CONTENTS 1.... GENERAL 1.1... Weighing Introduction 2.... SYSTEM OPERATION 2.1... General 2.2... Operation of the System 2.3... Weighing cycle - Lift Truck 2.4... Zero Cycle 2.5... Tare Function 2.6... Totalizing Feature 3.... INSTALLATION 3.1 Description of Key Functions and Indication Lamps 3.2... Lift Truck Condition 3.3... Installation Kit 3.4... Display Installation 3.5... Sensor Installation 3.6... Electrical Installation 3.7... Fitting Instruction Stickers Lift trucks 4.... SETUP FUNCTIONS AND CALIBRATION 4.1... Available Functions 4.2... Calibration Procedure 4.3... Setup Function Checklist 4.4... Specifications Ws 805-101 Rev 1.00 Installation Manufactured to CE marked standards
1 GENERAL 1.1 WEIGHING INTRODUCTION: The Ws 805 digital indicator is state of the art in weighing technology. The unit features a High - speed microprocessor to deliver an unambiguous weight reading. The Ws 805 has been designed specifically to give reliable and stable readings. The Digi - Lock feature gives a more accurate weight reading and is operator friendly. This allows the operator not to see any unwanted weight readings as the display is only activated when the Weigh button is pressed. The display locks and holds the weight reading for 6-8 seconds and the display then goes into sleep mode. Features include: All electronic workings Splash proof construction LED display Digi - lock holds and locks correct weight readings Zero/Tare maintenance keys trims small deviations at zero and allows a Tare function Add key (Totalizing)
2 SYSTEM OPERATION 2.1 GENERAL The Ws 805 weighing system works on the principle that the lift truck hoisting hydraulic pressure is directly proportional to the applied load on the forks. This hydraulic pressure is converted to an electronic signal that is shown on the display directly as load from the forks. It is important that all weighing be carried out in a repeatable fashion. There are stickers on the mast and carriage to assist the operator in weighing at the same location each time a weigh cycle is used. 2.2 OPERATION OF THE SYSTEM There are two (2) phases for correct operation of the Ws 805 weighing system ZERO phases. A weighing operation designed to check and reset any minor variations with no load on the forks. WEIGHING phase. An operation designed to acquire the weight of the load and lock it on the Ws 805 display. Typical operation of the system is as follows- 1. Press the On\Off button to power up the display (preferably with the motor of the vehicle running) The display will be flashing 0 press the On/Off Button this will activate the indicator ready to weigh. 1. Perform zero cycle (no load on the forks) 2. Weigh loads as required following correct procedure (2.3) "weighing cycle" 3. Periodically re-check system zero ( 0 ) This instruction should appear on a sticker affixed to the vehicle as a guide for the operator.
2.3 LIFT TRUCK STANDARD WEIGHING CYCLE: The following procedure should be adopted for each weighing cycle performed. 1. Raise the fork truck carriage until the sticker located on the carriage aligns with the 1 on the sticker. 2. Now lower the carriage so that the roughly lines up with the 2 on the mast. At this point press the Weigh key on the display. The weight will be displayed for 6-8 seconds the display will then go into sleep mode. REMEMBER!!! Raise to 1 Lower to 2 Press Weigh key The display will then locks and hold the displayed weight for 6-8 seconds The display will then go into sleep mode until the Weigh key is activated 2.4 ZERO CYCLE The zero or "no load" reading of the display should be checked periodically, If the display does not read zero with no load on the forks, then a zero weigh cycle must be performed. NB: the forks should not be on the ground, as this will cause a weighing error. TO CHECK ZERO. Simply perform a standard weigh cycle without any load on the forks of the lift truck. HOW TO ZERO THE Ws 805 WEIGHING SYSTEM Raise to 1 Lower to 2 Press the Weigh key The display will now show 0 ( if not on 0 with no load ) Press the Zero key this will zero out minor deviations N.B. Zero should be checked periodically to maintain system accuracy
2.5 TARE CYCLE This feature is designed to enable the operator to tare out a pallet or container. This will then give a net weight of articles loaded on the pallet or in the container. HOW TO TARE A PALLET OR CONTAINER ON THE Ws 805 WEIGHING SYSTEM Place a pallet or container on the forks of the lift truck and perform a standard weigh cycle with the article to be tarred. Raise to 1 Lower to 2 Press the Weigh key The display will now show the weight of the pallet or container to be tarred (eg: 300) Press and Hold the Zero key The display will now show 0 (the net lamp will be displayed) The Tare cycle is complete HOW TO RELEASE THE TARE Remove the pallet or container from the forks of the lift truck and perform a standard weighing cycle. Raise to 1 Lower to 2 Press the Weigh key The display will now show the