Kimax 1 - extended-1.pub

Installation and Instruction manual

2

Before you start the installatation procedure, make sure that the instruments has not suffered any damage during transport. Note that the Kimax 1 instruments must be installed and connected in accor-dance with the regulations valid for the vehicle and country in question. The Kimax 1 instruments must be protected from gravel, water spray from wheels and other factors that may damage the instruments. We recommend to mount the instruments in a position where it is protected from water jets and rinse water. Once you have decided where the instrument is to be mounted in the cabin, you have to consider the cable routing. Special attention should be given to potential damaging factors such as e.g. hinging point for tilting the cab. Once you have decided where the instrument is to be mounted on the chassis, you have to consider the cable routing. Special attention should be given to tensile forces, cuts and other factors that may damage the cables and hoses. Connection of compressed air. Before you carry out any installation work related to the air suspension, make sure that the suspension has been brought to the lowest possible position.

Table of contents:

Basic safety rules:

KIMAX 1 - Installation- and Instruction manual

Electricalinstallation

Sensorinstallation Calibration Daily useProtecting

CalibrationSetupIntroduction Additionalinformation

Warranty Kimax 1 cabin, trailer and hydraulic are all covered by Sense-Tech Weighing Systems ApS guarantee. Electronic failure and broken components caused by normal use are re-paired or exchanged when necessary, when send to the factory. Damage to your vehicle caused by installation of Kimax instruments or loss of time caused by recalibration or repayments of Kimax instruments are not covered by Sense-tech Weighing Systems ApS in any case.

0 Introduction

5 Overview—daily use

7 Calibration

9 Alarm—setup

10 Configuration

12 OBC and printer output

13 Protecting your calibration

14 Electrical installation

16 Sensor installation (air)

20 Sensor installation (hydraulic)

21 FAQ

22 Dimension and technical specification

3

How does it work

The Kimax 1 on board scale is an axle pressure gauge that uses pressure gauging on the air suspension to indicate the load and to keep you informed at all times about the present load situation. A mechanical system on the vehicle maintain a fixed level of the chassis height through a level valve which add or subtract compressed air to the bellows according to the ac-tual load on the vehicle. Top of bellows, shock absorber and level valve are fixed on the chassis of the vehicle.

The pressure in the suspension system and in the bellows, represent the weight of the vehicle. The weight of the vehicle is a linear function of the pressure in the suspension system, se diagram below. The Kimax 1 instrument is customized to your vehicle by means of giving in the actual unloaded weight in tons when the truck is unloaded, - and giving in actual loaded weight in tons when the truck is loaded. System accuracy is affected by the mechanical condition of your vehicle, e.g. the condi-tion of the shock absorbers.





0

2

4

6

8

10

12

14

16

0,00 1,00 2,00 3,00 4,00 5,00 6,00 7,00

To

nn

e

Bar

Kimax 1 - calibration diagram (example)

Axle 1

Level valve

Storagetank

Maintainlevel

Air-pressure for KIMAX

Shock absorber

4





Basic Kimax 1 installation:

Single air inlet is used on vehi-cles with combined level con-trol for one or more axles.

Dual air inlet is used either on vehicles with split level control for one or more axles. Or on vehicles with two or more individual axles arranged in a combined level control system.

Using Kimax 1 on two or more individual axles offer you a limited accuracy, - for better accuracy we recommend to use Kimax 2 for multiple axle purpose.

5

Overview:

Basically you get Kimax 1 instruments in two different models A cabin version intended for mounting in-side the cabin of your vehicle. A trailer version intended for mounting out-side on the chassis of your vehicle. The trailer version is splash-water proof and are designed to withstand the environmental conditions around a vehicle on the road at all seasons. Each model you can get in a single or a dual air inlet version.

In daily use you just read the actual load on your axle or axle group, by reading the dis-played value. The display can be set to read out values as xxx tonne / kg - xx,x tonne / kg – x,xx tonne / kg.

Kimax 1 has a keypad with a total of four keys and a display with three LED digits, which is easy to read even in a dark cabin or outside in sunshine.


