons. The display will show “bbbb.LitE

LitE”. Press the PRINT/ACCUMULATE button. The flashing display shows the current

LitELitE

setting. Press the ZERO or the LOCAL/TOTAL buttons to toggle between Auto, on, and off. With ‘Auto’ selected (default), the backlight will automatically light up when low level light conditions are detected. When the desired setting is displayed, press the PRINT/ ACCUMULATE button.

2. The display will show “SEtP1 shows the current setting. When the weight displayed is equal to or greater than the set point, the corresponding icon is displayed on the LCD. During normal weighing mode, the S1 icon on the display will light when the weight is greater than or equal to set point 1. Use the LOCAL/TOTAL button the advance the number and the ZERO button to move the number flashing to the left. When the display shows the desired number, press the PRINT/ACCUMULATE button.

3. The display will show “SEtP2 shows the current setting. During normal weighing mode, the S2 icon on the display will light when the weight is greater than or equal to set point 2. Use the LOCAL/TOTAL button the advance the number and the ZERO button to move the number flashing to the left. When the display shows the desired number, press the PRINT/ACCUMULATE button.

4. The display will show “vEr show the current version of firmware loaded in the scale. Press the PRINT/ACCUMULATE button.

5. The display will show “AAAA. rt shows the current setting. This number is how many readings will be averaged together before the reading is sent to the display. Higher values will result in a more stable reading, but will take longer to settle to the final value. Note that the scale updates at 4Hz, so an Average Rate of ‘8’ equates to 2 seconds of averaging. Enter a ‘1’ to effectively disable averaging. Use the Lb/Kg button the advance the number and the ZERO button to move the number flashing to the left. When the display shows the desired number, press the PRINT/ACCUMULATE button.

6. The display will show “AAAA.tHrS shows the current Average Threshold setting. This setting enables dynamic averaging, which can improve the settling time of a large Average Rate. If the scale senses a large weight change, it will temporarily suspend averaging, jump to the new weight, and resume averaging. Enter a value of 1-10000 to set the threshold (in display divisions) at which the dynamic averaging triggers. Enter ‘0’ to disable dynamic averaging. When disabled, the averaging will never be suspended. When the display shows the desired number, press the PRINT/ACCUMULATE button.

7. The display will show “AAAA. oFF shows the current setting. The number displayed is the minutes that the scale can remain

idle before it automatically shuts down. Setting this number to “000

SEtP1”. Press the PRINT/ACCUMULATE button. The flashing digit

SEtP1SEtP1

SEtP2”. Press the PRINT/ACCUMULATE button. The flashing digit

SEtP2SEtP2

vEr”. Press the PRINT/ACCUMULATE button and the display will

vErvEr

rt”. Press the PRINT/ACCUMULATE button. The flashing digit

rt rt

tHrS”. Press the PRINT / ACCUMULATE button. The flashing digit

tHrStHrS

oFF”. Press the PRINT/ACCUMULATE button. The flashing digit

oFF oFF

000” will disable the

000000

Page 21 of 44

Page 22

function, meaning the scale will never shut itself off. Use the LOCAL/TOTAL button the advance the number and the ZERO button to move the number flashing to the left. When the display shows the desired number, press the PRINT/ACCUMULATE button.

8. The display will show “Prt t

Prt t”. Press the PRINT/ACCUMULATE button. The flashing digit

Prt tPrt t

shows the current setting. The number enables the scales different print modes. (0 for ondemand, 1 for continuous, 2 for accumulating total axle format, and 3 for accumulating total standard format) Use the LOCAL/TOTAL button to increment and the ZERO button to decrement the number. When the display shows the desired number, press the PRINT/ACCUMULATE button.

9. The display will show “PbAUd

PbAUd”. Press the PRINT/ACCUMULATE button. The flashing

PbAUdPbAUd

display shows the current setting of the printer baud rate. The baud rates available are: 1200, 2400, 4800, 9600, 19200, 38400, 57600, and 115200. Use the LOCAL/TOTAL button or the ZERO button to toggle through the available rates. When the display shows the desired number, press the PRINT/ACCUMULATE button.

10. The display will show “UnitS

UnitS”. Press the PRINT/ACCUMULATE button. The lb or the kg

UnitSUnitS

icon will flash in the upper left of the display. This will set the scale to measure pounds (lb) or kilograms (kg). Use the LOCAL/TOTAL button or the ZERO button to toggle between the settings. When the desired icon is flashing, press the PRINT/ACCUMULATE button.

11. The display will show “Proto

Proto”. Press the PRINT/ACCUMULATE button. The flashing

ProtoProto

display shows the current setting. There are 4 protocol settings for the scale, Standard (“StAnd

StAnd”), Low Power (“Lo Pr

StAndStAnd

Lo Pr”), Current Loop (“CCCC.L00P

Lo PrLo Pr

Standard is a setting for use in specific wireless and wired scale networks. Low Power will significantly improve the wireless battery life for all non-‘host’ scales (maximum number of scales in this mode is 32).

Current Loop is used when connecting to older legacy PT300 scales. The legacy cables (part #’s 100488, 100489, or 100490) must be used when in this communication mode. See section titled “Totalizing/Printing in Current Loop Mode” for more information.

When scales are not part of a totalizing network, battery life will be improved if “nonE chosen. Use the LOCAL/TOTAL button or the ZERO button to cycle through the settings. When the desired protocol is flashing, press the PRINT/ ACCUMULATE button.

12. The display will show “iiii.bAud

bAud”. Press the PRINT/ACCUMULATE button. The display will

bAudbAud

show the current setting flashing. This is the setting of the interface baud rate. There are two settings available, 9600 and 115200. Use the LOCAL/TOTAL button or the ZERO button to toggle between the settings. When the desired baud rate is flashing, press the PRINT/ ACCUMULATE button.