negative weight of the removed pallet or container (eg: - 300) Press the Zero key The display will now show 0 The Tare release cycle is complete 2.6 TOTALIZING FUNCTION: The Total is the addition of successive loads stored as a total. This running total will continue to accumulate the individual weights when the Add key is pressed. The Ws 805 will show the number of weighs and accumulated weights. HOW TO ADD THE INDIVIDUAL WEIGHTS TO THE TOTAL REMEMBER!!! Raise to 1 Lower to 2 Press the Weigh key The weight will be displayed for 6-8 seconds To Add a shown weight to the total, press the Add key while the weight is displayed The display will now show eg: Add 01 the weight has now been added to a progressive total The display will then go into sleep mode
HOW TO SEE THE TOTAL Press the Total key, the current total will be displayed in the following format Eg: (450) flashing intermittently HOW TO RETURN TO NORMAL WEIGHING MODE Press the Total key to return to normal operation (this will NOT clear the current total.) HOW TO CLEAR THE TOTAL Press the Total key the current Total will be displayed flashing Press the Zero key. The display will now show 0 flashing press the Total key the Indicator will go into sleep mode and the current Total has been cleared. N.B. This function can be performed without doing a standard weighing cycle.
3 INSTALLATION 3.1 DESCRIPTION OF KEYS USED FOR SETUPS AND CALIBRATION The following keys are used to enter and select data: The ON\OFF Key is used to switch the display on\off it is also used as a return key to exit the totalizing function and return the display to sleep mode in normal operation. The ZERO/ TARE Key is used to zero out minor deviations with no load applied to the system or is used to tare out a container or pallet and used as the up arrow key in the setup and calibration of the system. The TOTAL Key allows you to view the current accumulation of weight totals. The ADD Key is used enter the setup and calibration data in to the scale memory. The WEIGH Key is used mainly as the Enter key and side arrow select key when the system is in set up mode in normal weighing operation the Weigh key activates the weighing cycle. DC DESCRIPTION OF INDICATION LIGHTS: Power indication this lamp indicates there is power to the display unit. NET Tare indication this lamp indicates there is a Tare weight entered in the system. ZERO Zero indication This light indicates the system is on Zero 0 (no load on the forks) Lb Lb indication This light indicates the system is in Pound measurement mode. Kg Kg indication This light indicates the system is in Kilogram measurement mode. STAB Stability indication this lamp indicates the weighing indicator is stable and ready to weigh accurately.
3.2 LIFT TRUCK CONDITION: To achieve an accuracy of approximately + or 1to 2 % of the capacity of the vehicle, the machine should be in the best possible mechanical hydraulic condition. Whilst most lift trucks are not in prime condition, they can give satisfactory results. The following may be checked before commencing the installation. The lift ram(s) has no leaks. A creep of 25mm of the mast, with a load of 25% of the fork trucks lift capacity over 1 hour period, constitutes a leaky mast or control valve and fitting the Ws 805 system could result in erratic weight readings. The mast slides and channels are not bent or tight, or otherwise damaged The mast rollers or bearings are not missing or damaged NOTE: Due to the potential safety hazards to personnel, it is strongly recommended that only qualified mechanics work on the machine. 3.3 INSTALLATION KIT: To facilitate installation, a kit containing all necessary hardware has been included the contents of this kit are marked on the side of the monitor-packing carton. Typically this includes the following components. Ws 805Display Sensor assembly Display Monitor with mounting bracket Operation stickers (3) Hydraulic hose and fitting Power cable includes inline fuse 3.4 DISPLAY INSTALLATION CAUTION! (1) The Ws 805 control unit has been designed to operate under adverse conditions of dust, temperature and water. It offers splash- proof protection to water ingress. However, locating the control unit directly in sunlight, particularly behind the window in a cab, may cause the unit to be subject to extremely high temperatures, which may damage the electronic system. Accordingly it is recommended that the unit be mounted in a sun shaded location or if this is not possible, a sunshade be erected over the unit to block direct sunlight. (2) When the control unit has been mounted and orientated for convenient operation and display viewing, check that the cables and connectors are not under any mechanical stress and the cables are neatly secured away from accidental mechanical abuse. (3) The control unit is mounted with a side pivot bracket. Ensure that the actual Ws 805 case is not touching any part of the machine such that its movement within the bracket is restricted.
