LoadMan Operating Manual

LoadMan Operating Manual
LoadMan® LM310
Reference Guide
For
Cart Lifter
Weigh-In-Motion
Rear Loader Refuse Trucks
Revision 03.2016-4
Creative Microsystems, Inc.
15224 SE Renton Issaquah Road
Renton, WA 98059
Phone: 1.888.LOADMAN
1.888.562.3626
1.425.235.4335
Email: [email protected]
[email protected]
LoadMan is a registered trademark® of
Creative Microsystems Inc.
Copyright ©2013 Creative Microsystems
All Rights Reserved
ii
SAFETY WARNING
Using this system while operating a motor vehicle
may be distracting, dangerous, or prohibited.
Operator remains responsible for safe travel, should
obey laws and regulations, and should exercise good
judgment at all times. Failure to pay full attention to
the operation of the vehicle may cause an accident
resulting in serious consequences.
You assume sole responsibility and risk for using this
system.
iii
iv
Table of Contents
TABLE OF CONTENTS
SAFETY WARNING
III
INTRODUCTION
7
OPERATIONAL BASICS
11
Power................................................................................................................... 11
LoadMan Front Panel and Display ...................................................................... 12
LoadMan Operating Modes ................................................................................ 13
Measurement Units – English / Metric............................................................... 16
Introduction to the PROGRAM FUNCTION Display ............................................ 17
Connectivity & Communications ........................................................................ 18
Introduction to LoadMan Load Manager Software............................................ 20
NORMAL OPERATING MODE
23
Weight and Information Displays ....................................................................... 24
Route Information Displays ................................................................................ 27
PROGRAM FUNCTION Displays ........................................................................... 31
SETUP & CALIBRATION MODE
37
Basic Navigation .................................................................................................. 38
Setup & Calibration Commands.......................................................................... 39
INITIAL STARTUP AND CALIBRATION
65
1. Verify Wiring ................................................................................................... 65
2. Power On
................................................................................................... 65
3. Verify Arm Angle Sensor ................................................................................ 66
4. Verify Cart Lifter Load Cells Respond Correctly ............................................. 67
5. Calibrate Cart Lifter Arm Angle ...................................................................... 68
6. Verify Angle Measurements Respond Correctly ........................................... 69
7. Verify Weigh-In-Motion Response................................................................. 69
v
Table of Contents
8. Calibrate System............................................................................................. 71
9. Calibrate Cart Lifter System Under Load ....................................................... 75
TROUBLESHOOTING GUIDE
77
1. NO ARM SENSOR! ........................................................................................... 77
2. NO LEFTCART SIG! .......................................................................................... 78
3. NO LEFTCART SIG! .......................................................................................... 79
4. Load Measurements Inaccurate..................................................................... 79
COLLECTING LOAD DATA
81
Out-of-Sequence or Unplanned Collections ....................................................... 81
WIRING DIAGRAM
85
APPENDIX A – ERROR MESSAGES
86
APPENDIX B – SETUP & CONFIGURATION COMMAND TREE
87
APPENDIX C – CELL STATE CODES AND DESCRIPTIONS
91
APPENDIX D – DOWNLOADING LOADMAN METER SOFTWARE 93
Connecting PC/Laptop to LM310
93
INDEX
103
vi
Introduction
INTRODUCTION
The LoadMan® LM310 is a precision instrument capable of running and
controlling many different vehicle weight measurement applications. The
Application Software documented in this manual supports LoadMan’s Weigh-InMotion Cart Lifter Weighing Systems. These Weighing Systems are usually
mounted on vehicles that weigh residential carts in motion – as they are picked
up, dumped, and lowered to the ground.
The LoadMan® system is completely automatic and the driver/operator does not
need to press any buttons or take any actions to obtain a weight reading. The 16
character display provides all the information needed to understand the status
of the weighing system. For example, the meter automatically provides the
following instruction displays during the weigh-in-motion process:
READY TO WEIGH
WEIGHING LOAD
GROSS WEIGHT
DUMP LOAD
WEIGHING TARE
NET WEIGHT
TRUCK


The cart lifter arm is below the start of the weighing
window and the system is ready to begin weighing.
Message while cart is lifted up through the weighing
window.
Displays weight of the cart and its gross load weight.
Weighing is complete and load is ready to dump. The
gross load weight measured going up is still displayed.
Measuring the empty cart weight while cart is coming
down.
Displays the computed net weight of the dumped
material.
Displays the accumulated load net weight that has been
dumped into the truck.
LM310 –An onboard in-cab-meter for displaying weight, route and system
information.
ARM310 – A computer based arm weigh-in-motion assembly mounted on
7
Introduction

the arm of the cart lifter (bolted to the lift arm of the cart lifter).
CART310 -- A cart weigh-in-motion assembly mounted between the two
mounting plates which support the cart lifter assembly.
Figure 1. ARM310 Connected with CART310
The CART310 weigh-in-motion assembly converts the sensitive analog data
signals from the two cart lifter loadcells to digital, using a precision digital to
analog encoder called a CanCoder™. It also receives the angular position of the
cart lifter arms measured by the ARM310 along with speed; converts the
information to digital, and transmits the data up the LM310 meter for display
and processing.
The ARM310 weigh-in-motion assembly also contains an angle sensor; so the
weighing system not only knows the position and speed of the cart lifter, but
also the angular position and speed of the lift mechanism at all times.
The CART310 cart box computer gathers the weight measurement from the cart
lifter loadcells, the lift arms angular position and speed from the ARM310. It
then processes this information to determine the weight of the cart plus its
contents while going up (gross weight). Then, in the same manner, measures
the tare weight of the cart going down. The difference between these two
weights determines the net weight of the material that was dumped into the
truck (NET).
All of this information is transmitted to the LM310 in-cab meter and displayed to
the driver/operator. The load data record can wirelessly transmit to LoadMan’s
8
Introduction
Load Management Software if the data collection software is operating in the
back office.
LoadMan's Load Management Software allows remote tracking of trucks,
drivers, customers, routes and products by account or job. Route lists are
created with the software and downloaded to the LoadMan® meter. Any
recorded load data and/or GPS position data in LoadMan’s data collection
memory will be automatically transferred to the Load Management Software without any prompting or intervention from the driver – whenever a wireless
modem or wireless Bluetooth connection is established between the truck’s
LM310 computer and the back office software.
9
Introduction
10
Operational Basics
OPERATIONAL BASICS
This section will introduce the operational basics of the LM310 LoadMan®
Meter. Anyone new to the use of the LoadMan® Meter should first read this
section to become familiar with:

Front panel display

Keypad definitions and use

Basic navigation

Programming basics

Connectivity & Communications

LoadMan Load Manager Software
Power
Connecting power at the rear panel causes LoadMan to power on, displaying the
message “LOADMAN”, followed by “PROG VERSION X.X”. The Program Version
number X.X represents the application software version and aids in tracking
software updates.
With power on, and within any operating mode, momentarily pressing the
POWER button causes LoadMan to briefly display the “GOODBYE!“ message.
When power is applied, the message “CYCLE ARMS” may appear if the cart
lifter is not in the READY TO WEIGH position. Repositioning the Cart Lifter
Arm to the normal Ready to Weigh position will return the display to
“READY TO WEIGH”.
11
Operational Basics
LoadMan Front Panel and Display
As shown in Figure 2, the LoadMan LCD display has a 16 character alphanumeric
field for displaying operational messages as well as setup and calibration
instructions. There are 6 push-buttons used for power, programming and
display selection.
Figure 2. LoadMan LM310 Meter Front View
PROGRAM Keys
These PROGRAM keys are used to enter a command (like ZERO TRUCK), print a
load record (PRINT LAST LOAD), change a programmable number (like setting the
TRUCK tare weight in Setup & Calibration), or setting the Date and Time.

If a selected display is programmable, pressing the PROGRAM key will
initiate a flashing cursor in the display, signifying that LoadMan has entered
the Program Mode.

For programmable displays, use the PROGRAM key to move the flashing
cursor left to the next programmable digit/item in the display.

Once the flashing cursor is positioned over the item to be changed, use the
PROGRAM key to increase/bump the digit/item to its next value.

Continue to use the /PROGRAM keys until the display has been
programmed to the correct value.

The SET PROGRAM key will execute the command and save any changes
made to the display.
12
Operational Basics
LoadMan will take NO action on selections and/or changes until the
SET PROGRAM key is pressed. And, if a selected display is not
programmable, pressing any of the PROGRAM group of keys will have no
effect.
SELECT Keys
The SELECT keys are used to manually scroll through any of the currently
available vehicle weight displays and route information. These keys are also for
scrolling through setup & calibration command options.


The SELECT key will sequence forward through a group of displays.
The SELECT key will sequence in reverse through a group of displays.
Weight and Message Display
Any weight information, route information or status message information shown
on the 16 character display will depend on the overall setup and configuration of
the LoadMan Meter (discussed in later sections).
LoadMan Operating Modes
LoadMan has two distinct operating modes: the Normal Operating Mode and
Setup & Calibration Mode.
Introduction to Normal Operating Mode
At power on, LoadMan enters the Normal Operating Mode which provides the
main operational, messaging and status information for the LoadMan weight
and route applications. Table 1. Normal Operating Mode Display contains a list
of display messages that can be manually accessed using the /SELECT keys,
or automatically cycle displayed.
Introduction to Setup & Calibration Mode
LoadMan’s Setup & Calibration Mode provides the operator the capability to
program advanced functionality, choose optional information displays, enable
communications, and to setup and calibrate a truck’s configuration. The top
level command options are summarized inTable 6, and detailed programming of
these options will be discussed in the section titled Setup & Calibration Mode
later in this guide. Also, a detailed command tree is located in Appendix B –
13
Operational Basics
Setup & Configuration Command Tree.
Activating – Setup & Calibration Mode w/SECURITY OFF

Continually depress the POWER button, through the “GOODBYE!“
message, and until the “LOADMAN SETUP“ message is displayed.

The first setup & calibration category displayed is “SET ZERO?---->NO”.
Activating – Setup & Calibration Mode w/SECURITY ON

Continually depress the POWER button. The messages “GOODBYE!“ and
“ENTER PASS CODE!“ will display.

At the prompt, “PASS CODE 0”, use the /PROGRAM keys to program
the security code to “123”and save the code with the SET PROGRAM key.

If correct, LoadMan displays the message, “LOADMAN SETUP”.

And the first setup & calibration category displayed is “SET ZERO?---->NO”.

If the security code is NOT correct, the error message, “SECURITY FAILED” is
displayed, and the Setup & Calibration mode cannot be accessed.
When finished with any of the setup categories and to return LoadMan to the
normal operating mode:

Press the SELECT key until “EXIT SETUP?-->NO “ is displayed.

Then press PROGRAM key to display “EXIT SETUP?-->YES“.

Finally, press the SET PROGRAM key.
LoadMan will now return to the normal operating mode – Information Display.
14
Operational Basics
Table 1. Normal Operating Mode Display
Information
Display







Weight
Displays



Route
Information
Displays






Date & Time
READY TO WEIGH
WEIGHING LOAD
GROSS
LOAD / DUMP
LOWER ARMS
NET
RECORDING LOAD
Use the SELECT
key to sequence
forward through
available displays
LAST
TRUCK
TARGET
LOAD NAME
LOAD ACCOUNT #
STOP #
PRODUCT NAME
EVENT NAME
ASSET NAME
DATE & TIME
15
Use the SELECT
key to sequence
in reverse
through available
displays
Operational Basics
Table 2. Setup & Calibration Commands
SET ZERO
Calibrates the Cart Lifter Arm Angle
sensor to zero.
SET SPAN
Calibrates the truck’s load of
material to readings taken from
another scale.
SET TARE
Sets the empty weight of the
vehicle.
INSTALL
Provides the capability to setup
and/or change the operating
configuration of LoadMan.
SET DEFAULTS
Returns all settings to factory
default settings.
ERASE DATA
Permanently erases all data in
LoadMan’s data collection
memory.
TROUBLESHOOT
Provides detailed angle sensor,
loadcell, communications and
other LoadMan information that
can be useful for isolating issues.
SELECT
Sequence
forward
through
available
displays
/PROGRAM
Keys for
programming
values and
command entry
SET PROGRAM
To enter/activate
command or
value
SELECT
Sequence
in reverse
through
available
displays
Measurement Units – English / Metric
The LoadMan meter comes preconfigured at the factory to display weight
measurements in English or Metric units. Throughout this manual, English units
will be used when explaining commands and presenting examples, but
everything presented in this manual is valid for both English and Metric
configured meters.
Metric Units – Setting Kilograms/KG
To configure LoadMan to display weights in metric units, kilograms/KG:
16
Operational Basics






First enter the Setup & Calibration Mode as just described above.
Use the SELECT key to locate “INSTALL?----->NO”.
Press PROGRAM to choose “YES ”; then SET.
Use the /SELECT keys to locate “SET DISPLAYS->NO”.
Press PROGRAM to choose “YES ”; then SET.
Now use the PROGRAM and SET PROGRAM keys to choose and set
“DISPLAY UNITS=KG”.
This exercise introduced the programming and configuration process. More
programming and configuration will be covered later in this manual. But for
now, when finished programming and to return to the normal operating mode,
press SELECT to locate “EXIT SETUP?”; choose “YES” with the PROGRAM key;
and save/exit by pressing the SET PROGRAM key.
Introduction to the PROGRAM FUNCTION Display
Use the PROGRAM FUNCTION display to access and activate one of the
command options listed in Table 3.
Table 3. PROGRAM FUNCTION Commands
SHOW NET
Set display to show Truck
NET weight operation.
SHOW GROSS
Set display for Truck GROSS
weight operation.
Prints the most recent load
data measured to a preconfigured printer
Resets the cart lifter load
cells to read zero
Initiates the automatic
display cycle of weight
information and status
messages
Zeros the accumulated
truck load TOTAL and
provides option to capture
a landfill dump weight
PRINT LAST LOAD
ZERO CART LOAD
CYCLE DISPLAY
ZERO TRUCK
17
Use the /SELECT keys
to locate the
PROGRAM FUNCTION
display.
Use the /PROGRAM
keys to sequence through
available program
options.
 = forward
 = reverse
Use the SET PROGRAM
key to activate command.
Operational Basics
Either of the /PROGRAM keys will sequence through the available
PROGRAM FUNCTION displays, and once an item is selected, the SET PROGRAM
key will activate and save the selection. LoadMan will then return to the normal
operating mode.
While within any of the PROGRAM FUNCTION options, the /SELECT
keys will abort programming and return LoadMan to manual display.
Connectivity & Communications
RS232 Ports
LoadMan comes standard with one RS232 port (9-pin female connector) that is a
available for connecting peripheral devices like printers, barcode wands, etc.
During setup and configuration, this is referred to as RS232 port #1.
RS232 Port #2 (9-pin male connector) is not available for connecting peripherals.
This port is dedicated to factory configuration and service diagnostics.
Wireless Communications
The LoadMan meter may come equipped with an optional Bluetooth wireless
modem, or a GSM cellular modem. The modem is used to connect and
communicate with LoadMan’s Load Manager Software. If the Bluetooth option
is ordered, it will occupy RS232 Port #1. The 9-pin female connector described
above will become RS232 Port #2.
The GSM cellular modem is separate dedicated antenna port. The Load Manager
Software allows remote tracking of trucks & drivers, plus customer accounts and
route location; and exchanges the load records and location information through
one of these modems.
GPS
The LoadMan meter may also come equipped with an optional onboard GPS
modem and antenna. When recorded GPS coordinates are uploaded into
LoadMan’s Load Manager Software, office management can use the
latitude/longitude coordinates to track truck routes and aid with several other
advanced location based functions from the office. Refer to Figure 4. LoadMan
Connectivity Example.
18
Operational Basics
Figure 3. LoadMan Meter Rear View
Figure 4. LoadMan Connectivity Example
19
Operational Basics
Introduction to LoadMan Load Manager Software
Figure 5. LoadMan Load Management Software
LoadMan's Load Management Software allows remote tracking of trucks,
drivers, customers, routes and products by account or job. LoadMan offers two
versions of Load Management Software:
1.
2.
Load Management Cloud Based Software - Database is in the cloud and
assessed thru standard internet enabled web browsers
Load Manger Desktop Software – Database is at customer’s location or on
remote servers. Users use Windows to access all functions of the Load
Management software.
Each fleet truck’s data collection memory can be accessed by the software to
gather:



Routes, vehicle ID, driver ID, and customer accounts
Products hauled or delivered - by account or job
Load weights, load sites and commodity
20
Operational Basics



Truck and load locations by GPS coordinates
Events encountered (Waste & Recycling)
Time & date stamp on all loads
This load data is uploaded to a back office management database, where load
data can be further studied by date, customer, account, driver, etc., and even
exported to popular accounting and spreadsheet programs.
Visit our LoadMan website for more information about LoadMan Load Manager
and to view a video demonstration:
http://loadman.com/products/software/
21
Operational Basics
22
Normal Operating Mode
NORMAL OPERATING MODE
At power on, LoadMan enters the Normal Operating Mode, which provides the
main operational, messaging, and status information for the LoadMan weight
and route applications. The first display is the Information display that shows
detailed load and process information about the in-motion weighing cycle. This
initial information display and other weight, route and programming displays are
discussed in this chapter. Refer to Table 4.
Table 4. Normal Operating Mode Display
Information
Display







Weight
Displays



Route
Information
Displays



DATE & TIME


Use the SELECT
key to sequence
forward through
available displays
LAST
TRUCK
TARGET
LOAD NAME
LOAD ACCOUNT #
STOP #
PRODUCT NAME
EVENT NAME
ASSET NAME


Date & Time
READY TO WEIGH
WEIGHING LOAD
GROSS
LOAD / DUMP
LOWER ARMS
NET
RECORDING LOAD
23
Use the SELECT
key to sequence
in reverse
through available
displays
Normal Operating Mode
Weight and Information Displays

INFORMATION DISPLAY – This display is where the weigh-in-motion system
normally operates. It has been set up to automatically provide the operator
all the instructions and information needed to run the in-motion weighing
system.

CYCLE ARMS
Infrequently – if the cart lifter arm is not in the READY TO WEIGH
position at power on, this message informs the operator to re-position
the cart lifter arm back to the READY TO WEIGH position so weighing
can begin.

READY TO WEIGH
Informs operator that the cart lifter weigh-inmotion system is ready to weigh.

WEIGHING LOAD
This message is displayed once the cart lifter arm
has reached the start of the weighing window.
There is no need to stop the arm during the
weighing sequence as LoadMan computes the
weight while the arm is in-motion.

GROSS xxxxxx
Gross weight of the loaded cart – once the arm
has been raised above the weighing window.
xxxxxx represents the gross weight of the cart
and its contents.
24
Normal Operating Mode

DUMP xxxxxx
LOAD xxxxxx
These two messages display alternately to
inform the operator to complete the lifting
process by completely dumping the load.
xxxxxx represents the gross weight of the container and contents.
If the arms are lowered before reaching the programmed DUMP set
point, LoadMan ignores the weight and display the message,
“IGNORING LOAD!”.

LOWER ARMS
LoadMan displays this message once the load
has been dumped and the arm is being lowered.

WEIGHING TARE
Message displayed as the emptied cart is being weighed – while the
arm continues lowering below the weighing window.

NET xxxxxx
Displays the net weight where xxxxxx
represents the weight of the material
just dumped into the truck.

RECORDING LOAD
The message indicates that the weigh-in-motion process has
successfully completed and the net weight has been entered into the
load record. Additionally, the recorded net weight is added to the
accumulated total weight of the TRUCK.
25
Normal Operating Mode

WEIGHT DISPLAYS – While in the Normal Operating Mode, LoadMan
presents various weight displays, some of which can be configured in the
INSTALL/SET DISPLAYS group of the Setup & Calibration commands (see the
section on Setup & Configuration Mode for instructions on choosing
optional weight displays).

LAST xxxxxx LB – Displays the net weight of the contents dumped from
the last cart picked up and weighed.

TRUCK xxxxxx LB – Displays the total net weight of the contents
dumped into the truck for all containers since the last ZERO TRUCK
command was executed. (See PROGRAM FUNCTION below for
executing the ZERO TRUCK command).

TARGET xxxxxx LB – This is a programmable display that shows the
current target net weight set point. When turned on, this display allows
the operator to set a target net truck weight that will activate an alarm
when exceeded.
(To enable the TARGET display, use the INSTALL/SET DISPLAYS/TARGET
SETPT->ON command in Setup & Calibration).
To program the TARGET weight:

In the Normal Operating Mode locate the TARGET display using the
SELECT key.

Now use the /PROGRAM keys to program the target load
weight.

Press SET PROGRAM to set and activate the target weight.
Software Alarm – To enable an overload display message when the
TARGET net truck weight is exceeded, use the INSTALL/SET
DISPLAYS/FLASH OVERLD command in the Setup & Calibration mode. So
in the normal operating mode, the message “GROSS >>> TARGET” displays
any time a net truck weight exceeds the target weight (“NET >>> TARGET”
when in the NET display mode).
26
Normal Operating Mode
Hardware Alarm – To activate a hardware alarm (like a light or buzzer),
an overload hardware signal will short to ground whenever the net
truck weight exceeds the TARGET set point value. See Figure 8. LM310
Wiring Diagram for Cart Based Weight System.
Route Information Displays
While in the Normal Operating Mode, LoadMan presents various optional
displays that can be configured in the INSTALL/SET DISPLAYS group of the Setup
& Calibration commands (see the section on Setup & Configuration Mode for
instructions on choosing optional status displays).

LOAD NAME & ACCOUNT # – Configuring these two optional displays allows
the operator to display, select and record a Load Name and its associated
Account Number for every load in a pickup route. This display function can
be turned on or off by using the INSTALL/SET DISPLAYS/FLASH LDNAME,
FLASH ACCT# and FLASH STOP# commands in the Setup & Calibration Mode.
When these options are turned on, the Load Name, Account Number and/or
Stop Numbers will flash on the LoadMan display. This helps the driver
identify the pickup account.
When enabled, up to 940 sixteen unique alphanumeric character load
names along with their associated seven digit account numbers can be
downloaded from LoadMan’s Load Manager Software. The Stop Number is
the sequence number the pickups were loaded into LoadMan from Load
Manager Software. Load Manager Software uses various communication
methods (such as wireless Bluetooth or cellular modem) to connect and
download route and account information. When the Load Manager
software downloads route information to the LoadMan meter, the number
of Load Names, Account Numbers and Stop Numbers are set automatically.
The load name, account number and stop number combination is tied to
each load to be picked up on the operator’s route. When a load is recorded
– confirmed by the RECORDING LOAD information display message – the
currently displayed load name, account number and stop number are
recorded into LoadMan’s data collection memory. After all of the load and
route information is recorded, LoadMan automatically sequences to the
next load name/account number in the route list (if enabled with the SET
27
Normal Operating Mode
RECORD Option of the Setup and Calibration Mode).
Unexpected departures from the planned sequence in the route list can be
managed using the PROGRAM group of keys to select an out of sequence
stop and load or by using account barcodes from a Route Sheet. Use Geo
Routing Mode to only display those accounts within defined radius (300 to
1000 feet) of the Trucks location. Refer to the section Collecting Load Data
for details.

STOP # xxx – In addition to the optional Load Name and Account Number,
every load has a Stop Number (#) that is recorded in LoadMan’s data
collection memory whenever a load is recorded.
The Stop Number represents the sequence in the route list of Load Names
and Account Numbers that have been downloaded by the LoadMan Load
Management Software. The Stop Number is programmable and allows the
operator to select accounts by programming any stop number that has been
previously loaded into its memory from Load Manager Software. Each time
a load is recorded, LoadMan automatically increments the stop number (if
enabled with the INSTALL/SET RECORD/INCR STOP# command).
This optional display function can be setup to flash during a weight display
using the INSTALL/SET DISPLAYS/FLASH STOP# command in the Setup &
Calibration Mode.
The stop number is reset to one (1) whenever LoadMan’s Load
Manager Software downloads route information.
The operator can override the current stop number by using the PROGRAM
group of keys to program a desired stop number. Refer to the section
Collecting Load Data for the out of sequence instructions.

PRODUCT NAME – LoadMan allows up to 50 different Product Names to be
captured whenever a load is recorded into the data collection memory.
(These product names can be downloaded with LoadMan’s Load Manager
Software.) This optional display function can be setup to flash a PRODUCT
NAME during a weight display by using the INSTALL/SET DISPLAYS/FLASH
PRODUCT command in the Setup & Calibration Mode. When the Load
Manager Software downloads route information to the LoadMan meter, the
28
Normal Operating Mode
number of Product Names is set automatically.
When enabled, and before a load is recorded, the operator can select a
product name (e.g., RECYCLE, CARBOARD, COMPOST, etc.) that will be
recorded in LoadMan’s data collection memory. To choose a product name:
 Locate the current PRODUCT display using the /SELECT keys.
 Locate the particular product name using the /PROGRAM keys.
 Activate the product name with the SET PROGRAM key.
When a load is recorded – confirmed by the RECORDING LOAD information
display – the product name is recorded into LoadMan’s data collection
memory along with the account name, account number, stop number and
any other enabled route options.
Once a product name has been selected, it remains in effect for all
subsequent load recordings. The product name should be reprogrammed whenever the product condition changes.

EVENT – LoadMan provides up to 50 different Event Conditions that can be
recorded whenever a load is recorded into the data collection memory.
(These event conditions can be downloaded with LoadMan’s Load Manager
Software.) This optional display function can be setup to flash an EVENT
condition during a weight display by enabling the function with the
INSTALL/SET DISPLAYS/FLASH EVENT command in the Setup & Calibration
Mode. When the Load Manager software downloads route information to
the LoadMan meter, the number of event conditions is set automatically.
When enabled, and before a load is recorded, the operator can select an
event condition (e.g., ROAD CLOSED, CONTAINER LOCKED, etc.) that will be
recorded in LoadMan’s data collection memory. To choose an event
condition:
 Locate the current EVENT display using the /SELECT keys.
 Then locate the particular event condition using the /PROGRAM
keys.
 Activate the event/problem condition with the SET PROGRAM key.
When a load is recorded – confirmed by the LOGGING EVENT information
display – the Event condition is recorded into LoadMan’s data collection
memory along with the account name, account number and any other
29
Normal Operating Mode
enabled route options.
Once an event condition has been selected and recorded, it reverts
back to the NO EVENT condition for all subsequent load recordings.
New event conditions should be re-programmed anytime an event or
problem is encountered, and before a load is recorded.

DATE and TIME – The currently displayed Date and Time is recorded in
LoadMan’s data collection memory whenever a load is recorded into the
data collection memory. This display function is not optional.
Programming DATE and TIME – Using the programming basics discussed in
the previous section, the date and time can be changed with the PROGRAM
keys:
 Locate the Date and Time display with the SELECT key.
 Now use the /PROGRAM keys to program the time (hours, minutes,
AM/PM) and date (month, day, year).
 Press SET PROGRAM to set and activate the new time.
30
Normal Operating Mode
PROGRAM FUNCTION Displays
Use the PROGRAM FUNCTION display to access and activate any of the
command options listed below in Table 5.
Table 5. PROGRAM FUNCTION Commands
SHOW NET
Set display for NET weight
operation.
SHOW GROSS
Set display for GROSS
weight operation.
Prints the most recent load
data measured to a
configured printer.
Resets the Cart Lifter load
cells to read zero
Initiates the automatic
display cycle of weight
information and status
messages
Zeros the accumulated
truck load TOTAL and
provides option to capture
a landfill dump weight
PRINT LAST LOAD
ZERO CART LOAD
CYCLE DISPLAY
ZERO TRUCK
Use the /SELECT
keys to locate the
PROGRAM FUNCTION
display.
Use the /PROGRAM
keys to sequence through
available program
options.
 = forward
 = reverse
Use the SET PROGRAM
key to activate command.
Either of the /PROGRAM keys will sequence through the available
PROGRAM FUNCTIONs, and once an item is selected, the SET PROGRAM key will
activate and save the selection. LoadMan will then return to the Information
Display.
While in the PROGRAM FUNCTION displays, LoadMan will take no action
until the SET PROGRAM key is depressed.
While within any of the PROGRAM FUNCTION options, the /SELECT
keys will abort programming and return LoadMan to manual display.

SHOW GROSS – Set the display for GROSS weight mode, enabling LoadMan
to display the gross TRUCK weight – which is the payload weight plus the
tare weight programmed in the SET TARE mode of the Setup and Calibration
31
Normal Operating Mode
mode.
While in the GROSS display mode, the truck’s weight
(TRUCK xxxxxx gLB) will be displayed in gross weight. Choosing the GROSS
weight display will terminate the NET display operation.

SHOW NET – Set the display for NET weight mode, enabling LoadMan to
display the net TRUCK weight (or the payload weight). While in the NET
display mode the truck’s weight (TRUCK xxxxxx nLB) will be displayed as net
weight. Choosing the NET weight mode display will terminate the GROSS
mode display operation.

PRINT LAST LOAD – Prints the most recent load measurement to an output
device connected to an RS232 Port; such as a printer. Load data includes
the current load data, date and time, GPS coordinates, and any other
optional route display information that has been enabled with the
INSTALL/SETUP RS232/PRINT commands (i.e., Account Name, Account
Number, Stop Number, Product Name, Event, etc.).
Figure 6. Print Ticket Example shows a sample printout from
an in-cab printer (the diamonds () represent optional fields that may be
setup with the INSTALL/RS232/PRINT commands in Setup & Configuration
Mode).
DATE: 02-12-10
TIME: 12:34:56 PM
** LOAD NAME ***
ACCOUNT # 31560
STOP #
194
* PRODUCT NAME *
TARGET 9600 LB
LOAD
560 LB
TOTAL 14445 LB





Figure 6. Print Ticket Example
If you would like to take advantage of custom print capabilities, contact
LoadMan directly to obtain related technical specifications and
documentation or get a development quote.

ZERO CART LOAD – Zeros the cart lifter loadcells so it will read zero. This
command is useful when there is nothing loaded on the cart lift. This
command should be used when LoadMan weighs something other than zero
when no cart is on the cart lifter when going up and down. If this is the case,
32
Normal Operating Mode
executing this command will direct LoadMan to lead the operator through a
process to zero the Cart Lifter weight reading.