13. The display will show “rAdio

rAdio”. Press the PRINT/ACCUMULATE button. The display will

rAdiorAdio

show the current setting flashing. This is the radio enable status and is either on or off. Use the LOCAL/TOTAL button or the ZERO button to toggle between the settings. When the desired status is flashing, press the PRINT/ ACCUMULATE button. If you select “no” the scale will skip the rest of the settings and return to normal weighing.

L00P”), or “None

L00PL00P

None”.

NoneNone

PT300 Users manual

Rev G, Feb 2011

nonE” is

nonEnonE

Page 22 of 44

Page 23

14. The display will show “rF CH

rF CH”. Press the PRINT/ACCUMULATE button. The flashing digit

rF CHrF CH

shows the current setting. All scales in a system must be set to the same radio channel setting in order to communicate with each other. Use the LOCAL/TOTAL button to increment and the ZERO button to move the number flashing to the left. When the display shows the desired number, press the PRINT/ACCUMULATE button.

15. The display will show “rF

rF.PAn

PAn”. Press the PRINT/ACCUMULATE button. The display will

rFrF

PAnPAn

show the current setting with the number on the right flashing. All scales in a system must be set to the same Personal Area Network ID setting in order to communicate with each other. Use the LOCAL/TOTAL button to increment and the ZERO button to move the number flashing to the left. When the display shows the desired number, press the PRINT/ACCUMULATE button.

16. The display will show “rF

rF.ECP

ECP”. Press the PRINT/ACCUMULATE button. The display will

rFrF

ECPECP

show the current setting flashing. This is the encryption enable status and is either on or off. Use the LOCAL/TOTAL button or the ZERO button to toggle between the settings.

When the desired status is flashing, press the PRINT/ ACCUMULATE button. If “Yes selected go to the next step. If “no

17. The display will show “00000

00000” with the number on the right flashing. Use the

0000000000

no” was selected got to step 17.

nono

LOCAL/TOTAL button to increment and the ZERO button to move the number flashing to the left. Enter any number from 0 to 65534. This is the encryption key. For security

purposes, this setting is not accessible to view and will always show as “00000 don’t want to change the key enter “00000

00000” to leave it unchanged. All scales in a system

0000000000

must be set to the same encryption key setting in order to communicate with each other. When the desired encryption key is displayed, press the PRINT/ ACCUMULATE button.

18. The display will show “rF

rF.dEF

dEF”. Press the PRINT/ACCUMULATE button. The display will

rFrF

dEFdEF

show “0000” with the number flashing. Use the LOCAL/TOTAL button to increment and the ZERO button to decrement the number. Setting the number to 3 will restore the default radio settings. All other numbers will have no affect on the radio set-up. When the desired number is flashing, press the PRINT/ ACCUMULATE button. The scale will return to normal weighing.

If the scale does not have the radio option installed, the “rF CH

rF CH”, “rF Pan

rF CHrF CH

Encryption key will be view only.

PT300 Users manual

00000”. If you

0000000000

rF Pan”, “rF ECP

rF PanrF Pan

rF ECP” and the

rF ECPrF ECP

Rev G, Feb 2011

Yes” was

YesYes

Page 23 of 44

Page 24

Cabled Scale Usage

Legacy PT300

PT300 Users manual

Rev G, Feb 2011

Totalizing/Printing in Current Loop Mode

To use your next generation PT300 scales with the older legacy PT300 scales, the scales need to be set to Current Loop (“CCCC.L00P

Before you attempt to do either of these, a few terms and definitions must be understood. These terms only apply to scales that are cabled together. Also, legacy cables (part #’s 100488, 100489, 100490) are wired differently than the next generation PT300 cables (part #’s 101029, 101032, 101035) and must be used in Current Loop communication mode.

Master Scale: If more than one scale is being used, the first scale in line is referred to as the Master Scale. Normally these scales have continuous output, If you requested a demand output use the print button on this scale when printing or totalizing.

Slave Scale: If more than one scale is being used, any scale that is not the master scale is referred to as a Slave Scale.

Master Slave Slave Slave

scale A scale B scale C scale D

L00P”) mode. Change the protocol (“Proto

L00PL00P

Proto”) option in the mode menu.

ProtoProto

Printer

Example of Master/Slave designations

The master and slave designations are determined by the cable and not the scale itself. The cable also determines if the scale transmits data on demand (when the print button is pushed) or continuously. If continuous, the print button doesn't have to be activated to totalize or print. Please refer to the cabling diagrams

Page 24 of 44

Page 25

PT300 Users manual

Rev G, Feb 2011

Totalizing

When more than one scale is being used, the last one in line can be used to show the total weight of all the scales added together. To totalize, turn on the scales in sequential order starting with the master scale (“scale A") and make sure all of the slave scales are in the total mode. The indicating bar on the upper left side of the display is on when in the total mode. This

does not mean that the scale is receiving; only that it is capable of receiving.

If transmitting on demand, press the print button on the master scale and the last scale in line (slave scale D in the diagram) will show the total weight of all the scales.

Example: Scale A will display the total of A only. Scale B will display the total of A + B. Scale C will display the total of A + B + C. Scale D will display the total of A + B + C + D.

Printing

Use the print button on the master scale when printing. If more than one scale is being used, put the slave scale(s) in the total mode. This will allow the printer to print the total weight of all the scales.

NOTE: The important thing to remember is that the printer will print whatever is displayed on the last scale in line before the printer.

In addition to the weight, the printer will print a letter that signifies the number of scales that it printed the weight from. Example: The letter A signifies the weight is from one scale. The letter B signifies the weight is from two scales etc..