3.5 INSTALLATION OF THE PRESSURE SENSOR GENERAL (1) CAUTION - The electronic pressure sensor provided is an industrial grade device designed to be installed in an arduous environment. However, it must be remembered that it is still, essentially, a delicate electronic sensor, and accordingly, to ensure maximum life, reliability and accuracy, it must be treated with due care. (a) DO NOT apply a spanner or similar tool to any part of the sensor except the 'flats' provided expressly for the purpose of tightening the hydraulic coupling. (b) DO NOT mount the sensor in any location where it is liable to be subjected to physical or mechanical abuse of any kind. (c) DO NOT mount the sensor where it will be repeatedly immersed or sprayed with water or oil. (d) DO NOT mount the sensor where the cable entry and cable will be subject to physical abuse, liable to be stressed or subject to excessive movement. (2) It is important that the pressure sensor be tapped into the hydraulic line which supplies oil to the lift cylinder. (3) Tapping any other line will result in the incorrect operation of the Ws 805 system. The line should be tapped between the control valve and the lift cylinder. The tap can be carried out satisfactorily in a number of ways but probably the simplest is to use the l /8 BSP T fitting, supplied with the kit. (4) (a) Lower the forks to the ground and stop the engine. (b) Remove the cap from the hydraulic oil reservoir to release the pressure. (c) Operate the 'lift' levers to ensure all pressure is relieved from the system. (d) Remove the hydraulic hose where it is mounted to the lift cylinder (or some other convenient joint). Drill and tap side down, between the end of hose fitting with 1/8 BSPT Adaptor supplied. (e) Refit hose and connect 7/16 JIC hose to new fitting and feed line to sensor. CAUTION! Ensure hoses and cables are clear of moving parts that may cause damage.
3.6 ELECTRICAL INSTALLATION (1) The Ws 805 system is designed to operate on 12v D.C. (optional 24, 36, 48 or 72v) automotive battery systems, positive or negative earth. (2) The control unit may be wired into the main electrical loom if there is a provision for additional connections via the ignition key circuit. (3) However, it is advisable in many cases to connect the Ws 805 unit directly to the ignition key circuit (including 1 AMP in-line fuse) to reduce the possibility of electrical interference from other apparatus connected to the electrical system. (4) The Ws 805 unit comes equipped with pre-terminated cables. The battery connection end is supplied with free leads. COLOUR CODE: RED - Battery + (Positive) BLACK - Battery - (Negative) For negative earth vehicles it is preferable to bond the -ve (BLACK) lead securely and directly to the machine chassis. (Reverse for + ve earth vehicles). (5) An in-line fuse holder and 1 AMP fuse is supplied with the Kit and MUST be fitted in series with the non-earthed cable lead to the Ws 805 unit. CAUTION - WELDING! TO AVOID DAMAGE TO THE SENSITIVE ELECTRONIC COMPONENTS IN THE SYSTEM, THE POWER SUPPLY CONNECTOR SHOULD BE UNPLUGGED FROM THE Ws 805 UNIT WHILST ANY ELECTRIC WELDING IS BEING CARRIED OUT!
CABLE LOOMS AND CONNECTORS The power/aux functions are connected to the Ws 805 unit via 2 cables one is a 2 core power input the other is 4 way sensor input. CABLE COLOURS (a) Power Supply: 12 volts D.C. + Red /Positive power input - Black/Negative power input (ground) (b) Sensor connections: Ws 805 Display Pin (1) + Input (Red) Red (+ output) Pin (2) - Input (Yellow) Black (- output) Pin (3) + Output (Blue) Green (+ input) Pin (4) - Output (White) White (- input) Sensor UY Connector Ws 805 Display Sensor connection: Using the UY Connector. 1. Locate the cable 2. Separate the required colours 3. Hold connector with button side down, insert wires all the way into the sockets 4. Use pliers or a similar tool to crimp the connection. 5. Check cables are secure in the connector. Caution: The connector contains sealant which may be irritating to the eyes. In case of contact, flush eyes with plenty of water and seek medical assistance.