REMOVE CART
Make certain there is no load on the cart lifter.
SET ARM ANGLE - LoadMan now displays the ARM Angle. Raise or
lower the arms of the cart lifter to where the cart lifter mounting plate
is vertical. When the angle is ±1 degree of zero, LoadMan will zero the
Loadcell readings in this static position, and display ZERO COMPLETE to
confirm the zero cart load and zero cart angle.
Calibrate System for ZERO CART LIFTER LOAD Switch
LoadMan also features a ZERO CART LOAD switch that is mounted on the
left outside plate of the cart lifter scales. This light/switch allows the
operator to work at the rear of the truck, reading the green strobe light
while leveling the cart arm angle to zero.
Depressing this switch initiates the zero load process that was just described
above. And it also features a green light strobe that provides real-time
feedback on the cart angle. The closer the angle to zero, the faster the light
flashes. And when the fork angle is between 0 and +/-1, the light will hold
steady.
When finished zeroing the load, the light provides a high frequency
“chattering” strobe indicated that the Zero Weight is calibrated accurately.
When finished, depress the switch to turn off the light and the zeroing
process.

CYCLE DISPLAY – Directs LoadMan to automatically cycle through all of the
available displays (order listed in Table 4. Normal Operating Mode Display).
The duration of each item displayed is configurable using the INSTALL/SET
DISPLAYS/CYCLE command in the Setup & Calibration Mode (default is 2
seconds).
33
Normal Operating Mode
Pressing either the /SELECT keys will terminate the automatic
cycle display and allows manual selection of the display by using either
of the /SELECT keys.

ZERO TRUCK – Zeros the accumulated TRUCK load total. Thereafter,
TRUCK xxxxxx nLB will display the accumulated net weight of any recorded
loads. Or, TRUCK xxxxxx gLB will display the truck’s accumulated gross
weight - total of the truck’s tare weight and the accumulated weight of any
recorded loads.
It is recommended that the driver zero the truck after any transfer station or
landfill dump - resetting the accumulator to zero - before continuing the
route or starting a new route.

ENTER GROSS SCALE WEIGHT! – The ZERO TRUCK command also
features the option to capture the gross platform scale weight of the
loaded truck just before a landfill dump. This weight will be recorded
and reported to LoadMan Load Manager to assist in tracking all the
truck’s tipping weights at landfills and transfer stations. Note that the
landfill scale location must be geocoded in order for Load Manager to
record the scale weight in the correct landfill customer record.






SCALE 000000 LBg
Use the /PROGRAM keys to the platform scale weight (the
gross weight of the truck).
Press SET PROGRAM to set and activate.
ENTER TARE SCALE WEIGHT SCALE 0000000 LBt
Use the /PROGRAM keys to enter the truck’s tare scale weight.
Press SET PROGRAM to set and activate.
34
Normal Operating Mode
LoadMan responds with the confirmation that the truck’s net load
weight has been recorded at the scale location, followed by
confirmation that the net truck weight has been set to zero.

RECORDING LOAD!

ZEROING TOTAL!


If no SCALE value is entered then LoadMan will respond with the
message:
NO LANDFILL SCALE
Followed by the confirmation:
ZEROING TOTAL – meaning that the truck’s net weight has been set
to zero.
35
Setup and Calibration Mode
36
Setup and Calibration Mode
SETUP & CALIBRATION MODE
LoadMan’s Setup & Calibration Mode provides the operator the capability to
program advanced functionality, setup and calibrate a truck’s configuration,
choose optional information displays, enable communications, and troubleshoot
issues. Refer to Table 6.
Table 6. Setup & Calibration Commands
SET ZERO
SET SPAN
Used for setup and calibration of
the Cart Lifter Arm Angle Sensor
and the Cart Lifters load sensors
Calibrates LoadMan to readings
taken from another scale
SET TARE
Sets the empty weight of the
vehicle
INSTALL
Provides the capability to setup
and/or change the operating
configuration of LoadMan
Returns all settings to the original
factory default settings
SET DEFAULTS
ERASE DATA
Permanently erases all data in
LoadMan’s data collection memory
TROUBLESHOOT
Provides detailed sensor, loadcell,
communications and other system
information that can be useful for
isolating issues
37
SELECT
Sequence
forward
through
available
displays
/PROGRAM
Keys to change
“NO” to “YES”
SET PROGRAM
To activate
command
SELECT
Sequence
in reverse
through
available
displays
Setup and Calibration Mode
Basic Navigation
Activating – Setup & Calibration Mode w/SECURITY OFF

Continually depress the
POWER button, through the “GOODBYE!“
message, and until the “LOADMAN SETUP“ message is displayed.

The first setup & calibration category displayed is “SET ZERO?---->NO”.
Activating – Setup & Calibration Mode w/SECURITY ON

Continually depress the
POWER button. The messages “GOODBYE!“ and
“ENTER PASS CODE!“ will display.

At the prompt, “PASS CODE 0”, use the /PROGRAM keys to program
the security code TO “123”and save the code with the SET PROGRAM key.

If correct, LoadMan displays the message, “LOADMAN SETUP”.

The first setup & calibration category displayed is “SET ZERO?---->NO”.

If the security code is NOT correct, the error message, “SECURITY FAILED” is
displayed, and the Setup & Calibration mode cannot be accessed.
Navigating and Programming – Setup & Calibration Mode
The SELECT keys are used to manually scroll through the seven setup, calibration
and troubleshooting categories.

The SELECT key will sequence forward through a group of displays.

The SELECT key will sequence in reverse through a group of displays.
Once the desired setup category is displayed, use either of the /PROGRAM
keys to toggle “NO”, “YES” or other options; and then press the SET PROGRAM to
select and activate the setup category.
For programmable displays (like setting a tare weight):

Use the PROGRAM key to move the flashing cursor left to the next
programmable digit/item in the display.

Once the flashing cursor is positioned over the item to be changed, use the
PROGRAM key to increase/bump the digit/item to its next value.

Continue to use the /PROGRAM keys until the display has been
programmed.

The SET PROGRAM key will execute the command and save any changes
made to the display.
LoadMan will abort the process of programming displays if either of the
/SELECT keys are pressed.
38
Setup and Calibration Mode
Exiting – Setup & Calibration Mode
When finished with any of the setup categories and to exit setup & calibration:

Press the SELECT key until “EXIT SETUP?-->NO “ is displayed.

Then press PROGRAM key to display “EXIT SETUP?-->YES“.

Finally, press the SET PROGRAM key to exit.
LoadMan will now return to the normal operating mode and will reinitiate the
information displays of weight and status messages.
Setup & Calibration Commands

SET ZERO – Zeros the cart lifter loadcell weight reading. This command is
useful when nothing is loaded on the cart lifter but LoadMan still weighs
something other than zero when the cart lifter is going up and down. If this
is the case, executing this command will direct LoadMan to lead the
operator through a process to zero the cart lifter’s weight reading.

ZERO ARM ANGLE

Use the PROGRAM key to select “ZERO ARM ANGLE?” and activate
with the SET PROGRAM key. “THIS IMPACTS YOUR CALIBRATION” and
then the “PROCEED?NO” comes up. Use the Program Group of
keys to change the NO to YES and then press the SET Key.


“POSITION ARMS TO ZERO ARM ANG” and then “READY?-->NO” comes up
on the display. Move the cart lifter mounting plates so they are
perfectly vertical (recommend using a Level for this step). When
ready, use the Program keys to change the NO to a YES and press
the Set Key. “ZEROING ARM ANGLE”, then “ZEROING COMPLETE”. The
arm angle sensor mounted on the cart lifter arms is now calibrated
to read zero in the cart lifter’s current position.
ZERO CART LOAD

LoadMan responds with “REMOVE CART!” and then “SET ARM ANG =0”
and then starts displaying the cart lifter arm angle. Raise or lower
the cart lifter arms until the angle reading is within ±1 degree of
zero. At that point, LoadMan will automatically calibrate the
loadcell readings to read zero.
39
Setup and Calibration Mode

LEARN ZERO? – Learn Zero is the process of “custom learning” the zero
response of the cart tipper’s loadcells; fine tuning the accuracy of each
loadcell. This is accomplished by a series of lifts (12-15 lifts are
recommended). Without this procedure the loadcell measurements
could be inaccurate and misleading.
The process is quite simple. Just follow the LoadMan display
instructions:

Activate with the SET PROGRAM key.

REMOVE CART! – Remove the cart for the entire LEARNING
process.

RAISE ARMS!

LEARNING ZERO UP

LOWER ARMS!

LEARNING ZERO DN

CYCLES – Displays the number of LEARN cycles completed.
The above process should be repeated from 12-15 times to allow
LoadMan to fully determine each loadcell’s zero response; fine tuning
the accuracy of each loadcell.
When finished repeating this process, simply let the cart lifter rest at
zero. LoadMan will provide screen instructions to complete the LEARN
process:

UPSELECT IF DONE - SELECT.

SAVE ZERO? – Use the PROGRAM programming key to choose
“YES”, and confirm with the SET PROGRAM key.

SAVING ZERO DATA – Wait for LoadMan to process before
activating any further keys.

SET SPAN – Used to calibrate LoadMan to the readings taken from another
scale. Use this setup command to calibrate a truck load of material that has
been weighed on another scale; or alternately, calibrate LoadMan to the
weight of a loaded cart weighed on another calibrated scale.
Prior to performing SET SPAN setup on a truck load of material,
LoadMan must display a ZERO TRUCK net weight when the vehicle is
empty. If not, then perform a PROGRAM FUNCTION/ZERO TRUCK
command when the vehicle is empty. Otherwise an inaccurate
40
Setup and Calibration Mode
calibration will result.
Prior to performing the SET SPAN setup command with a calibrated
container, an empty cart load should measure a net weight of zero. If
not, then perform a PROGRAM FUNCTION/ZERO CART LOAD
command. Otherwise an inaccurate calibration will result.

SET SPAN Calibration Procedure -- This procedure is used for either
calibrating a loaded cart or for calibrating a single container that is
loaded with a calibrated weight that is near 80-100% of the cart lifter’s
load capacity.

o
o
o
o
o
o
o
o

Use the PROGRAM key to select “SPAN TRUCK?” and activate with
the SET PROGRAM key.
LoadMan asks for confirmation with “ADJUST SPAN?” Press SET
Program key to confirm.
LoadMan responds with instructions to “ENTER METER LOAD”.
METER xxxxxx LB” – Use the /PROGRAM programming keys to
enter the weight readings obtained from the LoadMan meter. This
would be the net (TRUCKn) or gross (TRUCKg) weight for the truck,
or the net load weight (LAST) for a container. Press the SET
PROGRAM key to save.
Press the SELECT key and LoadMan will respond with the
directions, “ENTER CAL LOAD”.
Use the /PROGRAM programming keys to enter the weight
readings obtained from the calibrated scale. Press the SET
PROGRAM key to save.
Now press the SELECT key and LoadMan will respond with the
directions, “DO AUTOCAL?-->NO”. This display is confirming that the
weights have been entered properly.
If a mistake was made when entering the truck’s net (or gross)
weight (TRUCKn or TRUCKg) or the calibrated load weight (LAST),
simply use the SELECT key to back up and re-enter.
Once confirmed that the entries are correct, select “YES” and press
SET.
LoadMan will now complete the SPAN calibration and confirm with,
“DOING SPAN ADJUST” and “SPAN COMPLETE!”.
41
Setup and Calibration Mode

LEARN SPAN? – Learn Span is the process of “custom learning” the
calibration of the cart tipper’s loadcells. This is accomplished by a series
of lifts (12-15 lifts are recommended). Without this procedure the
loadcell measurements could be inaccurate and misleading.
The process is quite simple. Just follow the LoadMan display
instructions:

Activate LEARN SPAN with the SET PROGRAM key.

ENTER SPAN CAL (Factory default is 400LB). Press SELECT key to
continue.

ENTER CAL LOAD – This is the calibrated weight of a cart loaded
with a known scale weight from another calibrated scale. This load
should be tightly secured within the cart for safety, and to make
certain there is no abrupt bouncing of the container’s contents
during the calibration procedure.

Use the /PROGRAM programming keys to enter the weight
reading obtained from the calibrated scale. Press the SET
PROGRAM key to save, and press SELECT key to continue.

LoadMan will respond with LOAD CAL WEIGHT! and has initiated
the LEARN SPAN calibration process:





RAISE ARMS!
LEARNING SPAN UP
LOWER ARMS!
LEARNING SPAN DN
CYCLES – Displays the number of LEARN cycles completed.
The above process should be repeated from 12-15 times to allow
LoadMan to fully determine each loadcell’s span; fine tuning the
calibration of each loadcell.
When finished repeating this process 12 to 15 times, simply let the cart
lifter rest at zero. LoadMan will provide screen instructions to complete
the LEARN process:

UPSELECT IF DONE - SELECT.

SAVE SPAN? – Use the PROGRAM programming key to choose
“YES”, and confirm with the SET PROGRAM key.

SAVING SPAN DATA – Wait for LoadMan to process before
42
Setup and Calibration Mode
activating any further keys…this may take few moments.

SET TARE – Sets the empty weight of the vehicle – referred to as the tare
weight. LoadMan uses the configured tare weight to display the gross
weight of the vehicle when LoadMan is configured for gross weight
operation (activated by the PROGRAM/SHOW GROSS command). The gross
weight is the net weight (or payload weight) plus the tare weight; and it is
the tare weight that is set by using this command.
First obtain the tare weight by weighing the fully fueled empty truck at a
calibrated truck scale, and write down the tare weight here:
TRUCK TARE WEIGHT: ______________________________
When the SET TARE category is activated, the message “TRUCK xxxxxx LB” is
displayed where xxxxx is the current tare setting for the truck. Use the
/PROGRAM and SET PROGRAM keys to change and set the truck’s tare
setting.
Note that the truck tare is assumed to be a constant. This of course
will not be the case in the real world. Just the variation of the fuel
remaining in the truck can cause the truck’s empty weight to vary
1000 lbs. We recommend using a full tank of fuel when measure the
truck’s empty weight so this should always represent the highest
possible weight of the truck.
43
Setup and Calibration Mode

INSTALL – Provides the capability to setup and change the operating
configuration of LoadMan. When activated with “YES”, then the first
installation option is displayed; “LOADCELLS 2”. Most cart lifters will have
only 2 Loadcells but some models will have more.
The available INSTALL options are shown in Table 7. These categories are
selected and activated using the /SELECT, /PROGRAM and SET
PROGRAM keys.
Table 7. INSTALL - Installation Commands
LOADCELLS
SHOW NEG WTS
Displays the number of loadcells that
are configured for load weight
sensing. Default is 2.
Configures how LoadMan will display
negative weights
SET DISPLAYS
Programs LoadMan’s display options
SETUP MODEM
Configures the communications
modem
SETUP GPS
Programs the time period between
logging of GPS coordinates
SET RECORD
Configures options to customize how
load data is recorded and/or
displayed
Configures LoadMan’s RS232 port(s)
SETUP RS232
SERIALnum
Displays the serial number for the
LoadMan meter
SECURITY
Turns LoadMan meter security ON or
OFF
44
SELECT
Sequence
forward
through
available
displays
/PROGRAM
Programming
keys
SET PROGRAM
To activate
command
SELECT
Sequence
in reverse
through
available
displays
Setup and Calibration Mode
LOADCELLS – Displays the number of loadcells that are configured for load
weight sensing. This value is set to a default of “2”; which account for the two
cart lifter load cells that measure the weights loaded on the cart lifter. Some
cart lifter models will have more than 2. Use the /PROGRAM keys to adjust
this value if more load cells are used for the scale.