Page 25 of 44

Page 26

PT300 Users manual

Rev G, Feb 2011

Data Interface

Serial ASCII 20 mA current loop, active or passive. (The PT300 supplies the current for active current loop, and an external current is used for passive current loop. Passive is preferred for longer battery use between charges.)

1200 Baud 8 data bits 1 start bit 2 stop bits no parity M Kg Transmission Format: A_O_-XXXXXXX._Lb<CR><LF> Z

Format explanation: A = Scale code (Signifies the scale, could be A for scale A, B for scale B etc..) Space

M,O,Z = Error code (M = motion, O = over-capacity,

Z = zero, space = no error) Space Minus sign if negative, space if positive. 8 data bits Space Pounds/Kilograms Carriage return Line feed

Page 26 of 44

Page 27

PT300 Users manual

Rev G, Feb 2011

Calibration

Note: The PT300 scale is calibrated by the factory prior to shipment.

Note: The calibration will achieve the best accuracy if calibration loads are applied to PT300

platform through a metal block, separated from the platform by a thick piece of firm rubber; this setup best simulates the load applied by a tire. Loading without a block can damage the scale. See Tool List below for complete specifications.

Procedure: Calibration (Verification)

Check front/back load cell balance

Tools required

Twenty thousand pound calibration press.

1.5" x 1.5" x 12" aluminum loading block. Static dissipation station. #2 Phillips screwdriver for bezel and board mounts. Small slotted blade screwdriver. Torque-seal potentiometer shaft sealer.

Caution:

The following procedure must be performed at a static controlled workstation. Load cell locations used in the following procedure are shown below.

Load Cell Placement

Page 27 of 44

Page 28

PT300 Users manual

Rev G, Feb 2011

1. Position the corner fixture with rubber pad on the scale position #1. Apply 2500 lbs to the

loading block. Annotate the reading.

2. Repeat for the #2 position.

3. If all readings are within 5 pounds and the previous calibration passed all of the readings

continue with the rest of the calibration verification. If the corner check fails go to the corner adjust calibration procedure.

Scale Span Calibration

Tools required:

•

Calibration force generator; press or deadweights. This calibration source must cover the range of 10% to 100% of nominal capacity with an accuracy of 0.25% of reading or better.

PT300

•

100027 - 8" (± 0.25") x 8" (± 0.25") x 1.75" (minimum) aluminum loading block.

•

100028-A - 8" (± 0.25") x 8" (± 0.25") x 0.5" (± 0.125") rubber loading scale. (40 to 70 Shore A

rating)

PT300DW

•

100029

•

100030-A A rating)

4. Bring the scales to the calibration site. If there is more than 5°F difference in temperature

between the scale temperature and the calibration site allow the scales to reach room temperature.

5. Place scale on calibration fixture. Turn scale on. Wait 3 minutes for warm-up.

6. Apply test forces every 10% of the scales capacity and verify that the reading falls within 1% of

the applied force or 1 display division whichever is greater as shown in the sample table below.

7. If any value is out of acceptable limits proceed to the adjust calibration procedure.

8. If all values are within acceptable limits unit passes calibration verification.

- 12" (± 0.25") x 12" (± 0.25") x 1.75" (minimum) aluminum loading block.

- 12" (± 0.25") x 12" (± 0.25") x 0.5" (± 0.125") rubber loading scale. (40 to 70 Shore

20K Capacity

Test

force

(lb)

0 0 0 2000 4000 6000 8000

10000 12000 14000 16000 18000 20000

0 -20 20

Lower

limit

(lb)

1980 3960 5940 7920

9900 11880 13860 15840 17820 19800

Upper

Limit

(lb)

2020 4040 6060

8080 10100 12120 14140 16160 18180 20200

Page 28 of 44

Page 29

PT300 Users manual

Rev G, Feb 2011

Procedure: Calibration (Adjustment)

Tools required:

•

Calibration force generator; press or deadweights. This calibration source must cover the range of 10% to 100% of nominal scale capacity with a certified accuracy of 0.25% of reading or better.

PT300

•

100027 - 8" (± 0.25") x 8" (± 0.25") x 1.75" (minimum) aluminum loading block.

•

100028-A - 8" (± 0.25") x 8" (± 0.25") x 0.5" (± 0.125") rubber loading scale. (40 to 70 Shore A

rating)

PT300DW

•

100029

•

100030-A A rating)

•

140208 - #2 Phillips screwdriver.

•

140210 - Static dissipation station.

- 12" (± 0.25") x 12" (± 0.25") x 1.75" (minimum) aluminum loading block.

- 12" (± 0.25") x 12" (± 0.25") x 0.5" (± 0.125") rubber loading scale. (40 to 70 Shore

Page 29 of 44

Page 30

PT300 Users manual

Rev G, Feb 2011

Calibration Enable Jumper

To access the calibration mode the shorting strap labeled “RUN/CAL”, located on the right-middle of the circuit board (Intercomp, A/D 20 BIT rev E), it must be moved from shorting pins 2 and 3(RUN); to shorting pins 1 and 2(CAL). To access the shorting strap, remove the 10 screws on the outside edges of the display assembly. Carefully lift the display assembly up and place the assembly, display side down, on top of the weighing platform. Following calibration, replace the strap to shorting pins 2 and 3 (RUN); replace the assembly and reattach the assembly with the screws. This will ensure that the calibration information of the scale is protected from being changed.

Note: Care must be taken to ensure the wire harness is seated properly to prevent it from being pinched between the display assembly and the scale casing.