3.7 FITTING INSTRUCTION STICKERS: The kit includes three (3) to assist the operator in normal operation. It is important that all the calibration and weighing be carried out in a repeatable fashion. The stickers assist the operator to weigh in the same position each lift. Lift trucks Operator instruction sticker: Mount this on the dash of the Lift truck Arrow Sticker : This acts as a pointer for the operator and is located on the back of the fork Carriage. Position Sticker ( marked 1-2 ) : This sticker is affixed to the Stationary Mast in a position such that when the forks or bucket of the lift truck or bobcat are in the desired weighing position, the two (2) on the sticker is aligned with the Arrow previously fixed to the fork carriage. Generally, the forks or bucket are positioned around 300mm to 400mm off the ground for pallet weighing work. 4 SETUP FUNCTIONS AND CALIBRATION Method to access the function codes STEP 1 PRESS AND HOLD THE WEIGH KEY WHILE POWERING UP THE DISPLAY Hold down the Weigh key until SET-- is displayed on the monitor The display now shows F00 Now press the Weigh Key to program the required Passcode to enter the function required. With the display on F00 press the Weigh key. The display will show 000000 The first digit should be flashing. At this point you will enter the required security code- codes are required to be entered separately. (the last three digits only) This is done by using the following keys: Weigh to move across to required position Zero to select up value Press the Add key to enter the data. To exit the function setup Press the Total key. The function setup options can be changed when you are in the configuration mode this can be done when the display shows F00. Press the Add key the display will show 000000 with the first digit flashing enter the required security code. Refer to section 4.1 Press the Add key to accept the entered security code. The display will now show the function number, Press the Add key to enter the function.to change the values use the Total key or the Total Clr key to modify values. Press the Weigh key to enter the new value. The display will now show F00 press the On\Off key to exit the function configuration mode.
4.1 AVAILABLE FUNCTIONS The listed Security codes are to access the following options Function Security code Capacity, resolution and decimal point set up mode 000810 Calibration mode Zero and span 000220 F1 Power up on zero auto-range 000110 F2 Automatic zero tracking 000210 F3 Dynamic sampling range 000310 F4 Dynamic sampling time 000410 F5 Digital filtering 000510 F6 Digi-lock, (display hold time) 000610 F9 kg to lb Mode 000910 FUNCTION DEFINITIONS Capacity, resolution set up mode- 810 This function is the main set up of the system as you can program the capacity, resolution. This function must be performed prior to calibrating the system. Calibration mode Zero and Span- 220 The Zero calibration is used to zero out the offset of the sensor in the system. Span calibration is calibration of the weighing system with a known weight. F1 (Power up auto zero range 0,5,10 or 20% of maximum capacity)-110 This function is used to set the zero when the system is first powered up prior to weighing it may be used to mask any minor variations in the hydraulic system.(select 20% of capacity for maximum effort) F2 (Automatic zero tracking.5,1.0,2.0,3.0,5.0 divisions)-210 Designed to remove minor weight deviations at zero such as a build up of material or worn components or slight hydraulic variations. (Select 5 for maximum effort) F3 (Dynamic sampling range.5,1.0,2.0,3.0 divisions)-310 Designed to assist in the sampling of the hydraulic pressure to enable consistent accuracy of the system. Adjust according to the conditions when the weighing cycle is determined. (Select, 3.0 for maximum effort) F4 (Dynamic sampling time.5,1.0,2.0,3.0 divisions)-410 Designed to sample in a set time range the hydraulic pressure variations to enable consistent accuracy of the system. Adjust according to the conditions when the weighing cycle is determined. (Select, 3.0 for maximum effort ) F5 (Digital filtering.0,1,2,3,4,5 divisions)-510 Designed to filter the hydraulic pressure variations in the system Adjust according to the conditions when the weighing cycle is determined. (Select, 5 for maximum effort )