SHOW NEG WTS – Configures how LoadMan will display negative
weights. Use the /PROGRAM Programming keys to advance
through the 4 options.
NO
LoadMan will not display any measured negative net
weights; but instead will display negative weights as zero.
YES
Directs LoadMan to display all negative weights.
<75
LoadMan will display a weight of zero for any negative
weights between zero and negative 75 pounds. Any value
less than negative 75 pounds will display as measured.
<150
LoadMan will display a weight of zero for any negative
weights between zero and negative 150 pounds. Any
value less than negative 150 pounds will display as
measured.
45
Setup and Calibration Mode

SET DISPLAYS – This setup category programs LoadMan’s display
options. Refer to Table 8.
Table 8. SET DISPLAY Commands
DISPLAY UNITS
CYCLE
COUNT BY
ACCOUNTS
PRODUCTS
EVENTS
ASSETS
Selects the units for measuring and displaying
weights
Programs the viewing duration of each displayed
weight
Programs the resolution of the weight displays
The number of route Account names and numbers
that have been downloaded to Loadman
The number of route Product names that have been
downloaded to the Loadman meter
The number of route Events that have been
downloaded to the Loadman meter
FLASH PRODUCT
The number of assets that have been downloaded
to the Loadman meter
Display TARGET weight so a target overload set
point can be programmed
Active Load Name will be flashed every few seconds
on the meter display
Active Account Number will be flashed every few
seconds on the meter display
Active Stop # will be flashed every few seconds on
the meter display
Currently active PRODUCT will be displayed
FLASH EVENT
Currently active EVENT will be displayed
FLASH OVERLD
LoadMan will place a message on the display
anytime the TARGET weight has been exceeded
GEO ROUTE
Geo Route information will be downloaded from
Load Manager software and activated on command
TARGET SETPT
FLASH LDNAME
FLASH ACCT#
FLASH STOP#
46
Setup and Calibration Mode

DISPLAY UNITS – Selects the units for measuring and displaying
weights. The LoadMan meter comes preconfigured at the factory
to display weight measurements in English units. Use the
/PROGRAM and SET PROGRAM keys to program, select and set
either English or metric units.

English units – select pounds (LB

Metric units – select kilograms (KG)
o
CYCLE xxx SEC – Programs the viewing duration (xxx seconds) of
each weight, route or status message displayed during the Normal
Operating Mode automatic cycle display. Use the /PROGRAM
and SET PROGRAM keys to program, select and set the display
duration in seconds.
The Cycle Display Function can be completely disabled by setting
the xxx value to zero (0)
(Default is 2 seconds and maximum is 10 seconds.)
o
COUNT BY = xxx – Programs the resolution of the weight displays
where xxx is the minimum weight step displayed. The available
COUNT BY weight step options are, 1, 2, 5, 10, 20, 50, 100 or 200.
The COUNT BY rounding can be momentarily disabled on the
display by continually depressing the SELECT key that is used
to manually select a particular weight display. LoadMan will
display the weight count in increments of 1 as long as the
SELECT key is continuously depressed. Releasing the SELECT
key causes the display to return to the programmed COUNT
BY resolution.
o
ACCOUNTS – Load Manager Software will automatically load the
number of route account names and numbers that have been
downloaded into LoadMan’s memory. This number is
automatically set when LoadMan Load Manager Software
downloads ACCOUNTS but can be overridden with this command
(programming to zero will remove all accounts).
47
Setup and Calibration Mode
Regarding Account Load Names, Account
Numbers, Products and Events:
LoadMan allows up to 940 different Load Names &
corresponding Account Numbers, 50 unique Product
Names, 50 Events and 250 different Assets to be captured
upon each recording of a load - “RECORDING LOAD”. These
account names, products, events, and assets can be
downloaded to the meter with LoadMan’s Load Manager
Software.
o
PRODUCTS – Configures the number of route product names that
can be displayed (default is 0, max is 50). This number is
automatically set when LoadMan Load Manager downloads
PRODUCTS but can be overridden manually.
o
EVENTS – Configures the number of route events that can be
displayed (default is 0, max is 50). This number is automatically set
when LoadMan Load Manager downloads EVENTS but can be
overridden manually. Example EVENTS are ROAD CLOSED, GATE
LOCKED, NO BIN AVAILABLE, etc.
o
ASSETS – Configures the number of route assets that can be
displayed (default is 0, max is 250). This number is automatically set
when LoadMan Load Manager downloads ASSETS, but can be
overridden manually.
o
TARGET SETPT– Turns on or off the TARGET weight display. When
turned on, this display allows the operator to set a target overload
set point that will activate a hardware alarm and/or will trigger a
LoadMan display when the target net weight of the truck has been
exceeded. Especially useful for tracking and detecting the current
gross weight of the truck; avoiding overloads and fines.
o
FLASH LDNAME – When this display is activated to “YES”, the
currently active Load Name will be flashed every few seconds on
the weight display, aiding the operator to identify the current
account that will be saved when a load is recorded as an aid to
easily identify the active account.
48
Setup and Calibration Mode
o
FLASH ACCT# – When this display is activated to “YES”, the
currently active ACCOUNT# will be flashed every few seconds on
the weight display, aiding the operator to identify the current
account that will be saved when a load is recorded.
o
FLASH STOP# – When this display is activated to “YES”, the
currently active STOP# will be flashed every few seconds on the
weight display, allowing the operator to identify the current
account stop number that will be saved when a load is recorded
o
FLASH PRODUCT – When this display is activated to “YES”, the
currently active PRODUCT (refuse, recycling, cardboard, etc.) will be
displayed. When enabled, and to choose a product name:

Locate the PRODUCT display using the /SELECT keys,

Locate the particular product name using the /PROGRAM
keys,

Activate the product name with the SET PROGRAM key.
When the load is recorded, the product name will be recorded into
LoadMan’s data collection memory along with the account name,
account number, and any other enabled route options.
Once a product name has been selected, it will remain in
effect for all subsequent load recordings. The product name
should be re-programmed whenever the product condition
changes.
o
FLASH EVENT – When this display is activated to “YES”, the
currently active EVENT will be displayed. When enabled, and to
choose a problem condition:

Locate the current EVENT condition display using the
/SELECT keys,

Locate the particular problem condition using the
/PROGRAM keys,

Activate the problem condition with the SET PROGRAM key.
When a load is recorded, the event condition will be recorded into
LoadMan’s data collection memory along with the account name,
49
Setup and Calibration Mode
account number and any other enabled route options.
Once an EVENT condition has been selected and recorded
with the RECORD command, it will revert back to the NO
EVENT condition for all subsequent load recordings. New
event conditions should be re-programmed anytime a route
event/problem is encountered and before the next load is
recorded.
o
FLASH OVERLD – When activated to “YES”, LoadMan will place a
message on the display (and activate an optional hardware alarm)
anytime the TARGET weight has been exceeded. In the normal
operating mode the message, “GROSS >>> TARGET” will display
anytime a load exceeds the target weight. Especially useful for
tracking and detecting the current gross weight of the truck;
avoiding overloads and fines.
o
GEO ROUTE – Route information will be downloaded from
LoadMan Load Manager Software when set to “YES”. The GEO
ROUTE feature can then be selected as the active Operating Mode
using PROGRAM FUNCTION display in the normal operating mode.
Geo Route, also known a proximity routing, allows LoadMan to
determine whether route pickups are located within a proximity of
300 to 1000 feet (programmable). If only one customer name is
indicated on the 16 character display, then the driver can simply lift
the load as instructed on the display.
If more than one customer account is displayed, then LoadMan has
detected other customers with the proximity of the truck. The
driver must choose the correct customer in order to report the
correct weight with the correct customer account. Locate and
choose the customer account using the /PROGRAM keys.
Activate the account with the SET PROGRAM key

SETUP MODEM – When set to “YES”, the command configures the
communications modem.
The LoadMan meter may come equipped with an optional GSM cellular
50
Setup and Calibration Mode
modem.
The modem is used to connect and communicate with
LoadMan’s Load Manager Software. The Load Manager Software
allows remote tracking of trucks, drivers, customers and routes, and
exchanges the load and location information through this modem.
o
MODEM OPTION – Set this option to “YES” if the LoadMan meter
has been configured with a GSM modem board for remote
communications. If the modem is not installed, make certain to
choose the “NO” option.
o
MODEM ---- country – Sets the country in which the cell modem
will operate. The default configuration is USA.
 Choose USA or CANADA using the PROGRAM key,
 Activate the country with the SET PROGRAM key.
International Modems - If the country is outside the USA and
Canada, then the country should be left on USA. The meter has to
be ordered with an International Option for this to work properly.
o
CONN xxx SEC – Sets the time period (in seconds) between polling
connection attempts between the LoadMan meter and the
LoadMan Load Manager Software.
o
RSET xxxx SEC – Sets the time period (in seconds) when the
modem will reset if it has not been fully “exercised” within the xxx
time window. The factory default is 3600 seconds (1 hour). If the
RSET is executed, then the modem had probably been stuck in
some state. RSET will toggle power to the modem and reset. This
value can be adjusted with the /PROGRAM and SET PROGRAM
keys.
o
BAUD RATE>115200 – Indicates the baud rate of the modem. This
number should always be set to 115200.
If not, use
/PROGRAM and SET PROGRAM keys to correct the value.
51
Setup and Calibration Mode
o
Remote IP – The remote IP address fields contain the IP address of
the LoadMan TCP relay that coordinates data communication
between the vehicle and the LoadMan Load Management
Software. When using a cellular data modem, these IP addresses
must be set as documented:




RemoteIP1
RemoteIP2
RemoteIP3
RemoteIP4
74
93
98
177
If for any reason these LM310 values do match the values listed
here, then use the /PROGRAM and SET PROGRAM keys to
program, select and correct to the address fields as shown.
.

SETUP GPS – When set to “YES”, this command programs the logging of
GPS coordinates. The LoadMan meter may come equipped with an
optional internal GPS chip and antennae. LoadMan’s Load Manager
Software uses onboard GPS capability to track and map truck, load and
customer locations.
o
LOG xxx SEC – Programs the time period (xxx seconds) between
the logging of GPS coordinates into LoadMan’s data collection
memory. The factory default setting is 30 seconds.
When recorded GPS coordinates are uploaded into LoadMan’s Load
Manager Software, the software will be able to use the coordinates to
map load locations, track truck routes and aid with several other
advanced location based functions.

SET RECORD – Whenever a load is recorded using the RECORD LOAD
command, LoadMan uses several record options to customize the way
that the load data is displayed and recorded. Choose “YES” to program
the following RECORD options:
o
RECORD&PRINT – When set to “ON”, directs LoadMan to print the
recorded load data to the RS232 port(s) as it is recorded into
LoadMan’s data collection memory. If set to “OFF”, the load data
52
Setup and Calibration Mode
will be recorded to LoadMan’s data collection memory, but will not
be printed.
TIME: 12:34:56 PM
** LOAD NAME ***
ACCOUNT # 31560
STOP #
194
* PRODUCT NAME *
TARGET 9600 LB
LOAD
560 LB
TOTAL 14445 LB





Figure 7. Printed Load Ticket

o
INCR STOP # -- When set to “ON”, LoadMan will automatically
increment and select the next stop number (and associated
account information) from the downloaded route list after a load
has been recorded. If no Route has been downloaded then the
STOP # will simply increment on every load pickup.
o
CONTsp xxxxx LB – Container set point. LoadMan provides this
capability to prevent the recording of load data records when there
is no cart on the cart lifter. When programmed to a positive
number, and if the gross weight measured going up is less than this
set point value, then the weight will NOT be recorded as a load
data record when the load comes back down. If programmed to
zero then every lift will be recorded regardless of the gross cart
weight measured going up.
SETUP RS232 – Configures LoadMan’s RS232 ports.
LoadMan comes standard with one 9-pin RS232 port that can connect
to peripherals like printers for printing load and route information, or to
large scoreboard displays mounted on the truck to display weight
information. Also, the RS232 port can connect to input devices like
barcode readers for reading account and route information.
Optionally, the LoadMan meter comes with a second RS232 port
configured with either another 9-pin connector or with a Bluetooth
antenna. Here are the three possible RS232 port configurations:
53
Setup and Calibration Mode
Table 9. RS232 Port Configurations
RS232 Configuration
Standard
Option 1
Option 2
Port #1 Connector
9-pin
9-pin
Bluetooth Antenna
Port #2 Connector
9-pin
9-pin
For a Standard one port configuration:
o
Choose “RS232 PORT #1?” by pressing the SET PROGRAM key.
o
BLUETOOTH --->” should be set to “OFF ” as Bluetooth is not
available with the standard configuration.
o
Then configure the remaining port settings as described below –
beginning with BAUD RATE.
Note: For the standard 1 port configuration, if “RS232 PORT #2” is
chosen, any of the following RS232 configuration settings will be
ignored as the port is not present.
For Option 1 two port configurations (two 9-pin RS232 ports):
o
For the first port, choose “RS232 PORT #1?” by pressing the SET
PROGRAM key.
o
BLUETOOTH --->” should be set to “OFF ” as Bluetooth is not
available with this configuration.
o
Then configure the remaining port #1 settings as described below
beginning with BAUD RATE.
Repeat this process for the second port by choosing “RS232 PORT #2?”
and pressing the SET PROGRAM key. Then configure the remaining port
#2 settings as described below – beginning with BAUD RATE.
For Option 2, two port configurations (one Bluetooth port and one 9pin port):
o
For the first port, choose “RS232 PORT #1?” by pressing the SET
PROGRAM key.
o
“BLUETOOTH --->” should be set to “ON”.
For the second port, choose “RS232 PORT #2?” by pressing the SET
PROGRAM key. Then configure the remaining port #2 settings as
described below – beginning with BAUD RATE.
54
Setup and Calibration Mode
o
BAUD RATE – Programs the baud rate for the RS232 ports. The
baud rate must match the baud rate of the peripheral device that
will be connected to the port for LoadMan to properly
communicate. The available baud rates are: 600, 1200, 2400, 4800,
9600, 19200, 38400, 57600, 115200 baud (factory default is 9600
baud).
When the LoadMan meter is equipped with the Bluetooth
Option, then the baud rate for port #1 MUST be set at 9600
baud.
The following options are available only for RS232 9-pin ports:
o
TICKET PRINT ON – Programs the RS232 port for printing to a serial
printer mounted in the truck cab. Every time a cart is lifted and
weighed, it will print the contents of the load data measured when
the meter is showing RECORDING LOAD (If the Record and Print
Option is set to YES in SET RECORD options). Other print options
can be enabled with the print (PRT) commands described below.
o
SCOREBOARD ON – When the SCOREBOARD is set to “ON”, then the
total weight will be displayed to the truck’s scoreboard that’s
connected to the RS232 port. It will always show the last measured
load and other print options chosen with the SET RECORD/PRT
commands.
o
BARCODE – LoadMan supports automatic reading of account
information with a bar code reader/wand. When set to “ON”,
LoadMan configures the RS232 port to read from a barcode reader.
The following print options may also be offered for configuration,
depending on which type of output device was selected (choose “YES”
to activate any desired option).
o
PRT LOADNAME –Prints the active load account name.
o
PRT ACCOUNT – Prints the active load account number.
o
PRINT STOP# – Prints the active stop number.
55
Setup and Calibration Mode

o
PRT PRODUCT – Prints the active product name.
o
PRT EVENT – Prints the active event condition.
o
PRINT TRUCKg – Prints the truck’s gross weight. That is, the tare
weight plus the accumulated recorded load weights.
o
PRINT TRUCKn– Prints the truck’s net weight. That is, the
accumulated recorded load weights.
o
PRINT CONTg – Prints the total gross weight of the container and
its load as the arms are raised.
o
PRINT CONT – Prints the empty container weight (the container
tare weight) as the arms are lowered.
o
PRINT RFID – Prints the RFID tag read from the loaded container.
o
PRINT ASSET – Prints the ASSET number of the container.
o
PRT TRACE – Ignore. Used for factory service.
o
COUNTBY – When ENABLED, the printed loads will reflect step
(resolution) value that was configured in the SET
DISPLAY/COUNTBY command. When DISABLED the printed loads
will use the actual load weights measured instead of being rounded
to the nearest COUNTBY Setting programmed for the LM310
display.
o
LINE FEEDS xx – Programs the number of line feeds after every
PRINT TICKET printout (default is 2; 1 min; 10 max).
SERIALnum – Displays the serial number of the LoadMan meter.
The serial number programmed into the meter is only needed when the
LoadMan Load Manager data collection software features are used.
Whenever data is uploaded to the LoadMan Load Manager Software,
LoadMan will add the serial number to every load data record. This
feature is especially useful when maintaining records for a fleet of
trucks and is used to identify which truck the meter is in.
56
Setup and Calibration Mode

SECURITY – When set to “ON”, LoadMan will prompt for a valid
passcode whenever the LM310 meter is placed into SETUP and
CONFIGURATION Mode. When prompted, enter passcode “123”.
At this point, LoadMan has completed the INSTALL portion of the Setup and
Calibration Mode and will continue with the remaining Setup & Calibration
options (SET DEFAULTS, ERASE DATA and TROUBLESHOOTING).

SET DEFAULTS – Reset the LM310 to the factory default settings.
See Table 10. LM310 Factory Defaults below for a listing of the factory
default settings.

Use the PROGRAM key to choose either “DEFAULTS FOR LB?” or
“DEFAULTS FOR KG?” and press the SET PROGRAM key to activate.
 LoadMan responds with the message,
“THIS RESETS TO FACTORY DEFAULTS”.
 Followed by, ”PROCEED?-----> NO”.
 When selecting “YES” and activating with the SET PROGRAM key,
LoadMan responds with the message, “SETTING DEFAULTS”.
LoadMan will abort the process anytime “NO” is selected or if either of
the /SELECT keys is pressed.
57
Setup and Calibration Mode
Table 10. LM310 Factory Defaults
LOADCELLS
SHOW NEG WTs
DISPLAY
DISPLAY UNITS
CYCLE
COUNT BY
ACCOUNTS
PRODUCTS
EVENTS
ASSETS
TARGET SETPT
FLASH LDNAME
FLASH ACCT#
FLASH STOP#
FLASH PRODUCT
FLASH EVENTS
FLASH OVERLD
GEO ROUTE
MODEM
MODEM OPTION
MODEM
CONN
RemoteIP1
RemoteIP2
RemoteIP3
RemoteIP4
GPS
LOG

2
YES
LB / KG
0 SEC
20
0
0
0
0
OFF
NO
NO
NO
NO
NO
NO
NO
NO
USA
600 SEC
74
93
98
177
30 SEC
RECORD
RECORD&PRINT
INCR STOP #
CONTsp
REMOTE SWBOX
ON
ON
30LB / 15KG
OFF
RS232
BLUETOOTH
BAUD RATE
TICKET PRINT
BARCODE READ
PRT LOADNAME
PRT ACCOUNT
PRINT STOP#
PRT PRODUCT
PRT EVENT
PRINT TRUCKg
PRINT TRUCKn
PRINT CONTg
PRINT CONT
PRINT LOAD
COUNTBY
LINE FEEDS
SERIALnum
SECURITY
OFF
9600
ON
ON
NO
NO
YES
NO
NO
NO
YES
NO
NO
YES
DISABLED
2
factory setting
OFF
TARE SETTINGS
TRUCK
0 LB / KG
ERASE DATA – Activating this setup category will permanently erase all data
in LoadMan’s data collection memory.



When set to “YES”, LoadMan responds with the message,
“THIS WILL ERASE ALL LOAD DATA!”,
Followed by, ”PROCEED?-----> NO”.
When selecting “YES” and activating with the SET PROGRAM key,
LoadMan responds with the message, “ERASING ALL DATA” followed by
“LOAD DATA ERASED”.
LoadMan will abort the process anytime “NO” is selected or if either of
the /SELECT keys are pressed.
58
Setup and Calibration Mode

TROUBLESHOOT – Provides detailed sensor, loadcell, communications and
other system information that can be useful for isolating issues. In this
mode, each sensor’s response to a load can be examined in detail, and the
information can be used to manually change calibration settings. Refer to
Table 11.
Use the PROGRAM key to advance through the troubleshooting options,
and press the SET PROGRAM key to select an option to troubleshoot.
Table 11. TROUBLSHOOT Command Options
TROUBLE LOADCELL
TROUBLE COM
Displays individual Cart Lifter loadcell calibration
settings
Provides LoadMan’s communications settings.
TROUBLE VOLTAGE
Displays individual voltage readings.
TROUBLE GPS
Provides current GPS location readings.
TRB LOAD RECORDS
Displays number of load records in LoadMan’s data
collection memory.
Displays individual arm and Cart Lifter Arm Angle
sensor settings and readings.
Provides zero and span information for the Cart
Lifter.
TROUBLE POSITION
TROUBLE CAL

TROUBLE LOADCELL – Select this option with the SET PROGRAM key to
activate and use the SELECT key to advance through the individual
loadcell calibration settings.
CH1 SPAN
CH1
CH1 ZERO
CH2 SPAN
CH2
CH2 ZERO
xxxxxx
xxxxxx LB
xxxxxx
xxxxxx
xxxxxx LB
xxxxxx
Current CH1 span setting
Current CH2 weight reading
CH1 zero offset
Current CH2 span setting
Current CH2 weight reading
CH2 zero offset (xxxxxx =Setting or
measured setting.
TROUBLE COM – Provides detailed information to aid technicians in
59
Setup and Calibration Mode
troubleshooting. Select this option with the SET PROGRAM key to
activate and use the SELECT key to advance through the individual
loadcell calibration settings.

o
CONNECT xxx SEC – Displays the number of seconds until the
meter will attempt a cellular modem Internet connection to upload
record data to the LoadMan Load Management Software. The
default is 600 seconds. Any number up to six digits long can be
specified with the SETUP MODEM/CONN commands. The number
resets automatically if the connection fails within the specified
time.
o
CELLSTATE xxx – Used for diagnosing data collection software
problems. The number shown represents the current state of the
modem, which is used by technicians to help diagnose
communications problems. State “7” is common, meaning that the
modem is powered and ready. State “51” signifies that the antenna
is missing or there is no reception. Although the CELLSTATE number
can be as high as 200, generally any number of 80 and above
means that communications are established. See Table 14. Cell
State Codes and Descriptions
o
o
SIM H: – Represents the first 10 SIM card identifying digits.
SIM L: – Represents the second 10 SIM card identifying digits.
o
RESET BTOOTH – This resets the Bluetooth port to factory defaults.
o
OSversion x.x.xx – This number identifies the operating system
used by LoadMan. (Software updates must be compatible with the
operating system number.)
TROUBLE VOLTAGE – Select this option to read individual voltage levels.
o
VIN
Input voltage.
o
VLC1
Voltage output to Cart Lifter Power
o
VBAT
VBAT is the current output voltage of the onboard
rechargeable battery. A fully charged battery is
2.65V to 2.70V
60
Setup and Calibration Mode
This option also provides temperature voltage readings for the LCD
display:
o
TEMPsensor – xxxx
o
TEMPscaled – xxxx
o
CONTRAST – By reprogramming CONTRAST to a higher value, the
LoadMan display contrast will increase (maximum 1500). Similarly,
lowering to a lower value will decrease the display contrast.

TROUBLE GPS – Select this option to examine current GPS location
readings.
o
LAT deg – Displays the current GPS latitude location reading.
“NO GPS SIG” will display if no signal is available.
o
LON deg – Displays the current GPS longitude location reading.
“NO GPS SIG” will display if no signal is available.
o
SATTELITES – Displays the number of satellites available for
determining GPS coordinates. LoadMan must connect with at least
three satellites to determine the vehicle’s GPS coordinates.
o
ATLTITUDE – Displays the current GPS altitude reading in meters.
o
VEL East – Displays truck easterly velocity in miles-per-hour (mph).
VEL North – Displays truck northerly velocity in miles-per-hour
(mph).
o

o
NextLOG – Displays the number of seconds until LoadMan will next
record the vehicles’ GPS coordinates.
o
RECORDS – Displays the number of GPS records currently in flash
memory. When the ERASE DATA function is executed or after the
LoadMan Load Manager Software collects all the GPS data, this
number will reset to zero. Thereafter, the value is incremented
every time a GPS record is stored in LoadMan’s data collection
memory.
TRB LOAD RECORDS – Displays the number of load records contained in
LoadMan’s data collection memory (RECORDS xxxxxx). When the
ERASE DATA function is executed or after the LoadMan Load Manager
61
Setup and Calibration Mode
Software collects all the load data, this number is reset to zero.
Thereafter, the value is incremented every time a load data record is
stored in LoadMan’s data collection memory.
(A second value, ERASE CTR-xxxxxx, signifying the number of times data
has been erased, is provided for factory troubleshooting.)

TROUBLE POSITION – Choose this troubleshooting option to examine
individual arm sensor settings and readings.
o
o
o
WGH START – Displays the starting set point angle of the weigh-inmotion window. (Factory setting is 0.0 degrees.)
WGH END – Displays the ending set point angle of the weigh-inmotion window. (Factory setting is 75.0 degrees.)
WGH DUMP – Displays the dump load set point angle of the weighin-motion window. (Factory setting is 100.0 degrees).
With most cart tippers these weighing window settings should work
correctly. However, there will be some carts/bins that may come in
sizes that require different weighing window settings. Use these three
programming settings to adjust to cart as necessary.
Custom Adjustment of Weigh-In-Motion Window
The default weigh-in-motion angle assignments were derived from the
experience LoadMan gained working with customers and learning the
most common sized carts used. However, there are carts that might
not “fit” the weigh window of 0, 75 and 100. Especially larger carts
that are taller than the cart tipper and scale. For these larger carts, you
will most likely need to adjust the weigh window.
Here are some guidelines:

Set the WEIGHT START angle where the cart is off the ground 6” to
12”. This might be from 5 to 15.

The WEIGHT END should never be higher than 75.

When necessary, the WEIGH END can be set lower so that the cart
does not start dumping the load before the weigh window has
been completed.

WEIGH DUMP needs to be at least 10 to 25 above the WEIGH
END set point.
62
Setup and Calibration Mode
The weighing window angle set point settings can be programmed using
the / and SET PROGRAM keys.

o
ARM DIRECTION = +/- This display should be used if the arm angle
does not increase in value when the arms are raised. If the arm
angle decreases when the arms are raised, then the ARM
DIRECTION sign should be reversed.
o
ARMS xxx.x DEG – Displays the currently measured arm angle in
degrees.
o
ARM ZERO – The arm’s zero degree calibration constant set when
the arms are zeroed.
o
ArmSTRTup –First cart arm angle measured after passing WGH
START angle programmed going up.
o
ArmENDup – Last cart arm angle measured prior to passing the end
of weigh-in-motion window with the cart going up.
o
ARMENDdn – First cart arm angle measured after passing the end
of weigh-in-motion set point WGH END with the cart going down.
o
ArmSTRTdn – Last cart arm angle measured prior to passing the
WGH START set point weigh-in-motion window while the cart is
going down.
o
Trace – (Service use only)
o
TraceLst – (Service use only)
TROUBLE CAL – Provides zero and span information to assist with
troubleshooting and calibration of the weight sensors.
o
ZEROUpCAL – A zero calibration adjustment for weights measured
as the cart arm is raised. Normally this is zero but if going up there
is a persistent zero error, then you can program a constant zero
63
Setup and Calibration Mode
offset that will be added to every measurement going up.
o
ZERODnCAL – A zero calibration adjustment for weights measured
as the cart arm is lowered. Normally this is zero but if coming
down there is a persistent zero error, then you can program a
constant zero offset here that will be added to every measurement
coming down.
o
SPANUpCAL – The SPAN calibration adjustment for weights
measured as the arm is raised. Raising this number 10% will cause
the scale to read 10% more going up.
o
SPANDnCAL – The span calibration adjustment for weights
measured as the arm is lowered. Raising this number 10% will
cause the scale to read 10% more coming down.
o
SampDevUp – 500 is recommended. This is a setting to weed out
spikes in the weigh-in-motion cycle going up.
o
SampDevDn – 500 is recommended. This is a setting to weed out
spikes in the weigh-in-motion cycle coming down.
The following displays appear in the TROUBLE CAL sequence, but are for
technical reference only.
SampUpRaw
SampUpC1
SampUpC2
SampUpC3
LoadUpRaw
LoadUpC1
LoadUpC2
LoadUpC3
SampDnRaw
SampDnC1
SampDnC2
SampDnC3
LoadDnRaw
LoadDnC1
LoadDnC2
LoadDnC3
64
NetRaw
NetC1
NetC2
NetC3
Initial Startup and Calibration Procedures
INITIAL STARTUP AND CALIBRATION
The instructions in this section provide a step-by-step process for verifying and
calibrating a newly installed LoadMan Cart Lifter Weigh-In-Motion system.
Follow these steps to insure proper installation and operation.
1.
2.
3.
4.
5.
Verify Wiring
Power On
Verify Arm Angle Sensor
Calibrate Arm Angle
Verify Arm Angle Measurements
respond correctly
6.
7.
8.
9.
Verify Weigh-In-Motion Response
Calibrate System for ZERO CART
Load
Calibrate System Under Load
Fine Tune Span Adjust
1. Verify Wiring
Begin by verifying that the electronics are wired per the wiring diagram shown in
Figure 8 near the end of this manual.

Positive 10VDC to 28VDC should connect to the LoadMan 310 Meter at
pins 1 and 2 to power the system.

Verify connection of the cable harness from the LoadMan meter to the cart
lifter weigh-in-motion assembly.

Then verify the connection of the cable harness from the cart weigh-inmotion assembly to the arm weigh-in-motion assembly.

Finally, verify that the cart lifter loadcells are connected to the cart lifter
weigh-in-motion assembly.
2. Power On
With power off, briefly press the front panel POWER button. LoadMan will
power on and sign on with the display messages “LOADMAN”, followed by
“PROG VERSION X.X” (where X.X is the software version). LoadMan will then
confirm that the weigh-in-motion equipment is ready for operation with
message, “READY TO WEIGH!”.
65
Initial Startup and Calibration Procedures
When power is applied, the message “CYCLE ARMS” may appear if the cart
lifter is not in the READY TO WEIGH position. Repositioning the cart lifter
arm to the normal Ready to Weigh position will return the display to
“READY TO WEIGH”.
3. Verify Arm Angle Sensor
To verify the Arm Angle sensor is responding correctly, first enter the Setup &
Calibration Mode as described earlier and use the SELECT key to locate the
TROUBLESHOOT display.
Weigh-In-Motion Window

Press the PROGRAM key two times to locate the TROUBLE POSITION
option and press the SET key to activate. “WGH START 00.0” should display
on the meter display. WGH START is the programmable angular set point
where the weigh-in-motion window starts the weighing of each load.

If it isn’t programmed to 00.0, use the PROGRAM keys to reset the
angle to 00.0 and press SET to activate the value.


Press the SELECT key to display “WGH END 75.0”. WGH END is the
programmable angular set point where the weigh-in-motion window ends
the weighing of each load.
If it is not programmed to 75.0, use the PROGRAM keys to reset the
angle to 75.0 and press SET to activate the value.
66
Initial Startup and Calibration Procedures


Press the SELECT key to display “WGH DUMP 100.0”. WGH DUMP is the
programmable angular set point where LoadMan “stores” the recording of
the net load weight.
If it is not programmed to 100.0, use the PROGRAM keys to reset the
angle to 100.0 and press SET to activate the value
Custom Adjustment of Weigh-In-Motion Window
The default weigh-in-motion angle assignments were derived from the
experience LoadMan gained working with customers and learning the most
common sized carts used. However, there are carts that might not “fit” the
weigh window of 0, 75 and 100; especially larger carts which are taller than
the cart tipper and scale. For these larger carts, you will most likely need to
adjust the weigh window.
Here are some guidelines:

Set the WEIGH START angle where the cart is off the ground 6” to 12”. This
might be from 5 to 15.

The WEIGH END should never be higher than 75.

When necessary, the WEIGH END can be set lower so that the cart does not
start dumping the load before the weigh window has been completed.

WEIGH DUMP needs to be at least 10 to 25 above the WEIGH END set
point.
4. Verify Cart Lifter Load Cells Respond Correctly
To verify the loadcells are responding correctly, first enter the Setup &
Calibration Mode and use the SELECT key to locate the TROUBLESHOOT
display.

Press the PROGRAM key to locate the TROUBLE LOADCELL option and
press the SET key to activate.
67
Initial Startup and Calibration Procedures






The message, “CH1 SPAN 400,000” should be displayed. This is the normal
sensitivity used for the CH1 left cart lifter loadcell and should not be
changed.
SELECT till you get to CH2 SPAN which should also display 400,000.
If either of these values is incorrect, use the PROGRAM keys to reset
either SPAN and press SET to activate the value.
Press SELECT to display “CH1 xxxx.x LB” where xxxxx.x is the current
weight reading of the CH1 loadcell. It is calibrated in LBs or KGs.
Move the cart lifter arms so that the cart lifter plates are in the vertical
position and verify the CH1 and CH2 loadcells are reading near 0 lbs.
Hang a load on the cart lifter or push on it and both CH1 and CH2 loadcells
should go positive. If not, then you need to swap the CH1 and CH2 loadcell
connectors on the Cart 310 Electronics Box.
5. Calibrate Cart Lifter Arm Angle
If not already done, begin this procedure by first cycling the arms until the
message “READY TO WEIGH” is displayed.







Enter the Setup & Calibration Mode.
Press the SELECT key until “SET ZERO?--->NO” is displayed.
Press the PROGRAM key until “ZERO ARM ANGLE?” is displayed and then
press SET to activate.
The display now shows several sequential messages; “THIS IMPACTS YOUR
CALIBRATION” and “PROCEED?---->NO”.
Use the PROGRAM key to choose “YES”, and activate with the SET key.
LoadMan displays, “POSITION ARMS TO ZERO ARM ANG” and
“READY?----->NO”.
Move the cart lifter arms till the cart lifter mounting plates are perfectly
vertical (recommend using a level for this step), to set the arm angle sensor
to read zero at this position.
68
Initial Startup and Calibration Procedures
Once the arms are in position, use the PROGRAM key to choose “YES”,
and activate with the SET key.
LoadMan displays, “ZEROING ARM ANG!” while it is reprogramming the start
position of the weigh-in-motion window; and is finished “ZERO COMPLETE” is
displayed.


To verify this process worked correctly, enter the TROUBLE POSITION portion of
the TROUBLESHOOT display:

Now verify that the “ARMS xxxxx.x DEG” reads very near zero degrees when
the cart lifter mounting plates are perfectly vertical.

Furthermore, the arm angle (ARMS) should become more positive when
the arms are raised higher.

If the arm angle reads negative (-) as the arms are raised, you will be able
to correct this error in Step 6.
6. Verify Angle Measurements Respond Correctly
Verify Cart Lifter Arm Angle Response

Enter the TROUBLE POSITION portion of the TROUBLESHOOT display.

Press the SELECT key until the display reads, “ARMS xxxx.x DEG”.

Lift a cart from the ground until the arm angle reads 0.0 degrees. The cart
lifter mounting plates should be perfectly vertical when the arm angle
reads zero degrees. Also, the arm angle should increase as the arms are
raised and decrease as the arms are lowered. If so, ten proceed to Step 7.

If the direction is wrong, toggle the arm direction sign:

ARM DIRECTION = +/- This display should be used if the arm angle
does not increase in value when the arms are raised. If the arm angle
decreases when the arms are raised, then the ARM DIRECTION sign
should be reversed by using the PROGRAM key to choose “YES”, and
activate with the SET key.
7. Verify Weigh-In-Motion Response
To verify the weigh-in-motion response, first exit the Setup & Calibration Mode:

Use the SELECT key and choose the display, “EXIT SETUP?-->NO”.

Use the PROGRAM key to change “NO” to “YES” and press SET to activate.
LoadMan should now be in the Normal Operating Mode.

The display should now read, “READY TO WEIGH!”.
69
Initial Startup and Calibration Procedures

Raise the cart tipper up through a complete weighing cycle. If everything is
working properly the system should respond with the following:
o WEIGHING LOAD! while the arms are in the weigh-in-motion weighing
window.
o GROSS xxxxx LB as the arms pass the end of the weigh-in-motion
window.
o DUMP xxxxx LB and LOAD xxxxx LB (alternating) when the arms pass up
through the dump set point. This message indicates that the record
load data and auto accumulator functions have been activated.

Now lower the cart tipper and the display should show:
o LOWER ARMS while passing down through the dump set point.
o WEIGHING TARE as the arms pass down through the weighing window.
o NET xxxxx LB after the arms have passed below the start point of the
weigh-in-motion widow. This is the net payload that was measured and
dumped into the vehicle.
o RECORDING WEIGHT! – indicates that the weighing process is complete
and the load has been recorded.
In a few seconds LoadMan will indicate that it is ready for the next load
with the message, “READY TO WEIGH!”.
If all of this has worked correctly, proceed to the next step. If not, return to
step 3, ”Verify Angle Sensors are Responding Correctly”, and redo the
process until all is performing correctly.


Fine Tuning Loadcell Accuracy – LEARN ZERO
LEARN ZERO? – Learn Zero is the process of “custom learning” the zero response
of the cart tipper’s loadcells; fine tuning the accuracy of each loadcell. This is
accomplished by a series of lifts (12-15 lifts are recommended). Without this
procedure the loadcell measurements could be inaccurate and misleading.
The process is quite simple. Just follow the LoadMan display instructions:

Activate with the SET PROGRAM key.

REMOVE CART! – Remove the cart for the entire LEARNING process.

RAISE ARMS!

LEARNING ZERO UP

LOWER ARMS!

LEARNING ZERO DN

CYCLES – Displays the number of LEARN cycles completed.
70
Initial Startup and Calibration Procedures
The above process should be repeated from 12-15 times to allow LoadMan to
fully determine each loadcell’s zero response; fine tuning the accuracy of each
loadcell.
When finished repeating this process, simply let the cart lifter rest at zero.
LoadMan will provide screen instructions to complete the LEARN process:

UPSELECT IF DONE - SELECT.

SAVE ZERO? – Use the PROGRAM programming key to choose “YES”, and
confirm with the SET PROGRAM key.

SAVING ZERO DATA – Wait for LoadMan to process before activating any
further keys.
8. Calibrate System Under Load
LEARN SPAN? – Learn Span is the process of “custom learning” the calibration of
the cart tipper’s loadcells. This is accomplished by a series of lifts (12-15 lifts are
recommended). Without this procedure the loadcell measurements could be
inaccurate and misleading.
The process is quite simple. Just follow the LoadMan display instructions:

Activate LEARN SPAN with the SET PROGRAM key.

ENTER SPAN CAL (Factory default is 400LB). Press SELECT key to continue.

ENTER CAL LOAD – This is the calibrated weight of a cart loaded with a
known scale weight from another calibrated scale. This load should be
tightly secured within the cart for safety, and to make certain there is no
abrupt bouncing of the container’s contents during the calibration
procedure.

Use the /PROGRAM programming keys to enter the weight reading
obtained from the calibrated scale. Press the SET PROGRAM key to save,
and press SELECT key to continue.

LoadMan will respond with LOAD CAL WEIGHT! and has initiated the LEARN
SPAN calibration process:




RAISE ARMS!
LEARNING SPAN UP
LOWER ARMS!
LEARNING SPAN DN
71
Initial Startup and Calibration Procedures

CYCLES – Displays the number of LEARN cycles completed.
The above process should be repeated from 12-15 times to allow LoadMan to
fully determine each loadcell’s span; fine tuning the calibration of each loadcell.
When finished repeating this process 12 to 15 times, simply let the cart lifter rest
at zero. LoadMan will provide screen instructions to complete the LEARN
process:

UPSELECT IF DONE - SELECT.

SAVE SPAN? – Use the PROGRAM programming key to choose “YES”, and
confirm with the SET PROGRAM key.

SAVING SPAN DATA – Wait for LoadMan to process before activating any
further keys…this may take few moments.
Calibrate System for ZERO CART LIFTER LOAD

Begin this step by entering the INSTALL section of the Setup & Calibration
Mode and program the LoadMan meter to “SHOW NEGATIVE WEIGHTS” by
choosing “YES”. (Later, after completing this calibration, the meter can be
reprogrammed to hide negative net weights if desired.)

In order to obtain the most accurate calibration results, advance forward to
the INSTALL/SET DISPLAYS section and set the COUNT BY value to one (1);
using the PROGRAM key to choose “1”, and activate with the SET key.

Remove any cart off the cart lifter, EXIT SETUP, and return to normal
operating mode.

With LoadMan showing READY TO WEIGH, press the SELECT key to find
the PROGRAM FUNCTION display. Press the PROGRAM key to locate the
ZERO CART LOAD display; press SET to activate; and follow this procedure:
o LoadMan starts this process with the messages “REMOVE CART LOAD” and
“SET ARM ANGLE = 0”.
o Position the cart lifter arms until the arm angle is within a degree of
zero. LoadMan will provide instant feedback on the current Arm±
angle. When the arm angle is within a degree of zero for a couple
moments, LoadMan stops providing ± angle feedback and displays ZERO
COMPLETE – indicating the process completed successfully.
o Try a few lifts with no cart on the cart lifter and you should read zero
going up and zero coming down or very close to that.
72
Initial Startup and Calibration Procedures
Calibrate System for ZERO CART LIFTER LOAD Switch
LoadMan also features a ZERO CART LOAD switch that is mounted on the left
outside plate of the cart lifter scales. This light/switch allows the operator to
work at the rear of the truck, reading the green strobe light while leveling the
cart arm angle to zero.
Depressing this switch initiates the zero load process that was just described
above. And it also features a green light strobe that provides real-time feedback
on the cart angle. The closer the angle to zero, the faster the light flashes. And
when the fork angle is between 0 and +/-1, the light will hold steady.
When finished, the light provides a high frequency “chattering” strobe indicated
that the Zero Weight is calibrated accurately. When finished, depress the switch
to turn off the light and the zeroing process.
Calibrate Cart Lifter Gross “Going Up”
Verify that the cart lifter load measured going up is calibrated to zero. Begin this
process in the READY TO WEIGH state.

With no load on the cart lifter, slowly raise the cart lifter arms through the
weighing window to verify if the GROSS xxxxx LB measurement going up is
zero.

Perform several slow lifts going up to find an average gross weight. If zero,
then skip this next calibration step.

If the average gross weight going up is not zero, the meter should be finetuned to allow for the variance from zero.
o Go to the TROUBLESHOOT section of the Setup & Calibration Mode and
choose the section titled TROUBLE CAL.
This calibration adjustment will ALWAYS be listed in pounds even
when LoadMan is using KG in the normal operating mode.
o
Fine tune the ZEROUpCAL setting to account for the average gross
73
Initial Startup and Calibration Procedures
weight variance. For example, if the average gross weight is +10 LB
going up, then increase the ZEROUpCAL by 10 counts from the current
setting. (In KG mode, change the count 2.2X larger than the LB mode
value displayed.)
For this example program ZEROUpCAL to 10 using the PROGRAM
keys, and activate with the SET key.
o
o
After programming the adjustment EXIT SETUP; return to the READY TO
WEIGH state.
Verify that the GROSS xxxxx LB averages zero (0) over several slow test
weights. Repeat this process until an average reading of zero is
measured.
Calibrate Cart Lifter Net “Going Down”
After LoadMan returns to the READY TO WEIGH display, verify if the arm load
going down is calibrated to zero:

With no load on the cart lifter, slowly raise, and then very slowly lower the
arms through the weigh-in-motion window to verify if the NET xxxxx LB
measurement going down is zero.

Do several measurements going down to find an average net weight. If
zero, then skip this next calibration step.

If the average net weight going down is not zero, the meter should be finetuned to allow for the variance from zero.
o Go to the TROUBLESHOOT section of the Setup & Calibration Mode and
choose the section titled TROUBLE CAL.
This calibration adjustment will ALWAYS be listed in pounds even
when LoadMan is using KG in the normal operating mode.
o
Fine tune the ZERODnCAL setting to account for the average net weight
variance. For example, if the average net weight is +10 LB going down,
then adjust the ZERODnCAL 10 counts from the current setting. (In KG
mode, change the count 2.2X larger than the LB mode.)
For this example, program ZERODnCAL to 10 (ten) 10 using the
PROGRAM keys, and activate with the SET key.
o
After programming the adjustment, EXIT SETUP; and return to the
74
Initial Startup and Calibration Procedures
o
READY TO WEIGH state.
Verify that the NET xxxxx LB averages zero (0) over several slow test
weights.
9. Fine Tune Span Adjust
This step requires a loaded cart with a known weight; so have a cart weighed on
a known accurate scale. The cart should be loaded with a good size weight that
represents at least 80% of the cart lifter’s capacity. This load should be tightly
secured within the cart for safety, and to make certain there is no abrupt
bouncing of the container’s contents during the calibration procedure.