Page 30 of 44

Page 31

PT300 Users manual

Rev G, Feb 2011

Calibration menu

To initiate calibration simultaneously press the PRINT/ACCUMULATE and ZERO buttons. The display will show “StEP

calibration. Return to ‘Calibration Enable Jumper’ section to verify correct setting. Press the PRINT/ACCUMULATE button to access the parameter setting. At times it will be necessary to enter up to a five digit number. When this is necessary the current number will be displayed with the right most digit flashing. The flashing digit may be incremented by pressing the LOCAL/TOTAL button. To move one digit to the left, press the ZERO key. When you have finished entering a number press the PRINT/ ACCUMULATE button. The settings are saved once PRINT/ACCUMLATE is pressed to advance the menu, and the scale can then be turned off.

StEP

StEPStEP

UUUU. EnA

bP 1

bP 1bP 1 bP 2

bP 2

bP 2bP 2 bP 3

bP 3

bP 3bP 3

AdC

AdC.rt

AdCAdC

2Er0

2Er0.rrrr

2Er02Er0

ggggrAd

LL-01

LL-01LL-01

HH-01

HHHH

LL-01

LLLL

HH-02

HHHH

LL-02

LLLL

HH-03

HHHH

LL-03

LL-03LL-03 HH-04

HH-04

HH-04HH-04 LL-04

LL-04

LL-04LL-04

StEP”, if it does not, the calibration strap is incorrectly placed to allow

StEPStEP

Step Function Note

skip 000= no skip

001= skip to Weight Calibration 003= skip to cornering routine

EnA

EnA EnA

A2t

A2tA2t

rAd

rAdrAd

CAP

CAPCAP

Unit enable Yes or no

grad break point 1 Enter weight

grad break point 2 Enter weight

grad break point 3 Enter weight

ADC rate 0 or 1

rtrt

AZT (auto zero tracking) 1 d, 3 d, .5 d, oFF, or.6 d

Zero range 0= off, 1= 1%, 2= 2%, 3= 5%,

4 = 1%

graduation size 0.02, 0.05, 0.1, 0.2, 0.5, 1, 2, 5,

10, 20, 50, or 100

SAVE

SAVESAVE

capacity Enter scale capacity

No weight applied

First weight Enter first weight

0101

First weight Load first weight

0101

Second weight Enter second weight

0202

Second weight Load second weight

0202

Third weight Enter third weight

0303

Third weight Load third weight

Fourth weight Enter fourth weight

Fourth weight Load fourth weight

10 points available to enter 3 minimum recommended

Displays for 1 sec and advances

Default

000

000000

YES

YESYES

00000

0000000000

00000

0000000000

00000

0000000000

1111

1 d

1 d1 d

0000

d 1

d 1d 1

20000

2000020000

Page 31 of 44

Page 32

PT300 Users manual

Rev G, Feb 2011

Setting the Calibration Parameters

1. At any point in the following steps, data will be retained by the scale at the step completed if

the power is cycled off. To initiate calibration simultaneously press the PRINT/ACCUMULATE and the ZERO buttons. The scale shows “StEP The scale shows “000

000” with the far right number flashing. To go through all of the calibration

000000

parameters, press PRINT/ ACCUMULATE with the display showing “000 calibration parameters and proceed to step 11 enter “001

additional codes available. Use the LOCAL/TOTAL button to increment and the ZERO button to decrement the number. Press the PRINT/ ACCUMULATE button when the desired number is displayed.

3. The display shows “UUUU. EnA ACCUMULATE button. The display will read “YES button will toggle the display to “no

PRINT/ACCUMULATE button.

4. The display now shows “bP 1

the current setting with the far right number flashing. Use the LOCAL/TOTAL button to advance the number and the ZERO button to move the number flashing to the left. When the desired graduation break point is displayed press the PRINT/ ACCUMULATE button.

5. The display shows “bP 2

step 3 for graduation break point 2. When the desired graduation break point is displayed press the PRINT/ACCUMULATE button.

6. The display shows “bP 3

step 3 for graduation break point 3. When the desired graduation break point is displayed press the PRINT/ACCUMULATE button.

EnA” if proceeding through all parameters. Press the PRINT/

EnAEnA

no”. With the display showing “YES

nono

bP 1”. Press the PRINT/ACCUMULATE button. The display will read

bP 1bP 1

bP 2”. Press the PRINT/ACCUMULATE button. Repeat the process in

bP 2bP 2

bP 3”. Press the PRINT/ACCUMULATE button. Repeat the process in

bP 3bP 3

StEP”. Press the PRINT/ACCUMULATE button.

StEPStEP

000”. To skip the first 8

000000

001”. See Diagnostics section for

001001

YES”. Pressing LOCAL/TOTAL or the ZERO

YESYES

YES”, press the

YESYES

Multiple Graduation Break Points

The PT300 has the ability to have multiple graduation values set. Following is an example of setting graduation break points. Example:

Grad = Initial graduation equals by 0.1 lb Cap = 10000 (Capacity equals 10,000 lb)

bP 1

bP 1 = 1000

bP 1bP 1 bP 2

bP 2 = 2000

bP 2bP 2 bP 3

bP 3 = 5000

bP 3bP 3

Page 32 of 44

Page 33

PT300 Users manual

Rev G, Feb 2011

The scale would then display the following:

up to 1000 lb by 0.1 lb; up to 453.55 kg by 0.05 kg 1000+ to 2000 lb by 0.2 lb; 453.55+ to 907.1 kg by 0.1 kg 2000+ to 5000 lb by 0.5 lb; 907.1+ to 2267.8 kg by 0.2 kg 5000+ lb by 1.0 lb; 2267.8+ kg by 0.5 kg

To disable the breakpoints the graduation break points should be set to 110% of the capacity. The scale uses the same graduation from zero to capacity. This turns off the breakpoint feature.

7. The display shows “AdC

AdC.rt

rt”. Press the PRINT/ACCUMULATE button. The display shows the

AdCAdC

rtrt

current setting flashing. This sets the internal A/D conversion time at one of two choices. An entry of ‘0’ results in the full conversion time for the most stable results. An entry of ‘1’ results in a reduced conversion time which extends battery life. For the PT300 it is recommended to leave this set to ‘1’. Note that if this setting is changed, the scale must be recalibrated. Use the LOCAL/TOTAL button to increment and the ZERO button to decrement the number. When the desired ADC rate is displayed press the PRINT/ACCUMULATE button.

8. The display shows “AZt

AZt”. Press the PRINT/ACCUMULATE button. The display shows the

AZtAZt

current setting. Press the LOCAL/TOTAL or the Zero button to cycle through the auto zero tracking options. (1 d

1 d, 3 d

3 d, .5 d

1 d1 d

3 d3 d

5 d. oFF

oFF, or 6 d

5 d5 d

oFFoFF

6 d) If the displayed weight is less than the number

6 d6 d

of grads shown for a given amount of time, the weight will be zeroed off. When the desired auto zero tracking setting is displayed press the PRINT/ACCUMULATE button.

9. The display shows “ZEr0

ZEr0.rrrr”. Press the PRINT/ACCUMULATE button. The display shows the

ZEr0ZEr0

current setting flashing. Use the LOCAL/TOTAL button to increment and the ZERO button to decrement the number. The zero range is the percentage the zero can move from the original zero obtained at calibration. The zero button will not work if outside the zero range; and the

display will show “ZEr0

ZEr0.rrrr” with the error icon lit if the zero range is set to 1, 2, or 3. If 4-6 is

ZEr0ZEr0

selected, the zero button will simply not function when an attempt is made to zero the scale outside the range. When the number for desired zero range number is displayed press the PRINT/ACCUMULATE button. (0=off, 1=1%, 2=2%, and 3=5%, 4=1%, 5=2%, 6=5%)

10. The display shows “GGGGrAd

rAd”. Press the PRINT/ACCUMULATE button. The display shows the

rAdrAd

current setting with the number flashing. Press the LOCAL/TOTAL or the Zero button to cycle through the graduation options. When the desired graduation setting is displayed press the PRINT/ACCUMULATE button. (grad options 0.02, 0.05, 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, or

100)

Note: The numbering for the “setting the calibration parameters” continues at Span Calibration.

At this point the display will show “SAvE

SAvE” for about 1 second and advance to show “CAP

SAvESAvE

CAP”.

CAPCAP

Page 33 of 44

Page 34

PT300 Users manual

Rev G, Feb 2011

Weight Calibration

One to ten load weights need to be applied to calibrate the scale. Using multiple point calibration allows the unit to weigh more accurately; by removing undesirable characteristics of load cells. A typical weight calibration is a three point calibration. This means three different and optimal loads are applied and entered (not including the zero point). If you do not conveniently have the three different weights available, you may also use one or two point calibration. To calibrate with one point, simply turn off the scale after completing step 13 as listed below. To calibrate with two points, turn off the scale after completing step 15 as listed below. The PT300 has the capability to apply and load up to 10 calibration points.

Corner Calibration (Both load cells)

Caution: Avoid directly touching any exposed circuitry. Use cotton gloves or similar protection.

Oils from the fingers will cause unacceptable performance in high humidity conditions. This degradation may not be obvious at the time of contamination. If the circuitry becomes contaminated it must be cleaned using isopropanol or an equivalent cleaner.

Note: If the scale fails corner verification perform the following routine. If the span is the only thing that need to be calibrated skip this section and go to span calibration.

1. Turn scale ON.

2. Press the PRINT / ACCUMULATE button. The display should show “StEP

Cal Enable Switch Access section and press the cal enable switch. Press the PRINT / ACCUMULATE button.

3. The display shows “000

button until the display shows “003 the PRINT / ACCUMULATE button.

4. The display shows “LLLLCCCC.bAL

show one digit flashing. This is the number of load cells in the scale. Increase the number

000” with the most right digit flashing. Increase the number with the Lb/Kg

000000

003”. This will access the Load Cell Balance routine. Press

003003

bAL”. Press the PRINT / ACCUMULATE button and the display will

bALbAL

Page 34 of 44

StEP”. If not return to the

StEPStEP

Page 35

PT300 Users manual

Rev G, Feb 2011

with the Lb/Kg button or decrease the number with the Zero button until the display shows “2222”. This is the number of load cells in the PT300. (Unless you have a 30K or 40K PT300DW, which has 4 load cells, enter “4444” in this case) If the number was changed the scale will save and restart. If this happens go back to step 2. If the number isn’t changed the display will

show “LC 00

5. Press PRINT / ACCUMULATE to read the zero load. For this step it doesn’t matter if there are

loading blocks on the scale or not.

6. The display will show “LC1-0

as per figure above. With no weight on the scale except the loading block fixture, press the PRINT ACCUMULATE button.

7. The display will show “LC1-L

same loading fixture. Once the load is applied press the PRINT ACCUMULATE button.

8. The display will show “LC2-0

as per figures 1 and 2 above. With no weight on the scale except the loading block fixture, press the PRINT ACCUMULATE button.

9. The display will show “LC2-L

same loading fixture. Once the load is applied press the PRINT ACCUMULATE button.

10. The display will show “SAvE

been internally compensated and saved. Perform corner calibration verification in normal weighing mode. This concludes the corner calibration.

11. To access the Span calibration, simultaneously press the PRINT/ACCUMULATE and the

ZERO buttons. The scale shows “StEP shows “000 press PRINT/ ACCUMULATE with the display showing “000 parameters and proceed to span calibration enter “001

LC 00”.