Save

Roll Down

Up




6

Gore-Tex membrane for venting the Kimax 1 housing, this means you do not get vac-uum in the housing under shifting ambient temperatures. Gore-Tex membrane is only present on the trailer versions of the Kimax 1 instruments. Protecting cap, has to be removed from the Gore-Tex membrane before you calibrate your instrument. When you paint the instrument in your own colours, make sure the venting openings in the Gore-Tex membrane is not covered by paint, - put on the protecting cap before painting.

Air inlet 1 for 6 mm hose.


6 mm PU hose for air inlets.




7

Calibration:

Two reference values are needed in order to make a correct calibration, viz. one value for unloaded vehicle LO, and one for loaded vehicle HI. By means of these two refer-ence values the Kimax 1 Axle Load Indicator will generate a complete axle pressure curve and display the present load in the display.

Setting the LO calibration point. Go to a weighing bridge with your empty vehicle. Enter the calibration menu by pressing the Roll button for 5 sec, and the display is reading LO. Press the roll button once again shortly, and the display reads the last saved LO value in tonnes. You can change the readout by Up and Down keys until you get a value equal to the actual empty weight you read on the weighing bridge. You save the value by pressing Save but-ton, and the display reads HI. In the case you want to maintain the pre-vious value, press Roll and the display reads HI without saving the modified LO

Setting the HI calibration point. Go to a weighing bridge with your loaded vehicle. Press the roll button once again shortly, and the display reads the last saved HI value in tonnes. You can change the readout by Up and Down keys until you get a value equal to the actual loaded weight you read on the weighing bridge. You save the value by pressing Save but-ton, and the display reads A1. In the case you want to maintain the pre-vious value, press Roll and the display reads A1 without saving the modified HI

During calibration you can modify LO and HI in a sequence as described above, or you can modify LO or HI individual, by bypassing parameter out of interest by pressing Roll several times until you read the value you need, or you leave the menu and read 3 nu-meric digits on the display. Under calibration you can not give in LO values higher than HI, and you can not give in HI values lower than LO.





0

2

4

6

8

10

12

14

16

0,00 1,00 2,00 3,00 4,00 5,00 6,00 7,00

To

nn

e

Bar


Lo - Axle 1

0

2

4

6

8

10

12

14

16

0,00 1,00 2,00 3,00 4,00 5,00 6,00 7,00

To

nn

e

Bar


Hi - Axle 1

8

RUN mode

LO LOW Value

HI

HIGH Value

A1 Alarm 1 Value

A2

VS

Alarm 2 Value

DP Dot position

Display Function

AA Analog Output

Only SW Program 2

For 5 sec.





9

Alarms:

Setting the A1 alarm level. Enter the Kimax menu by pressing the Roll button for 5 sec. (se flowchart on page 7) Press the Roll button shortly 4 times until the display reads A1. Press the Roll button once again shortly, and the display reads the last saved A1 value in tonnes. You can change the readout by Up and Down keys until you get a value equal to the alarm level you want. You save the value by pressing Save button, and the display reads A2. In the case you want to maintain the previous value, press Roll and the display reads A2 without saving the modified A1 value. You can leave the menu by pressing Roll shortly several times until you read 3 digit on the display. Setting the A2 alarm level. Enter the Kimax menu by pressing the Roll button for 5 sec. (se flowchart on page 7) Press the Roll button shortly 6 times until the display reads A2. Press the Roll button once again shortly, and the display reads the last saved A2 value in tonnes. You can change the readout by Up and Down keys until you get a value equal to the alarm level you want. You save the value by pressing Save button, and the display reads DP or AA depending on software version. In the case you want to maintain the previous value, press Roll and the display reads DP or AA without saving the modified A2 value. You can leave the menu by pressing Roll shortly several times until you read 3 digits on the display.


Kimax 1 offer you two different alarm func-tions. When you exceed the A1 alarm level, the three digits in the display starts flashing. When you exceed the A2 alarm level, a re-lay internal in the Kimax 1 switch on. The A2 switch function is available for ex-ternal use only through separate wires in the supply cable.

0

2

4

6

8

10

12

14

16

0,00 1,00 2,00 3,00 4,00 5,00 6,00 7,00

To

nn

e

Bar


Axle 1

Alarm 1

Alarm 2




10

Configuration:

Setting the DP position. Enter the Kimax menu by pressing the Roll button for 5 sec. (se flowchart on page 7) Press the Roll button shortly several times until the display reads DP. Press the Roll button once again shortly, and the display reads the last saved DP posi-tion. You can change the readout by Up and Down keys until you get the position you want. Valid positions are: XXX - XX.X - X.XX You save the value by pressing Save button, and the display reads VS. In the case you want to maintain the previous value, press Roll and the display reads VS without saving the modified DP value. You can leave the menu by pressing Roll shortly several times until you read 3 digit on the display.


Kimax 1 offer you some different configuration settings. In the AA menu you set the ton value which equals the 5 volt analog output, this func-tion is only available in optional article numbers. In the DP menu you set the position of decimal point in the display. Valid positions are: XXX - XX.X - X.XX In the VS menu you select the 3-digit LED display to auto off 2 minuts after last Roll keystroke or set the display to be instant on all the time (factory setting for trailer ver-sions).

0,0

1,0

2,0

3,0

4,0

5,0

6,0

7,0

8,0

0,0

2,0

4,0

6,0

8,0

10,0

12,0

0 1 2 3 4 5 6 7 8 9 10

AA

Ton

Axle 1

Setting the AA analog level. (Optional feature which only is available in separate articles). Enter the Kimax menu by pressing the Roll button for 5 sec. (se flowchart on page 7) Press the Roll button shortly several times until the display reads AA. Press the Roll button once again shortly, and the display reads the last saved AA value in tonnes.

You can change the readout by Up and Down keys until you get a value equal to the value you want to equals 5,0 V DC out, e. g. 18 tonnes + 10% for a 2-axle vehicle (lowest possible value is 10.0). You save the value by pressing Save button, and the display reads DP. In the case you want to maintain the previous value, press Roll and the display reads DP without saving the modified AA value. You can leave the menu by pressing Roll shortly several times until you read 3 digit on the display.





11

Setting the VS. Enter the Kimax menu by pressing the Roll button for 5 sec. (se flowchart on page 7) Press the Roll button shortly several times until the display reads VS. Press the Roll button once again shortly, and the display reads the last saved VS. You can change the readout by Up and Down keys until you get the value you want. Valid positions are: 000 = auto OFF and 111 = instant ON. You save the value by pressing Save button, and the display leaves menu. In the case you want to maintain the previous value, press Roll and the display leaves menu without saving the modified VS value. You can leave the menu by pressing Roll shortly several times until you read 3 digit on the display.





12

OBC serial output

Some of the Kimax 1 instruments offer you a RS-232 serial output, displaying the meas-ured values you can read on the display. The string of data is broadcasted every 6 second and can be picked up by a GPRS unit or as an example a FM 200 unit. For test you can set up a ”HyperTerminal” on your laptop with the below parameters, Bit pr sec 9.600 Data bit 8 Parity N Stopbit 1 Flowcontrol N and you can read the broadcasted values as numeric characters. You need to set up your GPRS or FM200 for receiving on the above parameters too. Due to retransmit the Kimax values through your GPRS unit, or receive the data in a FM200, you can set up a mask: “AXX.XS” .

Printer serial output

Some of the Kimax 1 instruments offer you a RS-232 serial output, for printers. The string of data is broadcasted every time you access the printer function on the in-strument, by pressing SAVE for 3 seconds. For test you can set up a ”HyperTerminal” on your labtop with the below parameters, Bit pr sec 4.800 Data bit 8 Parity N Stopbit 1 Flowcontrol N and you can read the broadcasted values as numeric characters. You need to set up your printer for receiving on the above parameters too. Most common printer with serial input can be used with Kimax 1.

Protocol: A XX.X S S end of message XX.X actual value A start of message





13

Protecting your calibration and configuration:

Locking your Kimax 1 To lock your Kimax 1 and hereby prevent unintended change in calibration, - activate Roll and Save at the same time, while the instrument is on, and you read LO on the display. Checking your software lock Press either UP or Down while you have entered the menu and are reading the LO value on the display. When the display returns --.-, the instrument is safely locked, when it returns a 3-digit number on the display, it is unlocked. Unlocking your Kimax 1 Pressing the UP, Down and Roll at the same time, while you power up the Kimax, it re-turns a number 1—4 indicating the Kimax 1 has been unlocked. If you want to maintain your previous calibration, power off Kimax once again for 10 seconds or more, when it is newly unlocked, next time you power your Kimax up it is unlocked and returns the reading you are familiarly with. Unlocking your software without changing software version, maintain your previous cali-bration. You can select a new software by pressing Up and Down. Select your software version by pressing SAVE while the version number 1—4 you want is present in the display. Changing software version means you have to recalibrate the instrument.

Printer OBC 5V analog cable

Version 1 4-wire

Version 2 ● ● 6-wire

Version 3 4 wire

Version 4 ● 5-wire

KIMAX 1 - Installation- and Instruction manual KIMAX 1 - Installation- and Instruction manual




14

Electrical installation:

Electrical connection Always disconnect the battery before you perform any installation work on the system of the vehicle. Do not route the cables next to ignition cables or other cables carrying large current. Make sure that the cables are not exposed to tensile or shearing forces. Protect the ca-bles with rubber grommet if you route the cables through holes. For connecting cables use crimp connectors or another approved method. Avoid short-circuiting the system by faulty connections or squeezed cables. Fasten the cables at suitable intervals.

Basic cabling Standard versions of Kimax 1 is supplied through a 4 x 0,75 mm2 cable.

Cabling with A2 alarm output Standard versions of Kimax 1 is offer you a alarm switch through blue and white





-+Battery

Fuse Switch Blac

kBl

ueW

hite

Brow

n

Battery+

Fuse Bla

ckSwitch B

row

nW

hite

Blue

-

Alarmlight

15

Optional cabling with printer and alam Optional versions of Kimax 1 is supplied through a 5 x 0,34 mm2 cable.

Cabling with all optional outputs Optional versions of Kimax 1 is offer you a alarm switch through blue and white wire, RS-232 output through green wire and 0-5 V analog through yellow wire.






+ -Battery

Alarmlight

Fuse Gre

y

Switch Yel

low

Whi

teB

row

n

Axle #3 7,40 tonAxle #2 7 ,20 ton

Axle #1 6,90 ton

Gre

en -

RS

-232

Tx

Grey

BrownBlack G

PR

S

FM20

0

Battery+ -

Fuse Gre

yBl

ueW

hite

Switch

lightAlarm

Brow

n

Gre

en -

RS

-232

Tx

Yel

low

0-5V

anal

og

Relay

Relay

White

Yellow

+12 to 30 V DC

Ground

Printer

Grey

Brown

Green

Relay

Relay

Ground

+12 to 30 V DC

White

Blue

Brown

Grey

Analog output Yellow

OBC Green

16

Air sensor installation:

Connection of compressed air. Before you carry out any installation work related to the air suspension, make sure that the suspension has been brought to the lowest possible position and all compressed air is released. It is important to install the hoses in such a way that they are not affected by other components. The hoses must be fixed at suitable intervals Route the hoses in such a way that they are not exposed to exhaust heat and other heating sources that may lead to the permissible temperature being exceeded. Avoid damages from gravel, friction and contact with sharp edges. Avoid excessive tension of the hoses.

First step in the installation is to identify the hose supplying compressed air to the bel-lows. This hose, typically 8 mm outer diameter, has to be cut through and assembled once again with the T-piece supplied with the Kimax instrument. The 6 mm output port of the T-piece has to be connected to the Kimax instrument ac-cording to the drawing on next page.





Level valve

Storagetank

Maintainlevel

Air-pressure for KIMAX

Shock absorber

17





Air

inle

t 1

Major airflow to/from bellows

Minor airflowtowards pressure sensor

6 mm

8 m

m

8 m

mT-piece

throttle


All air-inlets on Kimax instruments and all belonging fittings are quick-release type. You need to make a clean cut in a right angle with a sharp knife before you connect a new tube to a Kimax instrument. You can release the locking mechanism by push-in the releasing ring on the air-inlet. (An 7 mm open-ended spanner is a suitable tool for pushing-in the release ring mean-while you slightly pull out the tube).

18

Sensor layout on different vehicles:





19

KIMAX 1 - Installation- and Instruction manual KIMAX 1 - Installation- and Instruction manual




20


Hydraulic installation on forklift:

3

2 1

3

2 1

Brown Black

The hydraulic sensor is connected as in-dicated on this diagram.




21

FAQ:

Troubleshooting Hose leakage No power on instrument No pressure on suspension system Moisture inside on instrument glas Display flashing all the time Display is blanked No alarms Lo can not be set below Hi





22




Dimension:

Supply cable Air inlet 1

Air inlet 2

KIMAX 1

Air inlet 1

Air inlet 2

View from rear side

(Optional)


23




Kimax 1 & Kimax 2 are registered trademarks owned by Sense-Tech Weighing Systems

Set includes: Kimax 1 cabin 2 sensors Part number 10001 1 x display unit, cabin 1 x mounting bracket 2 x angle fittings 2 x air pressure throttle dia. 6mm 2 x T-fitting dia. Ø 8mm / 6mm / 8mm Kimax 1 cabin 1 sensors Part number 10003 1 x display unit, cabin 1 x mounting bracket 1 x angle fittings 1 x air pressure throttle dia. 6mm 1 x T-fitting dia. Ø 8mm / 6mm / 8mm

Technical specification Kimax 1 cabin:

Supply voltage 10 ... 30 Volt direct current

Current consumption max. 90 mA

Alarm 1 Flashing display

Alarm 2 NO relay cintact max. 0.5 A/ 30 VDC

Display Three-digits 7-segment LED, character height 20.3 mm

Decimal position 000 / 00.0 / 0.00

Measuring accuracy ±2 % of maximum load at 0 °C - +50 °C

Air connection Quick release connection, 6 mm hose

Maximum pressure 15.5 bar (225 psi )

Operating pressure range 0 to 10.5 bar (0 to 150 psi )

Operating temperature -25 °C...+70 °C

Storage temperature -40 °C...+70 °C

Dimensions 100 x 50 x 40 mm

Cable length 1,5 m - 4 x 0,75 mm²

Weight approx. 240 g

Imperviousness IP 64

Approval CE and e1

Technical specification Kimax 1 trailer:








Air connection Quick release connection, 6 mm hose

Maximum pressure 15.5 bar (225 psi )

Operating pressure range 0 to 10.5 bar (0 to 150 psi )





Weight approx. 1650 g


Approval CE and e1

Set includes: Kimax 1 trailer 2 sensors Part number 10002 1 x display unit, trailer 1 x 2 mm sturdy stainless steel frame 2 x angle fittings 2 x air pressure throttle dia. 6mm 2 x T-fitting dia. Ø 8mm / 6mm / 8mm Kimax 1 trailer 1 sensors Part number 10004 1 x display unit, trailer 1 x 2 mm sturdy stainless steel frame 1 x angle fittings 1 x air pressure throttle dia. 6mm 1 x T-fitting dia. Ø 8mm / 6mm / 8mm


24

Sense-Tech Weighing Systems ApS ● Bygade 43 A ● DK 7173 Vonge ● Tel +45 7670 3001 ● Fax +45 7670 3002 ● [email protected] ● www.sense-tech.com

Technical specification Kimax 1 cabin - hydraulic:








Maximum pressure 250 bar

Operating pressure range 0 to 250 bar





Weight approx. 240 g + 250 g


Approval CE and e1

Set includes: Kimax 1 hydraulic Part number 10105 1 x display unit, cabin 1 x mounting bracket 1 x 0—250 bar Hydraulic transmitter ½” inlet 1 x ½” to 3/8” adapter

Kimax 1 - extended-1.pub

Documents

Transcript of Kimax 1 - extended-1.pub