When LoadMan is READY TO WEIGH, pick up the loaded container and
move through the weigh-in-motion window at a slow speed. Do this
several times to obtain the average GROSS xxxxx LB reading going up and
note this average gross weight reading.

Next, perform a span truck calibration process.
o Use the PROGRAM key to select “SPAN TRUCK?” and activate with the
SET PROGRAM key.
o LoadMan responds with directions to “ENTER METER LOAD”.
o Use the programming keys to enter the average of weight readings that
were just obtained from the LoadMan meter. Press the SET PROGRAM
key to save.
o Press the SELECT key and LoadMan will respond with the directions,
“ENTER CAL LOAD”.
o Use the programming keys to enter the weight reading obtained from
the calibrated scale. Press the SET PROGRAM key to save.
o Now press the SELECT key and LoadMan will respond with the
directions, “DO AUTOCAL?-->NO”. This display is confirming that the
weights have been entered properly.
o To confirm that the weight entries are correct, select “YES” and press
SET.
o LoadMan will now complete the SPAN calibration and confirm with,
“DOING SPAN ADJUST” and “SPAN COMPLETE!”.
o EXIT SETUP and return to the READY TO WEIGH state.

At the READY TO WEIGH state, slowly pick up an empty container and move
up through the weigh-in-motion window.
75
Initial Startup and Calibration Procedures


Lower the container down through the weigh-in-motion window at the
slowest speed. Do this several times to obtain an average NET xxxxx LB
reading going down.
If the NET reading is not zero (0) then use to the TROUBLE CAL section of
the TROUBLESHOOT Setup & Calibration category to either increase or
decrease the SPANDnCAL value to correct the error using the ratio
calculation:
Ratio = Gross Weight Going Up ÷ (Gross Weight Up – Net Weight Down)



For example, if the average “going down” NET weight reading is +20 LB and
the average “going up” GROSS reading was 720 LB, then the system going
down is measuring only 720-20 = 700 LB. So the SPANDnCAL value needs to
be adjusted by the ratio: 720÷700 = 1.02857
Reprogram SPANDnCAL by multiplying the current SPANDnCAL value
times(x) the weight ratio. Then EXIT SETUP.
Continue this calibration process until the weights going up and going down
are equal, and the empty cart NET xxxxx LB reading is zero (0).
Once this calibration procedure is completed, the SPANUpCAL and the
SPANDnCAL values may not be equal, but they should not be different by
more than 500 counts for a system that is operating properly.
REMINDER – During these calibration procedures, COUNT BY was
programmed to 1 and SHOW NEGATIVE WTS was set to YES. Reprogram
either or both these values (if desired) for the normal operating of the
weighing system.
76
Troubleshooting Guide
TROUBLESHOOTING GUIDE
This section of the manual provides a guide to troubleshooting common issues
with the LoadMan Cart Lifter Weigh-In-Motion System. It is assumed that the
reader has already become familiar with using the programming keys and
understands how to access Setup & Calibration functions that are all detailed in
the chapter titled Setup & Calibration Mode.
LoadMan must receive all sensor signals in order to display the valid weighing
display message “READY TO WEIGH”. The four sensor signals are:
 Left Cart Loadcell Signal
 Right Cart Loadcell Signal
 Cart Arm Angle Sensor Signal
If any of these signals are not detected, then LoadMan suspends all weighing
functions and enters into a Troubleshooting Diagnostic Mode. When LoadMan
enters this mode, one to three diagnostic messages will be displayed:



NO ARM SENSOR!
NO RGHTCART SIG!
NO LEFTCART SIG!
or
or
or
ARM SENSOR OK!
RGHTCART SIG OK!
LEFTCART SIG OK!
1. NO ARM SENSOR!
This message is displayed when there is no communication to the arm weigh-inmotion sensor. The arm weigh-in-motion assembly (ARM310) contains a
microcomputer and arm angle sensor. The microcomputer communicates the
cart lifter arm angle measurement to the LoadMan CART310 box mounted
between the cart lifter plates. The CART310 sends all the results to the in-cab
meter for processing and display. If LoadMan cannot detect the arm assembly
microcomputer, then there are three possible sources to the problem:
77
Troubleshooting Guide
a)
The cable connection from the CART310 Box to the arm weigh-inmotion assembly box has failed or is not connected.
b) The arm weigh-in-motion assembly has failed. This unit is a potted
assembly to survive harsh outdoor environments. The unit is not fieldrepairable and must be replaced or rebuilt.
c)
The LoadMan meter has failed. The meter is not a field-repairable for
this type of communication failure. It must be replaced with a new or
rebuilt unit.
2. NO LEFTCART SIG! and NO RGHTCART SIG!
If these two messages are displayed, first make certain that the cable connecting
the LM310 Loadman Meter is properly connected to the CART 310 Box mounted
between the cart lifter plates.
a)
The CART310 weigh-in-motion assembly contains the digital to analog
converters for both the right and left cart lifter loadcells and receives
the cart lifter arm angle from the arm sensor box (ARM310) mounted
on the cart lifter arms. Check the cable that connects the LoadMan
meter (LM310) to the CART310 box mounted between the cart lifter
mounting plates.
b) If the cables are connected securely, then check the cable harness for
damage and perform a continuity check.
c)
If the cable is OK but the messages NO LEFTCART SIG! and NO
RGHTCART SIG! still display:
o Attempt to disconnect both loadcell cables that plugged into the
CART310 weigh-in-motion box to eliminate a fault in one or both of
the loadcells.
o If after unplugging both loadcells the messages NO LEFTCART SIG!
and NO RGHTCART SIG! still displays, then the CART310 weigh-inmotion box has most likely failed or the LoadMan Meter (LM310).
o The CART310 weigh-in-motion module is a potted assembly to
survive harsh outdoor environments. The unit is not field-repairable
and must be replaced or rebuilt.
78
Troubleshooting Guide
3. NO LEFTCART SIG! but RGHTCART SIG OK!
LEFTCART SIG OK! but NO RGHTCART SIG
If one of the loadcell signals is present but the other is not, then it is most likely
that one of the loadcells has failed. Swap the two loadcells on the weigh-inmotion assembly and see if the error message reverses. If it does, then one of
the loadcells has failed. Swap the loadcells again to make certain which loadcell
has failed. When isolated, replace the failed loadcell.
4. Load Measurements Inaccurate
Load measurements that are not repeatable or are inaccurate can be traced to
one of the following:



One or both loadcells have failed.
The CART310 digital to analog converter (CanCoder) has failed.
Cart arm angle measurements are faulty.
Check Loadcell Response and CART310 CanCoder

Press the PROGRAM key to locate the TROUBLE LOADCELL option and
press the SET key to activate.

Press SELECT to display “CH1 xxxx.x LB” where xxxxx.x is the current
weight reading of the CH1 loadcell.

Move the cart lifter to zero arm angle, which will cause the plates to be in a
vertical position. The CH1 load should read near zero (0) weight

Pick up an empty container and verify that the loadcell responds in a
positive direction.
o If the loadcell responds in a negative direction under load, then swap
the loadcell connectors on the CART310 Box as they are connected to
the wrong loadcell connectors.
o If the loadcell reading is bouncing hundreds (100’s) of counts, drifting,
or will not repeat the same reading under a given container load, then:

either the loadcell has failed;

or the cart lifter CART310 weigh-in-motion analog to digital
converter has failed;

or a loadcell cable has been damaged;

or the connector is loose and has moisture/dirt in the contacts.
Check for damaged loadcell cables or dirty contacts. If the contacts are
dirty then the pins should be cleaned with isopropyl alcohol and a Q-tip.
The signals on these pins are on the order of less than one millionth of a
79
Troubleshooting Guide
volt so any film residue or moisture on the contacts can cause the
loadcell signals to drift wildly.
If the problem persists after cleaning the contacts then the Cart310
CanCoder weigh-in-motion box should be replaced. If replacing the
Cart310 weigh-in-motion box does not fix the problem then the
loadcells should be replaced.

Press SELECT to display the message, “CH2 xxxx.x LB” and repeat the
above procedure for the CH2 loadcell.
Checking Cart Lifter Arm Angle Measurements
LoadMan relies heavily on the accuracy of the cart lIfter arm angle measurement
to determine accurate weight measurement results. The loadcell weight
measurement response is influenced by the cart lifter arm angle. Any error in
the arm angle will have a major effect on the overall accuracy of the weighing
system.
Furthermore, the arm angle informs LoadMan when to look at the cart lifter
loadcell signals. Any error in the arm angle can cause LoadMan to look at the
loadcell weight measurement response in the wrong part of the weighing cycle.
To check on the arm angle calibration:

While still in the TROUBLE POSITION option of the TROUBLESHOOT Setup &
Calibration category, view the current arm angle, “ARMS xxxx.x DEG”.

The arm angle should read zero degrees when the cart lifter has lifted the
cart off the ground near a foot.

If not, then got to step 5 of the Initial Startup and Calibration Procedures
and follow the directions for calibrating the arm angle.
80
Collecting Load Data
COLLECTING LOAD DATA
When a load is recorded, load data is stored into LoadMan’s data collection
memory. The load information is recorded and stored as shown in Table 12.
Table 12. Recorded Load Data
LOAD DATA
CONDITIONS FOR RECORDING DATA
Date & Time
Load Name
Optional (INSTALL/DISPLAYS/ACCOUNTS)
Account Number
Stop Number
Optional (INSTALL/DISPLAYS/ACCOUNTS)
Container Gross Weight
Load Weight (Dumped Load)
Container Net Weight (Empty)
Net Truck Weight (Payload Weight)
Product
Optional (INSTALL/DISPLAYS/PRODUCT)
Event
GPS Coordinates
Optional (INSTALL/DISPLAYS/EVENT)
If GPS modem and signal available
After each recording of a load, LoadMan sequences (when auto sequence
enabled) to the next Stop Number and its corresponding Load Name and
Account Number, and is therefore automatically set up for the next collection.
Out-of-Sequence or Unplanned Collections
It may sometimes be necessary to collect a load out-of-sequence or to record a
load that was unplanned during a collection route. There are several options
available through the front panel PROGRAM buttons for these and similar
situations.
81
Collecting Load Data
Programming the STOP# Display
If a printed copy of the route schedule is available, then the stop numbers will be
listed for each stop on the route. Use the route schedule to find the stop number
of the account that needs collected and recorded out-of-sequence. Then use the
SELECT and PROGRAM front panel keys to select the new stop number before
recording a load.
For example, LoadMan is currently displaying STOP #45, but instead, STOP #198
needs to be collected and recorded. Using the /SELECT keys, locate the
STOP # display; then use the /PROGRAM keys to change #45 to #198. This
will direct LoadMan to go directly to Stop #198 and the corresponding load
name and account number for the stop.
If a stop number is entered that is not found in the route list (i.e., a stop
number that is higher than any on the list) then LoadMan will display the
highest stop number in the route list.
Programming the ACCOUNT # Display
If the account number is known, use the SELECT and PROGRAM front panel keys
to enter the account number before recording the load. Then, when the SET
PROGRAM key is pressed, LoadMan will search the downloaded route list for the
entered account number. If the account number is found in the downloaded
route list, LoadMan will display/confirm with the associated stop number and
account number.
If the account number is not found in the downloaded route list, then LoadMan
automatically creates the new account and displays the message “CREATING
ACCOUNT”; followed by the display of a new stop number and the newly created
account number. The new stop number will be added to the downloaded route
list, along with the new account number, and a newly created load name
“UNPLANNED STOP XX”; where XX represents the number of unplanned stops in
memory. This new stop number, account number and load name will be added
after the last stop in the currently downloaded route list.
Selecting a Load Name Using the LOAD NAME Display
To select a specific load name from the list of downloaded route load names,
first use the /SELECT keys to locate the current LOAD NAME display. The
PROGRAM key will sequentially display the next load name from the route list.
A flashing curser will indicate that LoadMan has entered the Program Operating
Mode. Pressing the PROGRAM key will sequence forward to the next load
82
Collecting Load Data
name, while the PROGRAM key will sequence in reverse. Press the SET
PROGRAM key to select and load a displayed load name.
Recording a Product
Some companies will download routes that include specific product names for
describing their pickup services (e.g., cardboard, recycles, garbage, yard
clippings, etc.). To choose and record a product for the current Stop #:




PRODUCT displays must first be enabled with the SET DISPLAY/FLASH
PRODUCT command.
Locate the PRODUCT display using the /SELECT keys.
Locate the particular product name using the /PROGRAM keys.
Activate the product name with the SET PROGRAM key.
When the load is recorded, the product name will be recorded into LoadMan’s
data collection memory along with the stop #, account name, account number
and any other enabled route options.
Once a product name has been selected, it will remain in effect for all
subsequent load recordings. The product name should be re-programmed
whenever the product condition changes.
Recording Unexpected Events
Sometimes a problem/event will occur in the process of picking up or delivering
a load and it is valuable to record that event for a particular route stop (e.g., no
container, road blocked, gate locked, etc.). To choose and record an Event for
the current Stop #:

EVENT displays must first be enabled with the SET DISPLAYS/FLASH EVENT
command.

Locate the EVENT display using the /SELECT keys.

Locate the particular problem/event name using the /PROGRAM keys.

Activate the event name with the SET PROGRAM key.
When the load is recorded, the event condition will be recorded into LoadMan’s
data collection memory along with the stop #, account name, account number
and any other enabled route options.
Once an Event condition has been selected and recorded, it will revert back
to the NO EVENT condition for all subsequent load recordings. New event
conditions should be re-programmed anytime an event is encountered and
before a load is picked up and recorded.
83
Collecting Load Data
84
Wiring Diagram
Wiring Diagram
Figure 8. LM310 Wiring Diagram for Cart Based Weight System
85
Error Messages
Appendix A – Error Messages
Table 13. Table of Error Messages
Error Message
ABORTING CAL
ABORTING ZERO
AUTOCAL ERROR #1
ABORTING TRK CAL
NO ARM SENSOR!
NO LEFTCART SIG!
NO RGHTCART SIG!
SECURITY FAILED
ZERO COMMAND FAILED
Condition and Possible Resolution
Process for calibrating the Span has been
interrupted. Repeat the process.
Process for zeroing arm or load has been
interrupted. Repeat the process.
When calibration is attempted, LoadMan will
make one final check to make sure things are
acceptable.

If the SPAN numbers go to zero (0) then there
is a problem.