LC 00LC 00

LC1-0”. Prepare load cell 1 using the loading block and the rubber pad

LC1-0LC1-0

LC1-L”. Apply ¼ of the capacity of the scale to load cell 1 using the

LC1-LLC1-L

LC2-0”. Prepare load cell 2 using the loading block and the rubber pad

LC2-0LC2-0

LC2-L”. Apply ¼ of the capacity of the scale to load cell 2 using the

LC2-LLC2-L

SAvE” and then return to normal weighing mode. The cornering has now

SAvESAvE

StEP”. Press the PRINT/ACCUMULATE button. The scale

StEPStEP

000” with the far right number flashing. To go through all of the calibration parameters,

000000

000”. To skip the first 8 calibration

000000

001”.

001001

Corner Calibration (Single load cell)

1. Position the scale, loading block and pad to apply weight on the corner requiring adjustment.

2. Enter Cal mode.

3. Enter “20 the code as ‘x’. (Example: Enter “202

4. The display will appear to return to normal mode, except that now the ‘S1’ and ‘S2’ segments are blinking to indicate you are now in corner adjust mode for your selected corner.

5. Apply ¼ of the scales capacity to the loading pad over the corner to be adjusted.

6. Press LOCAL/TOTAL to increase or ZERO to decrease the corner’s weight. (Each press adjusts the display approximately 0.01%)

7. When the desired weight is showing on the display, press PRINT / ACCUMULATE to save the results and return to normal weighing. Return to calibration verification section and ensure all calibration parameters are met.

20x” at “StEP

2020

StEP” choice to adjust a single corner. The cell number to adjust is entered in

StEPStEP

202” to enter mode to adjust cell #2).

202202

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Rev G, Feb 2011

Span Calibration

Note: The numbering from the “setting the calibration parameters” continues here.

11. The display will show “SAvE

PRINT/ ACCUMULATE button. The display will show the current capacity setting with the far right number flashing. Use the LOCAL/TOTAL button the advance the number and the ZERO button the move the number flashing to the left. Enter the capacity of the scale and press the PRINT/ACCUMULATE button when the scale capacity is displayed.

12. The display shows “LL-00 ACCUMULATE button.

13. The display shows “HH-01 “00000

00000” with the far right number flashing. Use the LOCAL/TOTAL button to advance the

0000000000

number and the ZERO button to move the number flashing to the left. Enter the value of the first load and press the PRINT/ACCUMULATE button when the value of the first load is displayed.

14. The display shows “LL-01 scale press PRINT/ACCUMULATE button.

15. The display shows “HH-02 “00000

00000” with the far right number flashing. Use the LOCAL/TOTAL button to advance the

0000000000

number and the ZERO button to move the number flashing to the left. Enter the value of the second load and press the PRINT/ACCUMULATE button when the value of the second load is displayed.

16. The display shows “LL-02 to the scale press PRINT/ACCUMULATE button.

17. The display shows “HH-03 “00000

00000” with the far right number flashing. Use the LOCAL/TOTAL button to advance the

0000000000

number and the ZERO button to move the number flashing to the left. Enter the value of the third load and press the PRINT/ACCUMULATE button when the value of the third load is displayed.

18. The display shows “LL-03 the scale press PRINT/ACCUMULATE button.

19. The display shows “HH-04 “00000

00000” with the far right number flashing. Use the LOCAL/TOTAL button to advance the

0000000000

number and the ZERO button to move the number flashing to the left. Enter the value of the forth load and press the PRINT/ACCUMULATE button when the value of the forth load is displayed.

SAvE” for about 1 second and advance to show “CAP

SAvESAvE

LL-00”. With no weight applied to the scale press the PRINT/

LL-00LL-00

HH-01”. Press the PRINT/ACCUMULATE button. The display will show

HH-01HH-01

LL-01”. Apply the first load to the scale. With the first load applied to the

LL-01LL-01

HH-02”. Press the PRINT/ACCUMULATE button. The display will show

HH-02HH-02

LL-02”. Apply the second load to the scale. With the second load applied

LL-02LL-02

HH-03”. Press the PRINT/ACCUMULATE button. The display will show

HH-03HH-03

LL-03”. Apply the third load to the scale. With the third load applied to

LL-03LL-03

HH-04”. Press the PRINT/ACCUMULATE button. The display will show

HH-04HH-04

CAP”. Press the

CAPCAP

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Rev G, Feb 2011

20. The display shows “LL-04

LL-04”. Apply the forth load to the scale. With the forth load applied to

LL-04LL-04

the scale press PRINT/ACCUMULATE button.

Repeat step 12 and 13 for each additional “HH-05

HH-05” – “HH10

HH-05HH-05

HH10” and “LL-05

HH10HH10

LL-05”- “HH10

LL-05LL-05

HH10” combination. If

HH10HH10

the scale is turned off at any time the calibration data acquired to that point will be retained. After the PRINT/ACCUMULATE button is pressed after “LL-10”, the display will return to normal weighing.

Finished

Following calibration, replace the strap to shorting pins 2 and 3 (RUN); replace the assembly and reattach the assembly with the screws. This will ensure that the calibration information of the scale is protected from being changed.

Note: Care must be taken to ensure the wire harness is seated properly to prevent it from being pinched between the display assembly and the scale casing.

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PT300 Users manual

Rev G, Feb 2011

Troubleshooting

Problem Table

The following table describes some symptoms with possible causes and solutions.