F6 ( Digi lock, locks and holds the displayed weight for a selected time)-610 Designed to assist the operator in the time the weight reading is locked on the display this can be adjusted according to the requirements of the operator. ( select 9 for maximum effort ) F9 (Kg to Lb Mode) The unit can display in kg or lb this is function only will show kg or lb it does not switch between both. METHOD TO ACCESS FUNCTION CODES STEP 1 PRESS AND HOLD THE WEIGH KEY WHILE POWERING UP THE DISPLAY Hold down the Weigh key until SET-- is displayed on the monitor The display now shows F00 Now press the Weigh Key to program the required Pass code to enter the function required. The display on will show 00000 The first digit should be flashing. At this point you will enter the required security code- codes are required to be entered separately power off the display to start each new code. This is done by using the following keys: Weigh to move across to required position Zero to select up value Press the Add key to enter the data. To exit the function setup Press the On/Off key. ENTERING THE SETUP CONFIGURATION Security Code is 810 to enter the setup configuration mode. At this point you will enter the security code 810 it should look like this: 000810. Refer to step 1 for key operations. The display will now show: 600- (This is the current set Capacity) This is the capacity of the weighing range required - example - 3000 kg would be 3000. Press the Weigh key to change the set capacity this function has a maximum value of 5000. Press the Add Key to accept the capacity setting. The display will now show Diu Diu- This is the resolution of the system example- 10 kg would be 10 The division size selectable: 10,20,50 Press the Weigh key to access function The display will show (10) Use the Weigh key to select required value. Then press the Add key to enter setting. The display will now go into sleep mode. The Ws 805 has been designed to have preset division values which relates to the capacity of the machine.
F1 (Power up auto zero range 0,5,10,20% of capacity)-110 POWER UP AUTO ZERO RANGE Security Code is 110 for this section. At this point you will enter the security code 110 it should look like this: 000110. Refer to step 1 for key operations. The display will now show F1 Press the Weigh key. The display will now show 0. Use the Weigh key to change the figure and then press the Add key to enter the new value. The display will now show F00 press the On\Off key to exit the function configuration mode. F2 (automatic zero tracking.5 to 5.0 = maximum tracking)-210 AUTOMATIC ZERO TRACKING Security Code is 210 for this section. At this point you will enter the security code 210 it should look like this: 000210. Refer to step 1 for key operations. Adjust according to conditions. Press the Weigh key. The display will show 2.Set this figure to suit the working environment using the Weigh key and then press the Add key to enter the new value. The display will now show F00 press the On/Off key to exit the function configuration mode. F3 (Dynamic sampling range.5 to 3.0 = maximum range) DYNAMIC SAMPLING RANGE Security Code is 310 for this section. At this point you will enter the security code 310 it should look like this: 000310. Refer to step 1 for key operations. Adjust according to conditions. Press the Weigh key. The display will show 2.Set this figure to suit the working environment using the Add key to enter the new value. The display will now show F00 press the On\Off key to exit the function configuration mode. F4 (dynamic sampling time.5 to 3.0 = maximum time) DYNAMIC SAMPLING TIME Security Code is 410 for this section. At this point you will enter the security code 410 it should look like this: 000410. Refer to step 1 for key operations. Adjust according to conditions. Press the Weigh key. The display will show 2.Set this figure to suit the working environment using the Add key to enter the new value. The display will now show F00 press the On\Off key to exit the function configuration mode.
