Gen3 - Attachments - What is a Load Calibration & how to do it
The load calibration procedure will ask the operator to calibrate the load for the attachment.
For a complete list of all supported attachments for the Gen3 system please go to: Gen 3 - LMS Attachments
What is load calibration?
For an EQSS Gen3 system to properly monitor telehandler lifted loads and create safety cutouts to the hydraulics, two things are essential:
- Attachment manufacturer provided 'Load Chart' converted to digital format within the Gen3 Display for every attachment that will be used with the Gen3 system
- An Attachment load 'Calibration' for every attachment that will be used with the Gen3 system
Upon purchasing a Gen3 system from EQSS, there are already a quantity of attachments that are immediately usable (machine model dependent options). These load charts are fully tested and have approved load calibrations already included. If the attachment that you want to use on your telehandler is already represented within the Gen3 Display, then it's just a trivial matter of selecting it within the onscreen 'Attachment Selection Menu'. The attachment selection menu contains a list of all currently usable attachments for your particular make and model machine. However, for less operator confusion, some rental companies only list the attachments that they actually posses. All of the rest are disabled within the display software. It is of course possible to enable the rest by installing the EQSS Gen 3 Configuration Tool and then enabling other disabled attachments. Just keep in mind that operators will have to scroll through more onscreen options.
To use enabled attachments, simply change the physical attachment on the front of the machine, then scroll through the Gen3 Display until you find that attachment in the menu. Select the attachment, and your machine is ready to work. The Gen3 system will then monitor lifted weights and machine operating conditions. During normal use, if the Gen3 system deems an unsafe machine situation, then it will create a hydraulic cutout and halt a potentially dangerous situation from occurring. Cutting out the hydraulics when an unsafe condition is detected is the whole purpose of the Gen 3 safety system.
The Gen3 system also has a limited number of pre-loaded load charts (for most machines) that don't as yet have an approved load calibration. These can be enabled using the EQSS 'Gen-3 Configuration Tool' and then selected via the Gen3 Display. However, as no calibration exists for these attachments, the Gen3 onscreen Load Monitoring feature will not be possible until a load calibration has been completed for that attachment (further described below). Upon purchasing an EQSS calibration cable and downloading the free software suite, anyone with telehandler operation experience and an understanding of the Gen3 system, can perform a load calibration. The calibration is executed carefully and without bias
Load Calibration Required
When the Gen3 has an uploaded attachment load chart (but no calibration information), then an attachment calibration must be performed. The technician/operator will be required to perform the calibration procedure for each different attachment. The installed software suite includes the 'Gen3 calibration User manual'. This manual thoroughly explains the entire calibration sequence. It should be read and thoroughly understood before attempting a load calibration.
Brief Load calibration Outline
The first step in the procedure is to determine the pressure reading at different boom angles and lengths (with no load on the attachment); this is referred to as the zero calibration. The zero calibration is usually executed at two boom lengths and is made up of a series of boom angle calibration data steps/points. Each calibration step is sampled at a different boom angle. As the boom angle increases, the weight of the load (i.e. boom weight) shifts from the main lift cylinder to the boom pivot. Thus the pressure reading decreases as the boom angle increases. During a boom angle calibration step, the calibration software will ask to record the boom sensor data and store this information as a data point. These data points are then combined to produce a graph. The graph results in a curve. The graph points are then calculated to produce a curve of best fit. Finally, this curve of best fit is then used as a baseline reference point for the 'No Load' calibration profile.
The relatively straight line in the graph below, represents a good 'No Load' calibration. The data points align well with the straight line. Problems can occur when an inexperienced person performs a calibration; that has a number of these data points too far above or below the straight line. These 'outlier' data points can occur if samples are taken during the peak of a surge in the hydraulics. Uploading a badly executed load calibration can lead to erratic weight monitoring behavior by the Gen3 system, during the machine's normal operation. It is for this reason that we recommend the load calibration be performed again - if the results look a lot different to the graph below.
Example below of a good Zero Calibration – No Load
The same procedure is then repeated but with a different boom extension. If the boom segments extend in a non-proportional manner, a boom angle calibration should be performed at each extension where the next segment starts to extend. If the boom extends proportionally, it should only require another boom angle calibration at maximum extension. To complete the calibration, at least one boom angle calibration needs to be performed at a boom extension that is close to the maximum boom extension (allowed for the particular attachment being calibrated). The graph produces a similar graphed curve, however, the pressure required to lift the boom is greater when the boom is extended.
Once the zero calibration is completed, the system can now determine the resultant pressure with no load on the attachment (given the boom angle and length).
Outline of the Gain calibration:
Now do all of the above again with a known load weight - This is called: Gain Calibration
The gain calibration enables the system to know how the pressure increases when lifting a load. The operator will be required to lift a load with a known weight and then enter that weight into the software. The gain calibration is performed in a similar manner to the zero calibration; i.e. boom angle calibration steps at different boom extensions and the resultant graph curves will be similar.
Please be aware that the Gen3-LMS is only accurate when the lifted load is close to the rated capacity for the matching boom position. For example if you have a 4T telehandler and you lift a 1T load with the boom fully stowed in the 4T capacity region, the Gen3-LMS will not provide an accurate load reading. But as the boom is extended towards the 1T capacity region the Gen3-LMS load reading will become more accurate.
In simpler words, the Gen3-LMS system reads better onscreen accuracy as it approaches cutout limits (most often as the machine reaches maximum boom extension).
After the gain calibration is completed, the load calibration for this attachment is complete.
Before starting the load calibration make sure there are no faults or warnings displayed on the screen.
How to do a load calibration - Basic Outline
{see - eqss Gen-3 LMS Calibration Software - User Manual - for the complete procedure}
Calibration for attachments requires discipline, is time consuming and should be completed carefully.
To carefully and properly complete an attachment calibration, usually requires at least two hours of work.
The attachment calibration task requires:
1. A Gen 3 Calibration Cable (PN: AS001808 - purchased separately from EQSS)
2. A Laptop with Windows OS
3. An SD Card Reader
4. EQSS Calibration Software (part of the EQSS software suite)
5. An Operational Telehandler fitted with the EQSS Gen3 system
6. An accurate known weight (typically 800Kg - 1500Kg but will depend on the machine/attachment)
This article will NOT go deeply into the attachment calibration process as the software accompanying 'eqss Gen-3 LMS Calibration Software - User Manual', is a 41 page comprehensively written document that does a great job in describing and guiding the user through the calibration process. This document is automatically included when the EQSS software is installed (on the Laptop that will be used for the actual Calibration). Please take the time to read this manual as it also explains the functionality of the various parts of the software.
Download EQSS Update software
- Go to http://www.eqss.com.au in a web browser
- Click on Login in the top menu
- Type in the user name and password for your machine brand and click Log in (contact EQSS if you don't know your username and password)
- Click on Secure Menu in the top menu
- Click on the link EQSS Update Software Download
- Click on the link Download EQSS Update software V 1.7, to start the setup program download
- Once the download is complete, run the setup program to install the software
Download the latest model files using the EQSS Update software
- Run the EQSS Update software from Start Menu -> All Programs [All apps] -> EQSS -> EQSS Update
- Enter the same username and password into the User and Pass fields
- Click on Check For Updates to list the available updates
- Any new updates will automatically be ticked in the Select Updates window
- Click on Download Updates to download and install the updates
Note: It may also start the install processes for other software updates, run through the prompts to install the software - Once the downloads/installations are complete click on Quit
Running the EQSS Gen-3 Calibration Tool
- {Manual} Open the "eqss Gen-3 LMS Calibration Software - User Manual" : Start Menu -> All Programs -> EQSS -> EQSS Gen-3 Calibration Tool User Manual
- {Tool} Run the EQSS Gen-3 Calibration Tool - Start Menu -> All Programs -> EQSS -> EQSS Gen-3 Calibration Tool
- Begin by first executing the 'Sensors' Calibration
- Then proceed to Page 25 in the manual -- read and follow the instructions on the 'Load' - calibrating the load reading
- Continue through all of the steps until you complete [Gain Calibration - With load - Step 6]
When the EQSS software is downloaded:
The 'Gen-3 Calibration Tool User Manual' is also automatically downloaded and can be found on the Start Menu, within the EQSS folder.
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