Symptom No power up, nothing on display If any power reaches the control panel, the display driver turns on some random segments. Since we are not seeing

this we will assume that no power is reaching the scale circuitry. Some possible causes: Defective wiring harness: Inspect for damaged wiring. Defective battery pack: Measure battery voltage, charge or repair as needed. Defective ON switch: Bridge switch to see if unit turns on. Defective circuitry: Replace control panel. The power supply may be delivering power, but it might be eaten up with a defective circuit board or cable. Unplug the load cell cable. If the scale turns on at this point, a load cell lead is shorted. Turn the power off and try each cell lead in turn. If it is the load cell cable, look for a crushed cable. Symptom Power up to random display We know that some power is reaching the display driver circuit, but the control panel is not working correctly. Test for low battery voltage. Inspect for visible damage. If this fails replace the control panel. Symptom Scale shuts off If the scale turns off IMMEDIATELY after you take your finger off the off button, you may have very low batteries. If this is not the cause replace the control panel. Symptom "Locks up"

The scale may be mis-programmed. This can be corrected by restoring the correct control parameters. If the Average Rate setting is very high, an active load may not update the display quickly which may be interpreted as a lock up Symptom No backlight Cover the light sensor window. If the light does not turn on, replace the control panel. Please note that the light is not visible in bright sunlight. Symptom Slow operation This may be caused by a programmed change in the filter setting. There is a tradeoff between speed and stability of the display reading. This can be tuned by changing the “Average Rate” setting. Symptom Low battery indicator won't turn off It is possible that the output from the batteries is really low. Look at the cells and charger circuit for these problems. If the battery voltage is correct then you will need to replace the control panel. Symptom Jumpy or drifty weights

This can usually be traced to contamination on circuit boards or a bad load cell. This can also be caused by a rapid change in temperature. The scales need at least one-hour acclimation time for each 10 degrees Fahrenheit of temperature change. Another possibility is powerful radio interference. Symptom No response to one or more keys The switch may be defective. The control panel may be defective. The zero key does not function while the scale is in motion, this is not a defect. Also, the scale may be programmed to ignore the zero key if there is more than a certain amount of weight on the platform. Symptom "Bad" weights

First, check weighing technique. Are there air currents around the vehicle being weighed? Are the operators using dummy blocks on the un-weighed wheels? (NOT a recommended technique) Are the scales being used on level ground? Is the scale set on the wrong units settings? Is a new operator using the scales? If on a calibration press, are you using weight distribution blocks and rubber scales? Is the reference scale correct? Assuming all this, is the scale spanned correctly? If the reading is exactly 3/4 of the expected value, one of the cells leads may not be providing signal. This would probably be in the load cell or control circuit. The interconnecting wiring or cables may be pinched, cut or crushed. Symptom Batteries won't charge

Check for bad batteries. The charger circuit could be out. Check for bad connections or a defective charging cable. Look at the power source, whether it's a plug-in transformer, transport cart, or automotive ignition. Remove the battery cap with the scale plugged into the charger. If the scale turns on then the charger is working.

Caution: Changing any circuit board or load cell will affect the calibration. The calibration should be verified after any repairs.

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PT300 Users manual

clear the problem,

Rev G, Feb 2011

Error Messages

Error messages displayed can be a helpful diagnostic tool. The following table describes some possible causes and solutions.

Message Meaning

'EEPE

EEPE'

EEPEEEPE

Calibration information is held in a special permanent memory area. A checksum code is generated and written to this memory during the calibration process. Each time the power is turned on this code is regenerated and compared to the stored value. If a change is found this error message is displayed. Recalibration may clear the error display, but if the problem persists the control panel will have to be replaced.

'AD1

AD1'

AD1AD1

The A/D circuit board has indicated a fault and needs to be repaired or replaced.

'LCb

LCbxx'

LCbLCb

A load cell may have failed or there is a bad connection. The “xx” shows which cell or connection has failed: xx=1-8 (single digit) if there is a single load cell failure. A two-digit value for “xx” is a code to indicate multiple cells have failed or are disconnected

'LC

LC xx'

LC LC

A load cell circuit may have failed or there is a bad connection. The “xx” shows which cell or connection has failed: xx=1-8 (single digit) if there is a single load cell failure. A two-digit value for “xx” is a code to indicate multiple cells have failed or are disconnected

‘Lo

Lo.bAt

bAt’

LoLo

bAtbAt

This message indicates that the control panel has measured the battery voltage and found it to be too low. The most likely cause is that the batteries need to be charged. If the charge indicator fails to light up when the charger is plugged in, then the charger or cable may be defective. If the batteries have been charged for the recommended time and fail to run for the specified duration, then the batteries may need to be changed. If a new set of batteries fail to correct the situation, then the control panel may need to be replaced. Also check the battery holder and wiring.

'CAP

CAP'

CAPCAP

The control panel has detected a weight reading that is larger than expected. This may be caused by the application of too much weight to the platform. If this display is seen when there is no weight on the platform, then the most likely causes are a defective load cell or defective control panel. To isolate the problem, measure the signal across pins two and three on the load cell connector on the control panel. This should be between zero and one millivolt. If found to be higher or lower, then the load cell system must be checked. See procedure elsewhere in this manual. If the signal is within this range then the calibration data may be lost. Attempt to recalibrate the scale. If this does not then replace the control panel.

‘ZErO

ZErO.RRRR’

ZErOZErO

Scale tried to zero off a load outside the range specified in the zero range setting. Remove any load and press zero.

'diSP

diSP'

diSPdiSP

The most common cause of this error is pressing the zero key with a full load on the scale. When the load is removed, the full number with a minus sign will not fit on the display. Pressing the zero key again will clear this display.

‘COP

COP’ or

COPCOP

‘CLOC

CLOC’

CLOCCLOC

This won’t affect normal operations and can typically be ignored.

EEPROM FAILURE Calibration information lost or corrupted

A/D converter failure

Power-up Self Test has detected one or multiple load cell errors

Run-time checking has detected one or multiple load cell errors

Low battery voltage

Overload or calibration information lost or bad load cell

Zero Range Error

Number can't be displayed (such as -99999)

Diagnostic power-up message

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PT300 Users manual

Excitation

Excitation +

Signal

Signal +

5 Ω

700 Ω

Rev G, Feb 2011

Diagnostic tests and voltage measurements

Charger voltage

Ensure the scale is off during the entire test. Remove the batteries and connect a meter across the battery compartment observing correct polarity. Plug the battery charger in, the voltage should measure 5.8V DC or more. Unplug the battery charger and reinstall the batteries. Measure the voltage across the batteries. Depending on the state of charge on the batteries the voltage should be between 3.6 to 5.8V DC. Plug the charger back in. The voltage across the batteries should increase. If the correct voltage response is not observed, unplug the battery charger. Remove one of the batteries and connect a meter, set to measure current to the battery compartment connectors, observing correct polarity. Plug the battery charger in. The meter should read between 25 and 75 mA DC.

Lamp

Cover the light sensor. The backlight should light up. Please note that it is difficult to see the backlight in sunlight.

Keys

Press On/Off button, the scale should turn on. Press lb-kg, the scale should change units of measure. Apply 50 lb to 250 lb to the scale. After you get a stable display, press the ZERO key. The scale should go to a zero indication. Press the On/Off button and the scale should turn off.

Power down shutoff

Connect a variable supply to the input connector and remove the batteries. Connect the meter to the positive battery lead. Set the supply to 6 V and turn the scale on. Reduce the input voltage until the scale turns off. The voltage at shutoff should be between 3.2 and 3.5 Volts.

Load Cells

Each PT300 scale has two load cells. These load cells are the transducers that convert mechanical energy (weight) to electrical energy. Each load cell has 4 strain gages (700 Ω) and two temperature compensation thermistors. The four strain gages are wired together to form a Whetstone bridge.

Schematic Diagram (typical values)

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PT300 Users manual

Rev G, Feb 2011 The 5 Ω thermistors in series with the Excitation leads are for temperature compensation. They are balco thermistors that change resistance with temperature to maintain a constant signal voltage. These thermistors are specially manufactured for Intercomp load cell material and strain gage types.

Load cell leads color coding

Red : + Excitation (3.3 Volts) Green : + Signal White : - Signal Black : - Excitation (ground)

Check load cell zero output value

The signal at the main circuit board with the signal leads in place should be approximately 0.1 millivolts with no load applied to the cell. Larger values could indicate a defective load cell, wiring, or circuit board. The load cell must be tested separately to determine the source of the zero shift.

Check zero output from the load cell

You can use a power supply set to 3.3 Volts to provide the excitation voltage for this measurement. Connect plus 3.3 volts to the red lead and ground to the black lead or use the scale to provide the excitation by connecting the two excitation leads only (Black and Red). Turn the scale on to apply excitation voltage. Connect a meter capable of monitoring millivolt readings between the plus and minus signal leads (Green and White) The zero signal output (With excitation voltage applied) should measure approximately -1.00 to 1.00 millivolts). Larger values would indicate a defective load cell. This is most likely the result of an overload of the cell during use.

Check load cell resistance values

Load cell resistance can vary depending on the model and capacity. The load cells will be one of the standard resistance values given in the table below.

Nominal Cell

Resistance

Black – Red =

Black – Green =

Black – White = White - Green =

With the load cells disconnected, the resistance readings should be as specified. It is normal for all of the readings to be higher or lower than the values given by several percent. If there is several Ohm difference between the Black-Green and Black-White measurements the cell is defective. This test is most useful to detect a catastrophic failure of the cell or lead; you are typically looking for an open or a short when using this check.

350 ΩΩΩΩ 700 ΩΩΩΩ 1000 ΩΩΩΩ

385 Ω 770 Ω 1082 Ω 285 Ω 595 Ω 748 Ω 285 Ω 595 Ω 748 Ω 350 Ω 701 Ω 1000 Ω

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Rev G, Feb 2011

Step Entries

The ‘step’ choice that starts the calibration menu also allows special codes for technical diagnostic work. Typically only scale technicians should use these features. Here is the list of possible entries to the ‘step’ choice related to the PT300:

Message Meaning

000

000000 001

001

001001 003

003

003003 005

005

005005

121

121121 131

131

131131

201-208

201-208201-208

311

311311

711

711711 911

911

911911

Simply advance to the first Calibration Menu step.

Advance to weight calibration.

Enter corner calibration. (Also set the number of load cell inputs here.)

This brings you to the Mode Menu, just as if the cal strap had been left in the RUN position. Raw counts display diagnostic

Constant power to all cells diagnostic

Corner adjust cell 1-8. (Example: 202 will enter mode to adjust cell #2).

Restore all radio settings to defaults (CH = 1, Network ID = 8000, and Encryption disabled). Display will then show ‘save’ if successful, or

“no rf

no rf” if there is no radio installed or some other radio failure.

no rfno rf

Restore all settings to defaults, but leave weight calibration untouched.

Restore all settings to default settings, including weight calibration. It is recommended that this only be used as a last resort, as your previous calibration and settings will be lost after running this.

Step Choice Table

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PT300 Users manual

Connector

The diagram below shows the pin-out for the PT connector on the side of the PT300:

PT connector

A: RS-485 A B: 20 mA (-I) C: - Charging Voltage D: 20 mA (-0) E: +Charging Voltage F: 20 mA (+I) G: RS485 B H: RS232 TXD

Rev G, Feb 2011

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Page 44

How to reach Intercomp Service

Things to know:

-Inform the Service Dept. that the product is a next generation PT300 scale system (ADrevE version)

-When was the system purchased?

-Where was the system purchased?

For Intercomp Service call or fax:

FAX # (763)-476-2613 (763)-476-2531

1-800-328-3336

or fill out Service Support Form at :

www.intercompcompany.com

PT300 Users manual

Rev G, Feb 2011

Page 44 of 44

Holtgreven Truck Scale Resources User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual