Holtgreven Truck Scale Resources User Manual

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

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

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

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:...................................................................................................................................................... 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

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

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

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Page 2 of 44

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

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.

Page 4 of 44

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

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

Page 6 of 44

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)

Page 7 of 44

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

Page 8 of 44

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

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

Page 10 of 44

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

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

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

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

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Holtgreven Truck Scale Resources User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual