LNW-6 Manual - Lift-N

LNW-6 Manual - Lift-N
LNW-6
Table Of Contents
Important Notice................................................................................. ii
Caution ............................................................................................... iii
Introduction & Description ................................................................. 1
Principle of Operation
Pressure Transducer
Digital Indication
Power Requirements
DC Power Filters ................................................................................ 2
Installation .......................................................................................... 3
Lift Truck Conditions
Indicator Installation
Hose Installation
Installation Diagram ........................................................................... 4
Operation Setup ................................................................................. 5
Weighing Reference Point
First Stage Cylinder
Weighing Height
Repeatability is the Key to Good Weighing
Basic Operational checks
Operation ........................................................................................... 6
Description of Controls - Bottom Switches, Front Panel buttons
Operation Steps - Power up Display, ZERO Scale
Operation (cont.) ................................................................................ 7
Get Weight
Accum - Total Weights
Single Button Accumulation
Clearing Totals
Calibration Procedure ........................................................................ 8
Get ZERO, Put into Cal mode
Get Test Weight, Adjust Weight
Return to Normal weighing and check Weight
Basic Setup - User Controls .............................................................. 9
Capacity Setup - INC & CTBY ......................................................... 10
Troubleshooting ............................................................................... 11
Warranty ........................................................................................... 12
Parts List (partial) ............................................................................. 13
Manual Version 4 - effective 15 August 2011
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LNW-6
Important Notice
Your new LNW-6, Serial No.___________, was precalibrated
for installation on a Make ________________
Model _____________
before leaving the factory.
Note: Unit must be recalibrated after installation on your vehicle.
The Unit can be installed on almost any capacity truck from 1000 lbs
capacity to 100,000 lbs. capacity
Please read the Operating Instructions on pages 4 & 5 and
Troubleshooting on page 9 before attempting to re-calibrate
the indicator.
Do NOT spend over 30 minutes
in testing and adjusting.
If you spend more time than this or are having problems.
Please call for technical assistance
1-800-537-1886
LNW Tech ext. 109
If you call, please have available:
1. LNW Indicator Serial number ____________.
2. Program version (Shown on power up - typ. PR-477C)___________.
3. Make (Truck)____________.
4. Lift capacity of the vehicle____________.
5. Number of Lift cylinders______________.
6. D.C. voltage supplied by the truck______.
7. Description of the problem_________________________________.
Manual Version 4 - effective 15 August 2011
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LNW-6
**** CAUTION ****
Because Lift trucks can vary greatly in their configuration from
Manufacturer to Manufacturer and model to model, the instructions for installation of the indicator are general in scope.
A qualified lift truck technician may find an alternate means to
install the scale which is better suited to the situation.
Pacific Scale Co., Inc. strongly recommends that when installation procedures are followed which depart from those outlined herein, the safety of personnel and equipment must be
accorded primary consideration.
Manual Version 4 - effective 15 August 2011
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LNW-6
Introduction
Your new LIFT-N-WEIGH Model LNW-6 was designed to provide you with a reliable, versatile
and compact weighing system. While there are a number of variables affecting the hydraulic
system pressure - fluid viscosity, temperature, mechanical friction, leaking seals, etc., this
manual is intended to show you how to get the best performance out of your LIFT-N-WEIGH.
Description
Principle of Operation
The lift truck scale works on the principle that the lift truck hoisting pressure is directly
proportional to the applied weight on the forks. The hydraulic pressure is converted into an
electrical signal by a pressure transducer. After the completion of calibration procedures,
the reading on the display is the weight on the forks.
Pressure Transducer
The transducer uses a strain gage bridge to convert the hydraulic pressure in the lifting
cylinder into a proportional electrical output. This unit is capable of sensing pressure from 0
psi. to 5,000 psi at full scale. The transducer is built into the indicator enclosure for
maximum protection and easier installation. A high pressure hose from the lift truck (see
installation page) connects to a 1/4” NPT female swivel fitting on the back of the indicator
housing.
Digital Indication
The LNW indicator uses solid state technology to achieve a high degree of accuracy on the
test bench. This however, is downgraded by the friction and slight differences in psi. during
the lifting cycle in the lift truck. The load on the forks is displayed on a backlighted liquid
crystal display for easy viewing in both bright and poorly lighted situations.
Housing
A heavy cast aluminum housing helps protect the indicator against mechanical damage. All
openings are gasketed and sealed to minimize contamination from dust and moisture.
Power Requirements
The LNW-6 indicator has approx. 100 mA current draw. The LNW Units have the Wide
Input Voltage Regulator (WIVR) installed, as part of the standard unit, and can operate from
12 to 48 Vdc input and provide regulated power for the Printer and Setpoint options, if
purchased, provided reasonably clean power is supplied.
Due to problems of dirty power, including voltage spikes from gear pump
motors, if the LNW Unit is to be used on DC systems of greater than 24 volts, or used
with options on systems greater than 12 vdc, the installation of a Heavy Duty Line
Filter (HD-LF) and a Heavy Duty Voltage Regulator (HD-VR) may be required.
Note: If supplied Power falls below 11.5 volts on a regular basis, WIVR may need to be
bypassed. Contact Pacific Scale for information.
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LNW-6
DC Power Filters
Pacific Scale Co. builds LNW Indicators for use on a wide variety of equipment and
vehicles. Our internal Wide Input Voltage Regulator (WIVR) will work on an input voltage of
12-48 volts DC and has basic power line noise filtering built in.
Depending on design, some vehicles, particularly electric forklifts, may need additional
external power filtering to protect our LNW indicators from surges and power spikes that
may damage our WIVR.
We can pass along suggestions from what our customers have used, but each end user
must determine what their particular equipment requires to provide adequate clean power.
Due to recent electrical design changes on forklifts, Pacific Scale cannot
guarantee that our LNW units will work as is without external power filters and
conditioners supplied by the customer or with filters purchased as an extra
option.
The End User and/or Installer should use their experience and vehicle dealers suggestions
on the need for additional power filters and conditioners.
One source for vehicle mounted power conditioning equipment is www.servicemate.com
We hope each customer who solves a particular problem can share their experience with
our tech dept. to pass along to new customers via our www.forkliftscales.us website.
For further information contact LNW Tech Support at 1-800-537-1886
Or email: tech@forkliftscales.us
Pacific Scale Co. /LNW MFG
Manual Version 4 - effective 15 August 2011
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February 2005
pacificscale.com & forkliftscales.us
LNW-6
Installation
LIFT TRUCK CONDITION - While the LNW indicators are capable of very good accuracy on the
test bench, the lift truck condition is the primary limit on accuracy. To achieve the best
accuracy possible, usually approximately +/- 1-2% of the capacity of the truck, the lift truck
should be in good mechanical and hydraulic condition. The lifting mechanism must be
checked for satisfactory operation: leaks; proper fluid level; the mast slides for worn or bent
sections and mast rollers for worn bearings; hoist piston and ram seals for wear; insure
mast slides are clean and lubricated.
INDICATOR INSTALLATION - Mount the indicator bracket to facilitate viewing and necessary
clearances for adjustments (mounting bolts are provided). Connect the power cable to
power sources.
WHITE LEAD SHOULD GO TO THE POSITIVE TERMINAL AND BLACK LEAD SHOULD GO TO THE NEGATIVE
TERMINAL. CONNECTIONS SHOULD BE MADE DIRECTLY TO THE BATTERY TO AVOID ELECTRICAL NOISE.
Note - If the power source is above 24 VDC, the Heavy Duty Line Filter (HD-LF) and
Heavy Duty Voltage Regulator (HD-VR) option may required. Customer can supply
their own voltage converter and/or power filters as long as the LNW unit is supplied
with clean DC power.
HOSE INSTALLATION - The Standard LNW-6 comes standard with a 6’ hose. Custom lengths
are available. One end of the hose is connected between the lift valve and the primary lift
cylinder(s). The Indicator has the second end of the hose connected to the fitting on the
back. Locate the indicator so the hose and the electrical cable are clear of moving parts
and the display can be seen by the operator.
(See page 4 - Installation diagram )
a. Before loosening hydraulic fittings, insure the release of hydraulic pressure by lowering
the forks to the ground.
b. Somewhere between the lift valve and the lift cylinder(s), install a fitting (supplied by the
customer) that will accept the 1/4” NPT male on the end of the hose. Remember the
indicator must see the pressure in the main cylinder when lifting a load so watch for any
pressure bypasses. If truck has two (2) lift cylinders, be sure you install the hose so
pressure is read from both cylinders. Reading pressure from only one of two cylinders may
be done but may affect accuracy.
c. With the appropriate fitting installed between the lift cylinder and the valve, install one end of
the hose at the fitting and tighten. Attach the other end of the hose to the fitting on the indicator.
Before tightening, pressurize the system and bleed air from the hose.
d. Start the lift truck and check for leaks.
Check Operation (see pages 5 & 6)
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LNW-6
Indicator Installation
Indicator Installation
1. Power cord should be plugged in and connected preferably direct to the battery.
The LNW-6 has it’s own ON/OFF switch and internal resettable fuse.
Note: Unless customer requests it, do not wire to ignition switch. As the LNW units draw
minimal power, approx. 100 ma, the LNW is unlikely to drain a vehicle battery unless left on for more
than several days. Leaving an LNW On allows for better electronic stability.
2. If the lift truck has twin lift cylinders, be SURE that the hydraulic connection to the LNW-6
is plumbed into the system so it sees the pressure from the two (2) lift cylinders.
3. If the lift truck has three (3) cylinders, be SURE that the hydraulic connection to the
LNW-6 is plumbed into the cylinder doing the lifting in the first stage. This is usually the
Freelift cylinder.
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Operation
LNW-6
Weighing Reference Point
Point established for zeroing and weighing. This point must be within the freelift portion of the
uprights.
First Stage Cylinder
The LIFT-N-Weigh will weigh accurately only in the first stage on a truck with telescoping hoist
cylinders.
Weighing Height
Height that provides for consistent weights. (typically 16” to 20” above ground)
To mark weighing height;
a. Raise forks to approximately 16” to 24” above ground level.
b. Apply one (1) of the supplied red arrow decals to the mast (fixed portion) and
another to the fork carriage (movable portion) directly opposite the first arrow,
within clear view of the operator.
Consistent use is the key to good Repeatabe weighing
Note: Loaders will have a greater error Range than listed below for Forklifts.
(normally 5% of Capacity depending on equipment and use)
Get Zero
Pick up the empty forks, at a normal lifting speed, to several inches above the mark and
then lower to the mark. Press ZERO
Check for repeating Zero
Repeat procedure several times to assure display repeats within 1% to 2% of the truck
capacity. (e.g.: +/- 50 to 100 Lbs. on a 5,000 Lbs capacity truck) Do NOT keep setting
ZERO if it repeats within that range.
Check for repeating Weight
Pickup a known load (approx. 20% to 50% of the truck capacity) in the same manner and see
if it repeats within the range of 2% of truck capacity.
Then do Calibration if Weight is off
If Display repeats within the 2% range but the weight is wrong, go to the Calibration page and
follow the instructions. (Pages 6, 7, 8)
If Weight does not repeat, try different weighing height
Note: 16” is mentioned as a convenient weighing height. If repeatability is better at another
level, change the reference mark. While Weighing should be done in the first stage, it really
does not matter how it is done as long as you get repeatability at ZERO and with a load - all
within 2% of truck capacity.
Manual Version 4 - effective 15 August 2011
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Operation (Continued)
LNW-6
Description of Controls
Bottom Controls
Power Switch
ON/OFF Toggle switch on bottom right.
Out (right) is ON, In (left) is OFF
Remote Switch
Push button is a second/Remote ACCUM button.
Option: Replace Push Button with connector
for Remote external ACCUM switch.
Working Display and Weighing cycles
The LNW-6 normally displays a “working” weight reading, but for accuracy, the LNW-6
uses a weighing cycle for a more accurate “calculated” weight.
This eliminates some of the problems of hydraulic weighing systems.
Operation
First step - Turn On Scale
Scale cycles through its power up display.
Second item is Program version.
Second - Zero Scale
1.
2.
Lift empty forks at normal lifting speed to above the weighing mark
Lower to the weighing mark
3.
Press
to start a weighing cycle.
The Scale cycles through a weigh cycle,
getting a Calibrated ZERO
then showing a working ZERO (displayed value)
(continued on next page)
Manual Version 4 - effective 15 August 2011
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Zero
Weighing
Total Weights - ACCUM
Press to get
weight
While showing
Calibrated Weight
Press to add
weight to Total
Press to start a Weighing cycle
and automatically add to Total
OR
Operation (Continued)
LNW-6
Third - Get Weight
1.
2.
Lift the load at normal lifting speed to above the weighing mark
Lower to the weighing mark
3.
Press
to start a weighing cycle.
The Scale cycles through a weigh cycle,
Getting a Calibrated weight (indicated by *lb)
After approximately 20 secs or the scale is unloaded
the Display returns to the working (non-precision) display.
Accumulation - Totaling Weights
1.
2.
Lift the load at normal lifting speed to above the weighing mark
Lower to the weighing mark
3.
Press
to start a weighing cycle.
The Scale cycles through a weigh cycle,
Getting a Calibrated weight (indicated by *lb)
4.
While calibrated weight is displayed press
to add to the Total weight.
The display shows the Current Total for approximately 3 secs
Then the Display returns to the Calibrated weight
After approximately 20 secs or the scale is unloaded
the Display returns to the working (non-precision) display.
Single button Accumulation
1.
2.
Lift the load at normal lifting speed to above the weighing mark
Lower to the weighing mark
3.
Press
or the Remote button to start a weighing cycle.
The Scale cycles through a weigh cycle,
Getting a Calibrated weight, and displays
The Current Total for approximately 3 secs
Then the Display returns to the Calibrated weight
(indicated by *lb)
After approximately 20 secs or the scale is unloaded
the Display returns to the working (non-precision) display.
Clearing Totals
Remove the load from the forks. While holding the
until the Count shows Zero, to clear Totals.
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button, press and hold the
pacificscale.com & forkliftscales.us
Calibration
LNW-6
The Lift-N-Weigh is normally setup for and precalibrated to the customer’s supplied lift truck
specifications. This is a test bench calibration to the calculated pressure. Because of friction
in the lifting mechanism and control valve bleedback, weight errors may exist in the system
when installed on the customers equipment.
Note: If the SET UP of the unit needs to be changed refer to page 10 and make changes first.
The weight errors can be easily corrected by performing the following adjustments:
Step 1 - Get Zero. Lift the empty forks at normal lifting speed to about 18” to 24” and
lower a couple of inches. Press the
button.
Step 2 - Put into Calibration mode. Press and hold the
release the
Press the
button then press and
button. When the display blanks, release the
button.
and cycle through the menu choices to reach the
calibration menu (DO CALIB).
Step 3 - Get Test Weight. Press
then apply weight.
Lift a known weight equal to approximately 1/4-1/2 of lift truck capacity or more.
Raise the load in the same manner as when setting zero (Step 1), then press
The display will go through the weighing cycle then display the weight.
Step 4 - Adjust Weight. Press
to lower the weight display reading or press
raise the weight display reading until the reading is correct for the test weight used.
to
Note: To speed up the rate of change, while holding the up or down button, press the other arrow
button a few times. This can change the rate very much so simply release all buttons if changing too
fast.
Once the displayed weight is correct press the
button to return to regular operation.
Step 5 - Check Weight. Lift and weigh the test weight in the normal manner (see page 7)
Do this several times to insure that the system repeats within the 2% tolerance.
Repeatability is the key to good weighments.
REMEMBER - Repeatability & consistency are the key to good weight readings.
IF THE WEIGHT READINGS DON’T REPEAT WITHIN THE 2% TOLERANCE, TRY A DIFFERENT METHOD OF
LIFTING. IF A DIFFERENT METHOD WORKS, REMOVE THE LOAD AND RECHECK ZERO USING THE SAME
METHOD. IT DOESN’T MAKE ANY DIFFERENCE HOW THE WEIGHMENTS ARE DONE AS LONG AS THE ZERO AND
WEIGHT READINGS ARE DONE IN THE SAME MANNER AND THE WEIGHTS REPEAT WITHIN TOLERANCE.
Calibration should take less than 30 minutes.
Should you have any problems call 1-800-537-1886 ext. 109
Also see www.forkliftscales.us for further information
Manual Version 4 - effective 15 August 2011
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LNW-6
Basic Setup - User Controls
The
button allows access Time & Date set menu, Total setpoint, and Load setpoint.
After pressing the
button, use the
and
buttons to select:
To set the Time & Date for use with a printer or other RS232 device, simply press
The unit will then display
buttons. Then press
Adjust up and down with the
and
for the next parameter. MO, DAY, HR, MIN will each come up in
turn. Adjust up and down with the
and
buttons then accept by pressing
When used with a printer, after pressing the ACCUM button, the current Count and
current Weight will be output along with the time and date on a single line.
Example:
When the ACCUM Total is cleared it will output the Total Count and Total amount
along with the TIme and date.
Example:
To set the Total Setpoint (SP2) simply press
The unit will then display
button.
Adjust up and down with the
and
buttons then accept by pressing
. While holding the Up or Down button, you can speed
up the rate of change by pressing the opposite button one or more times. (range = 0 to
50,000)
In use, when the ACCUM value is over the value in SP2,
the display will flash
Total SP might be used when loading to prevent overloading.
Example:A Flatbed can handle up to 32,000 lbs., so the Total SP could be set to
31,900 to warn the forklift operator that he had reached capacity, as long as he
ACCUM each load, which is easy to do with the single button ACCUM.
To set the Load Setpoint (SP1) simply press
The unit will then display
button.
Adjust up and down with the
and
buttons then accept by pressing
. While holding the Up or Down button, you can speed
up the rate of change by pressing the opposite button one or more times.(range = 0 to
50,000)
In use, when the load value is over the value in SP1,
the display will flash
Typically used to prevent overloading a single lift, ie. max load per pallet.
Manual Version 4 - effective 15 August 2011
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SETUP
LNW-6
The Lift-N-Weigh is normally setup for and precalibrated to the customer’s supplied lift truck
specifications. If the information supplied was incorrect, or the user changes which vehicle
the LNW is installed, the SETUP may need to be done to set the Capacity and associated
parameters.
Note: The SOL TIME and FILTER values should remain as set. Consult with Pacific Scale if you think
you need to change those parameters. 1-800-537-1886
LNW Tech at ext. 109
Step 1 - Determine Capacity Consult the Capacity chart on the opposite page to select
the Capacity and Step Size (CTBY) Note the INC steps and CTBY size you wish to use.
Example: For 5000 lbs. capacity, by 5 lbs. step size. use INC 1000, CTBY= 5, FS= 5005
Step 2 - Put into Setup mode. While pressing and holding the
release the
Press the
Then press
button. When the display blanks, release the
to enter the Setup mode.
or press
to select the INC steps noted in Step 1.
to accept.
Step 4 - Select CTBY Press
Press
button.
and cycle through the menu choices to reach SETUP.
Step 3 - Select INC Press
Press
button, press and
or press
to select the CTBY size noted in Step 1.
to accept.
Step 5 - Select CTBY Confirm that the Full Scale (FS=) setting is correct.
Press
to accept and return to regular weighing mode.
If the Full Scale setting is not correct, press the
and the unit returns to INC - Step 3
Once SETUP is complete, Calibrate the unit per instructions. (Page 8)
REMEMBER - Repeatability & consistency are the key to good weight readings.
IF THE WEIGHT READINGS DON’T REPEAT WITHIN THE 2% TOLERANCE, TRY A DIFFERENT METHOD OF
LIFTING. IF A DIFFERENT METHOD WORKS, REMOVE THE LOAD AND RECHECK ZERO USING THE SAME
METHOD. IT DOESN’T MAKE ANY DIFFERENCE HOW THE WEIGHMENTS ARE DONE AS LONG AS THE ZERO AND
WEIGHT READINGS ARE DONE IN THE SAME MANNER AND THE WEIGHTS REPEAT WITHIN TOLERANCE.
Calibration should take less than 30 minutes.
Should you have any problems call 1-800-537-1886
LNW Tech at Ext. 109
Also see www.forkliftscales.us for further information
Manual Version 4 - effective 15 August 2011
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pacificscale.com & forkliftscales.us
LNW-6
Trouble Shooting
Malfunction
Probable Cause
Corrective Action
Indicator does not
Display numbers
Power leads reversed.
•
Connect White to Positive,
Connect Black to Negative
Power not connected.
Connect per instructions
Defective Indicator or plug
Replace Indicator or plug
Blown WIVR
Replace WIVR, add power filter
if needed.
Transducer connected to wrong
side of lift valve
Reconnect to output of valve
•
Hydraulic Hose obstruction
Repair or Replace hose
Loose hydraulic connection
Tighten couplings
Internal PT Wires broken
Check PT wires at terminal
Inconsistent weighing procedure
Follow recommended method
Inconsistent Zero setting
Follow proper procedure
Leaking Hoist cylinder
Repair cylinder
Air in hydraulic system
Bleed system
Mast not upright
Weigh & Zero w/Mast upright
Hoist cylinder fluid low
Add proper amount of fluid
Mast slides dirty
Clean & lubricate
Mechanical system worn/bent
Repair as required
Friction in cylinder, rollers, slides,
etc.
Lubricate mastparts & be sure
load on forks is against the
carriage
Indicator readings do
not change
Inconsistent weight
Display numbers jump
up & down erratically or
hash is displayed
Moisture on inside of
lens
Electrical interference caused by: Clean or replace plugs; check
Bad ignition system, rotating light, wiring & replace if needed;
etc.
clean noisy contacts, etc.
Moisture in case.
Replace Dry-packs inside.
Check cover gasket & screws
Tighten screws & or replace
gasket, replace Dry-packs
IF PROBLEMS STILL EXIST
CALL THE PACIFIC SCALE CO. SERVICE DEPARTMENT
1-800-537-1886
Manual Version 4 - effective 15 August 2011
LNW Tech at Ext. 109
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pacificscale.com & forkliftscales.us
LNW-6
Warranty
Pacific Scale Co., Inc. warrants to the original purchaser that it will repair or
replace - at its option - any part which in its judgement is defective in material
or workmanship. Such repairs or replacements shall be performed without
charge at Pacific Scale’s service facilities.
The defective unit is to be returned to Pacific Scale Co., Inc. prepaid with a
description of the problem, after calling and receiving a RETURN MATERIAL
AUTHORIZATION (RMA) number. No unit will be accepted for Warranty without an
RMA number.
This warranty covers:
Entire unit for a period of one (1) year;
Main electronics board for a period of five (5) years.
from the date of shipment from Pacific Scale Co., Inc. and is subject to the
following limitations:
Limitations: This warranty shall not apply to a. Damage which in the opinion of Pacific Scale Co., Inc. is the result of
overloading, misuse, water damage, negligence, alteration, accident or
service performed by other than Pacific Scale Co., Inc. authorized personnel.
b. The replacement of expendable or consumable parts.
c. Normal deterioration due to wear or damage and deterioration due to
extended storage or exposure while in the purchaser’s possession before
installation.
This Warranty is the only warranty expressed or implied. Pacific Scale Co.,
Inc. neither assumes nor authorizes any other person to assume for it any
other obligation or liability. Pacific Scale Co., Inc. will not be responsible or
liable for any consequential or contingent damages and its liability is limited to
the original purchase price of the equipment sold.
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LNW-6
Parts List, (partial)
Description
QTY
Part NO.
Bezel Frame ......................................................................1
L6-BZ
Bezel screws .....................................................................4
LC-SZ
Hose, high pressure synthetic, 6’, 1/4” NPT Male each end .....................1
LC-HH-72
Hose Fitting, 360 Deg. swivel ell .......................................1
LC-PT-FS
Main Board ........................................................................1
L6-MB
ON/OFF Power Switch, toggle, only .......................................1
LC-PS-ASSY
ON/OFF Power Switch Boot..............................................1
LC-SW-B
Power Cord Assy ...............................................................1
LC-PC-ASSY
Install Kit (Includes Power Cord, Scotchlok taps,
L6-Install Kit
Bolts & Nuts, and misc.)
.................1
Pressure Transducer .........................................................1
LC-PT
U-Bracket Mount (LNW-5/6 w/Knobs) ............................................1
LC-UB-ASSY
U-Bracket Knobs, Black ....................................................2
LC-UB-KB
Manual Version 4 - effective 15 August 2011
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