Likewise if the SPAN goes to values greater
than 999,999 then there is a problem.
If this occurs, LoadMan aborts the AutoCal and
reports an Error 1 message; meaning that that
AutoCal failed due to an incorrect entry.
Message displayed when there is no
communication to the Arm Weigh-In-Motion
sensor. See section titled Troubleshooting Guide.
No signal from the left cart lifter loadcell. See
section titled, Troubleshooting Guide.
No signal from right cart lifter loadcell. See section
titled Troubleshooting Guide.
Security passcode is incorrect. Setup & Calibration
cannot be accessed without a correct security
passcode.
Process for zeroing the loadcells has been
interrupted or took too long. Repeat the process.
86
Cell State Codes
Appendix B – Setup & Configuration Command Tree
Figure 9. Setup & Configuration Command Tree
87
Cell State Codes
Figure 10. Setup & Configuration Command Tree (Page2)
88
Cell State Codes
TROUBLESHOOT
TROUBLE CAL?
ZEROUpCAL xxxxxx
ZERODnCAL xxxxxx
SPANUpCAL xxxxxx
SPANDnCAL xxxxxx
SampDevUp xxxxxx
SampDevDn xxxxxx
SampUpRaw
SampUpC1
SampUpC2
SampUpC3
LoadUpRaw
LoadUpC1
LoadUpC2
LoadUpC3
SampDnRaw
SampDnC1
SampDnC2
SampDnC3
LoadDnRaw
LoadDnC1
LoadDnC2
LoadDnC3
NetRaw
NetC1
NetC2
NetC3
TROUBLE POSITION
WGH START x.x
WGH END x.x
WGH DUMP x.x
ARM DIRECTION= -/+
ARMS x.x DEG
ARM ZERO -/+xx
ArmSTRTup x.x
ArmENDup x.x
ArmENDdn x.x
ArmSTRTdn x.x
Trace
TraceLst
TRB LOAD RECORDS
RECORDS xxxxxx
ERASE CTR x
Figure 11. Setup & Configuration Command Tree (Page3)
89
Cell State Codes
Figure 12. Setup & Configuration Command Tree (Page4)
90
Cell State Codes
Appendix C – Cell State Codes and Descriptions
Table 14. Cell State Codes and Descriptions
Code Description & Meaning
0
1
2
3
6
7
10
11
12
20
21
30
31
40
41
50
51
60
61
70
80
81
82
83
84
85
86
87
88
89
90
92
Modem not detected
TCPInit is attempting 1st try to get an "ate" Response.
TCPInit is attempting 2nd try to get an "ate" Response.
Good ‘ate” response, starting SIM Card Read
SIM Card Number agrees with the one previously Stored in Flash
Memory
New SIM Card Number was detected. Flash Memory was erased and
the New SIM Card Number was stored to Flash Memory
No response to attempt to startup modem
Modem did not open, Stopping Stack
Modem did not open, Restarting Stack
Modem is ready to accept all AT Commands
Modem did not respond to 100ms Segmentation Command
Open GPRS Bearer
GPRS Bearer failed to Open
Set GPRS APN Name for USA or Canada
Modem failed to receive APN Name
Start GPRS Bearer
GPRS Bearer failed to start
Create TCP Client on IP 74.93.98.177 Port 57719
Modem failed to Create a TCP Client
Connected, setup to start exchanging data
Connected to Remote IP and in Data exchange mode
Responding to an Identify command from LFM
Modem did not Respond properly to Command Mode Command
Modem did not respond properly to Disconnect Command
Modem did not respond properly to Stack Close Command
Received <esc>tke Command - Erase Data
Received <esc>tkd Command – Disconnect
Sent Disconnect Command to Modem
Send Close Stack Command to Modem
Received <esc>tkt Command - Update Time of Day
Received <esc>tk1 Command - Start Route Download
Received Length and Start of Route Download
91
Cell State Codes
93
94
100
110
160
165
167
169
170
190
200
Route Download has completed successfully
Timeout occurred during Route Download
Received <esc>tk2 command - Start Data Dump
Responded to a SIM Card Read
Received <esc>tk3 command for GEO Route download
Received first 22 bytes &sending ACK command for Geo Route
Download
Received first 18 bytes &sending ACK command for Geo Route
Download
Ready to receive block during Geo Route Download
End of Geo Route Download
Geo Route Load error
Completed
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Downloading LoadMan Meter Software
Appendix D – Downloading LoadMan Meter Software
A circumstance could take place that might require an update to the LoadMan
meter software that is running in the LM310 Meter, CART310 Box and/or the
ARM310 Box.
Connecting PC/Laptop to LM310
Step1: Install LoadMan Load Management Software (LLM)
LoadMan provides an unlicensed version of its software as a platform for
connecting and programming the LoadMan electronics like the LM310 and the
ARM310. A copy of this software can be obtained from an Authorized LoadMan
Dealer. Territory dealers are listed on the LoadMan website:
http://loadman.com/dealer-listing/.
Step 2: Connect Windows PC to LM310 Display
There are two types of connectors to connect a Windows PC/Laptop to the
LM310 display.
 A direct serial connect between a PC COM port and the LM310 port#1 serial
port.
<or>
 A wireless Bluetooth connection between a PC
COM port and the LM310 Bluetooth port. A
common device to repurpose a USB COM port to
Bluetooth is the Parani SD100. For our
93
Figure 13. Parani
SD100 USB to
Bluetooth
Downloading LoadMan Meter Software
demonstration, we’ll use Bluetooth.
Step 3: Identify the PC’s Serial Communications Port
After the serial or Bluetooth connector has been attached to the PC, you must
learn the exact COM port number that is being used by reviewing the Windows
Device Manager Table.
To access Device Manager, use any of the following (3) methods (depends on
which Windows O/S you are using):
 Click Windows Start Button in lower left corner
o
Click Run,
o
Then type devmgmt.msc
<or>
 Right-click My Computer (sometimes it’s simply Computer)
o
Click Manage,
o
Then click Device Manager
<or>
 Right-click My Computer
o
Click Properties,
o
Click the Hardware tab,
o
Then click Device Manager.
94
Downloading LoadMan Meter Software

Within Device Manager, click and open-up “Ports (COM & LPT)”

Make sure and note the COM port listed.
(COM3 for this example).
Step 4: Configure COM Port in LoadMan Load Manager Software
Now that the PC Serial COM Port has been identified, return to the LoadMan
Load Manager Software to direct LLM to use this COM port for communicating
to the LM310.
95
Downloading LoadMan Meter Software

From LoadMan Load Manager
o
Click Tools
o
Click Connections

The “Add Connection” dialog is displayed with all the currently defined COM
ports available for LLM. We will be using the Bluetooth/Parani connections
In our example Note that BLUETOOTH is currently configured to COM1. To
change the configuration, click on Edit COM3 is not set-up/defined, so click
the Add key to set-up and configure the COM3 port.
96
Downloading LoadMan Meter Software
Shown here is the dialog box before setting-up any COM connection details.

In the Name Field, choose a name for the COM port – in our example, simply
call it “COM3:9600”. The 9600 indicates the baud rate on the port.
Under Baud Rate click on 9600.
Under Comm Port, click on COM3.
Ignore the rest of the fields as these defaults work fine.

Enter OK when complete.



97
Downloading LoadMan Meter Software


CLOSE the Connection table.
View the added COM3 port in the LLM Communications Table.
Step 5: Connect LLM to LM310 Using Terminal Emulation
 Make certain that the host PC that’s running LoadMan Load Management
Software is connected to the LM310’s Port#1.
 Power on the LM310.
98
Downloading LoadMan Meter Software

Initiate the Terminal Connect dialog with the LM310
o
Make certain LM310 Bluetooth in turned ON
o
From the Load Manager click on Tools
o
Select Advanced Functions
o
Click on Connect Comm Port…

Choose COM port (in our example COM3:9600) and click OK.
99
Downloading LoadMan Meter Software

When you can view this blank screen, click on Bluetooth Query….
…directing LLM to find the LM310 Bluetooth connection.
100
Downloading LoadMan Meter Software

Now, highlight the query result and press connect

Press and hold “Ctrl” and “T” keys simultaneously, until you see the following
menu.
Note the Dnload button at the top of the display. By clicking this button, you will
be asked for the file name to download to the LM310 to upgrade any currently
stored software version.
For downloading software for upgrading the CART310 Box or ARM310 Box, here
is a YouTube video describing the procedure:
VIDEO >> LoadMan ARM or CART Box Software Download
101
Downloading LoadMan Meter Software
102
Downloading LoadMan Meter Software
INDEX
CONN SEC command · 51
CONNECT · 60
Connectivity & Communications · 18
CONTRAST · 61
CONTsp command · 53
COUNT BY command · 47
COUNTBY command · 56
CYCLE ARMS · 24
CYCLE command · 47
CYCLE DISPLAY · 17, 31, 33
A
ABORTING · 86
ACCOUNT# · 27, 49
ACCOUNTS command · 47
Activating Setup & Calibration · 14, 38
ARM DIRECTION · 63, 69
ARM ZERO · 63
ARMENDdn · 63
ArmENDup · 63
ARMS DEG · 63
ArmSTRTdn · 63
ArmSTRTup · 63
ASSETS command · 48
ATLTITUDE display · 61
AUTOCAL · 86
D
DATE and TIME · 30
disabling COUNT BY · 47
DISPLAY UNITS command · 47
Downloading Software · 93
DUMP LOAD · 25
B
E
BARCODE command · 55
barcode readers · 53
BAUD RATE command · 51, 55
Bluetooth · 53
English units · 16
ERASE CTR · 62
ERASE DATA · 16, 37
ERASE DATA command · 58
Error Messages · 86
EVENT · 29
EVENTS command · 48
C
Calibrate Arm Angle · 68
Calibrate Cart Going Down · 74
Calibrate Cart Going Up · 73
Calibrate System · 71
Calibrate System for ZERO CART Load ·
33, 72, 73
Calibrate System Under Load · 75
Cell State Codes · 91
CELLSTATE · 60
COLLECTING LOAD DATA · 81
Command Tree · 87
F
FLASH ACCT# command · 49
FLASH EVENT command · 49
FLASH LDNAME command · 48
FLASH OVERLD command · 50
FLASH PRODUCT command · 49
FLASH STOP# command · 49
Front Panel and Display · 12
103
Downloading LoadMan Meter Software
G
M
GEO ROUTE command · 50
global positioning · 52
GPS · 18
GROSS · 24
Measurement Units · 16
Metric units · 16
MODEM command · 51
modem connection speed · 51
MODEM OPTION command · 51
H
N
Hardware Alarm · 27
INCR STOP # command · 53
INFORMATION DISPLAY · 24
Initial Startup and Calibration · 65
INSTALL · 16, 37, 44
Installation Commands · 44
International Modems · 51
NET · 25
NextLOG · 61
NO · 86
NO ARM SENSOR · 77
NO ARM SENSOR! error message · 86
NO LEFTCART SIG · 78
NO LEFTCART SIG! · 79
NO RGHTCART SIG · 78
Normal Operating Mode · 13
NORMAL OPERATING MODE · 23
L
O
LAST · 26
LAT display · 61
LEARN SPAN · 42
LEARN SPAN? · 71
LEARN ZERO · 40, 70
LEFTCART SIG OK! · 79
LINE FEEDS command · 56
Load Manager Software · 20
Load Measurements Inaccurate · 79
LOAD NAME · 27
LOADCELLS · 44, 45
LoadMan Load Manager Software · 27,
47, 51, 56, 61, 62
LoadMan Operating Modes · 13
LOG command · 52
LON display · 61
LOWER ARMS · 25
OPERATIONAL BASICS · 11
OSversion · 60
I
P
Power · 11
POWER button · 65
PRINT ASSET command · 56
PRINT CONT command · 56
PRINT CONTg command · 56
PRINT LAST LOAD · 17, 31, 32
PRINT RFID command · 56
PRINT STOP# command · 55
PRINT TOTAL command · 56
PRINT TRUCKn command · 56
printers · 53
PRODUCT NAME · 28
104
Downloading LoadMan Meter Software
PRODUCTS command · 48
PROGRAM FUNCTION · 31
PROGRAM FUNCTION Display · 17
PROGRAM Keys (SET, , ) · 12
Program Version (LoadMan) · 11
Programming the ACCOUNT # · 82
Programming the STOP# Display · 82
PRT ACCOUNT command · 55
PRT EVENT command · 56
PRT LOADNAME command · 55
PRT PRODUCT command · 56
SERIALnum command · 56
SET DEFAULTS · 16, 37
SET DEFAULTS command · 57
SET DISPLAYS · 44, 46
SET RECORD · 44
SET RECORD command · 52
SET SPAN · 16, 37, 40
SET SPAN calibration procedure · 41
SET TARE · 16, 37, 43
SET ZERO · 16, 37, 39
setting IP addresses · 52
Setting Kilograms/KG · 16
Setup & Calibration Commands · 37, 39
Setup & Calibration Mode · 13, 37
SETUP GPS · 44
SETUP GPS command · 52
SETUP MODEM · 44
SETUP MODEM command · 50
SETUP RS232 · 44
SETUP RS232 command · 53
SHOW GROSS · 17, 31
SHOW NEG WTS · 44, 45
SHOW NET · 17, 31, 32
SIM CARD # · 60
SIM H · 60
SIM L · 60
Software Alarm · 26
SPANDnCAL · 64
SPANUpCAL · 64
STOP # · 28
STOP# · 49, 55
R
READY TO WEIGH · 24
RECORD&PRINT command · 52
Recording a Product · 83
RECORDING LOAD · 25
RECORDS display · 61
Remote IP · 52
RemoteIP · 52
RESET BTOOTH command · 60
Route Display · 27
RS232 Port #1 · 18, 32
RS232 Ports · 18
RSET xxxx SEC command · 51
S
SAFETY WARNING · iii
SampDevDn · 64
SampDevUp · 64
SATTELITES display · 61
SCOREBOARD command · 55
scoreboard displays · 53
SECURITY · 86
SECURITY command · 57
SECURITY OFF · 14, 38
SECURITY ON · 14, 38
SELECT Keys (, ) · 13
Selecting a Load Name · 82
SERIALnum · 44
T
TARGET · 26, 46, 50
TARGET command · 48
TEMPscaled · 61
TEMPsensor · 61
Terminal Emulation · 98
TICKET PRINT ON command · 55
tonnes · 16
TRB LOAD RECORDS command · 61
TROUBLE CAL command · 63
105
Downloading LoadMan Meter Software
TROUBLE COM command · 59
TROUBLE GPS command · 61
TROUBLE LOADCELL command · 59
TROUBLE POSITION command · 62
TROUBLE VOLTAGE command · 60
TROUBLESHOOT · 16, 37
TROUBLESHOOT command · 59
TROUBLESHOOTING GUIDE · 77
TRUCK · 26
VLC1 · 60
W
WEIGHING LOAD · 24
WEIGHING TARE · 25
Weigh-In-Motion Window · 66
Weight and Message Display · 13
Weight Display · 24
WEIGHT DISPLAYS · 26
WGH DUMP · 62
WGH END · 62
WGH START · 62
Wireless Communications · 18
Wiring Diagram · 85
U
Unplanned Collections · 81
V
Z
VBAT · 60
Vel East display · 61
Vel North display · 61
Verify Angle Measurements · 69
Verify Angle Sensors · 66
Verify Cart Load Cells · 67
Verify Weigh-In-Motion Response · 69
Verify Wiring · 65
VIN · 60
ZERO · 86
ZERO ARM ANGLE · 39
ZERO CART LOAD · 17, 31, 32, 39
ZERO TRUCK · 17, 31, 34
ZERODnCAL · 64
ZEROUpCAL · 63
106
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