F5 (digital filtering 0 to 5 = maximum filter) DIGITAL FILTERING Security Code is 510 for this section. At this point you will enter the security code 510 it should look like this: 000510. Refer to step 1 for key operations. Adjust according to conditions. Press the Weigh key. The display will show 3.Set this figure to suit the working environment using the Add key to enter the new value. The display will now show F00 press the On\Off key to exit the function configuration mode. F6 (Digi lock, locks and holds the displayed weight for a selected time) DIGI-LOCK Security Code is 610 for this section. At this point you will enter the security code 610 it should look like this: 000610. Refer to step 1 for key operations. Press the Weigh key. The display will show 6. Set this value to the required lock and hold time from 1 to 9 seconds and press the Add key to enter the new value. The display will now show F00 press the On\Off key to exit the function configuration mode. F9 (Kg to Lb Mode) Kg to Lb Security Code is 910 for this section. At this point you will enter the security code 910 it should look like this: 000910. Refer to step 1 for key operations. Press the Weigh key. The display will show 9. Set this value to the required setting Kg mode= 1 Lb mode=0 press the Add key to enter the new value. The display will now show F00 press the On\Off key to exit the function configuration mode. 4.2 CALIBRATION PROCEDURE
STEP 1 PRESS AND HOLD THE WEIGH KEY WHILE POWERING UP THE DISPLAY Hold down the Weigh key until SET-- is displayed on the monitor The display now shows F00 Now press the Add Key to program the required Security code to enter the calibration function required. The display will show 000000 the first digit should be flashing. At this point you will enter the required security code. This is done by using the following keys: Weigh to move across to required position Zero to select up value Press the Add key to enter the data. ENTERING THE CALIBRATION MODE The security Code is 220 to enter the setup calibration mode. At this point you will enter the security code 220 it should look like this: 000220. AT THIS POINT A STANDARD WEIGH CYCLE MUST BE- PERFORMED Raise to 1 Lower to 2 REMEMBER!!! Press the Add key. The display will now show CAL Press the Add key. The display will now show ZERO ZERO-used to zero out the offset of the transducer The display will now show a number (this is the AD count on the sensor e.g. - 2145 Press the Add key to accept the Zero calibration. The display will then show 000000 with one digit flashing (you now enter the known test weight value e.g. 500) use the Weigh key to move across and the Zero key to scroll up to the required value. Then press the Add key to enter the test weight value. The display now will show LOAD Place The known test weight on the forks, You will then perform a standard weigh cycle. REMEMBER!!! Raise to 1 Lower to 2 Then press the Add key to show the calibration value. The display will now show a number (this is the AD count on the sensor with a load applied e.g. 122145 Let the count stabalise over a few seconds this will give a more accurate calibration. Press the Add key to accept the known weight calibration. The Indicator should say PASS this indicates the calibration was ok. The display will then go into sleep mode. This signifies that calibration is now completed and the system is ready to weigh 4.3 SETUP FUNCTION CHECK LIST
Function Default Installation Settings F1 Power up on auto-zero 0 F2 Auto zero tracking 2 F3 Dynamic sampling range 2 F4 Dynamic sampling time 2 F5 Digital filtering 3 F6 Digi-lock, (display hold time) 6 F9 Kg to Lb Mode Lb=0 kg=1 810 Default Installation settings CAP diu TEST WEIGHT VALUE 3000kg 10kg FACTORY DEFAULT 1,000kg Installation Test Weight TECHNICAL NOTE: Weighing. Wiring. On some machines there may be a necessity to raise only to 1 and NOT lower to 2 This is primarily due to the hydraulics of the machine. If inaccurate weights are being shown, recalibrate the system. Only raise the forks or the bucket to 1. Do Not lower to 2 Always make sure the sensor connection is good even if a terminal block is used.the connection may not be good. Never use a in-line crimp wire joining connector as these often because a lot of problems as the voltage to the sensor are 5 volt dc and the output from the sensor is millivolts so the output is very low the slightest change in connection will affect the display readings. Ws 805 BASIC TROUBLE SHOOTING GUIDE
Display will not turn on Display turns on But wont weigh Weighing is erratic Under load Weighing is not stable At zero Scale does not Calibrate No sensor output and The display is locked Check power source Not enough current Check sensor hydraulic tee off Check sensor connections Check sensor output counts are moving Check sensor output connections Check fuse Check the Ground cable Check filter setting Check input current Check sensor is counts are positive Check supply current Check all connections including 805 internal power connection Check sensor connections, Check sensor wires are connected to correct wires from the 805 unit. The load may be unstable or bouncing causing a hydraulic spike Lower the weighing cycle height Check the 805 in calibration mode to see the a/d counts of the sensor is ok. Check hydraulic tee off, sensor connections check the test weight value is set correctly Supply current is to low to activate sensor and display The Ws 805 continually monitors the condition of the internal circuits. Any faults or out of tolerance conditions are shown on the display as an error message. In the table below the following terms are used. Error codes Display Description The weighing value is Over Overload alarm under or over the limit Over Over Sensor cable not connected The Ws 805 will show the following messages during the calibration of the unit if a fault is detected. Error shown Display Decryption E32 E32 Not enough Load while trying to calibrate E33 E33 Sensor cables are crossed or not connected Not Enough sensor signal E34 E34 Too much load to while trying to calibrate NO ZERO NO ZERO The scale is not on zero in gross mode while trying to calibrate Ws 805 ENCLOSURE SCHEMATICS