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Dynatest FWD Owner's Manual

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DYNATEST FWD/HWD
TEST SYSTEMS
OWNER'S MANUAL
Version 2.8.17

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  • Page 1 DYNATEST FWD/HWD TEST SYSTEMS OWNER’S MANUAL Version 2.8.17...
  • Page 2 This document is subject to change without notice. No part of this document may be reproduced in any form without written permission of Dynatest. © 2017 Dynatest International A/S. All rights reserved Arial and Times New Roman are registered trademarks of The Monotype Corporation PLC.
  • Page 3 Please Read this first: For your own safety and the safety of others, please read this advice carefully. An FWD/HWD is a powerful, hence dangerous piece of equipment that may injure persons in cases of malfunction or mistreatment. Things that may happen: The weight may drop unexpectedly.

  • Page 4: Table Of Contents

    Connecting the Electronics ..................7-51 Leaving Base ....................... 8-54 Running the Program ....................9-56 Performing the Measurements ................10-69 The Dynatest FWD/HWD Hardware ..............11-84 Transducers/Cables ....................12-102 Calibration ......................13-105 Setup Details ......................14-113 The Compact15 System Controller ..............15-128 Maintenance ......................
  • Page 5 Dynatest Data Collection (DDC) ................4-25 Applet Overview ..................... 4-28 Completing the Setup ....................4-29 Preparing for Measurements ..................5-40 Checking the FWD/HWD Hardware ..............5-40 Drop Heights Adjustment ..................5-41 “Lock error” and “Plate not low error” ..............5-45 Weight Setup ......................6-46 Changing the U U F WDU U Weight Setup ................
  • Page 6 11.2 Trailer Specifications .................... 11-86 11.3 FWD/HWD Hydraulics ..................11-87 11.4 Electrical System ....................11-95 11.5 FWD/HWD Trailer Mounted Power Unit (Generator - Optional) ....... 11-98 Transducers/Cables ....................12-102 12.1 U U F WDU U Load Cell 86207 ..................12-102 12.2 U U H WDU U Load Cell 86205 ..................
  • Page 7 19.1 MS Access 2000 (MDB) ..................19-153 19.2 Comma Delimited (F25) ..................19-154 19.3 Nondelimited, 7+ Deflectors (F20) ..............19-159 19.4 Nondelimited, 7 Deflectors (FWD/HWD) ............19-164 19.5 Pavement Deflection Data Exchange (DDX) ............. 19-169 Error Messages ...................... 20-171 2017.06.19 FwdMan2.8.17.docx...
  • Page 8 The Compact15 System Controller ..............1-4 1.3.3 The Remote Control Box ................. 1-4 1.3.4 The Computer ....................1-4 1.3.5 FwdWin, a Windows based FWD/HWD Field Program ........ 1-4 Performance Specifications ..................1-5 1.4.1 Accuracy ......................1-5 1.4.2 Reproducibility ....................1-5 Tow Vehicle Installation ....................
  • Page 9 Distance Measuring Instrument ..............4-38 4.3.10 Global Positioning System (Optional) ............4-39 Preparing for Measurements ..................5-40 Checking the FWD/HWD Hardware ..............5-40 Drop Heights Adjustment ..................5-41 “Lock error” and “Plate not low error” ..............5-45 Weight Setup ......................6-46 Changing the U U F WDU U Weight Setup ................
  • Page 10 10.9 Exporting Data ...................... 10-80 10.10 Monitoring the System’s Status ................10-81 10.11 Manual Control ..................... 10-83 10.12 Exit ........................10-83 The Dynatest FWD/HWD Hardware ..............11-84 11.1 General Description ....................11-84 11.2 Trailer Specifications .................... 11-86 11.3 FWD/HWD Hydraulics ..................11-87 11.3.1 General Description ..................
  • Page 11 11.5 FWD/HWD Trailer Mounted Power Unit (Generator - Optional) ....... 11-98 11.5.1 Generator Operating Instructions ..............11-99 Transducers/Cables ....................12-102 12.1 U U F WDU U Load Cell 86207 ..................12-102 12.1.1 Key Features ....................12-102 12.1.2 Description ....................12-102 12.1.3 Specifications .....................
  • Page 12 19.1 MS Access 2000 (MDB) ..................19-153 19.2 Comma Delimited (F25) ..................19-154 19.3 Nondelimited, 7+ Deflectors (F20) ..............19-159 19.4 Nondelimited, 7 Deflectors (FWD/HWD) ............19-164 19.5 Pavement Deflection Data Exchange (DDX) ............. 19-169 Error Messages ...................... 20-171 2017.06.19 FwdMan2.8.17.docx...

  • Page 13: Introduction

    Benkelman or other beam type equipment is inaccurate at significant distances from the load because the deflection gauge must be supported within the deflection basin itself. The FWD, VMD or HWD may therefore - contrary to most other equipment - be used with analytically based structural design methods.

  • Page 14: General Specifications

    Dynatest 8600 System Processor. In conjunction with a newer model FWD, the Dynatest 8002 FWD featuring a loading range of 7 kN (1,500 lbf) to 120 kN (27,000 lbf), and a matching Hewlett Packard HP-85 Computer, this system was able to handle seven simultaneous deflections, one load and numerous site and configuration identifiers, in very short order, by a single operator doing inventory work.

  • Page 15: The Fwd/Hwd Mechanics

    FWD/HWD produces an essentially half-sine shaped, single “impact” load of 25-30 msec in duration, closely approximating the effect of a moving wheel load of up to 120 kN (27,000 lbf) (optionally 150 kN (33,000 lbf)) for the FWD/VMD or 240 kN (59,000 lbf) (optionally 300 kN (66,000 lbf)) for the HWD.

  • Page 16: The Compact15 System Controller

    1.3.2 The Compact15 System Controller The Dynatest Compact15 System Controller is a PC based control and signal processing unit, which is networked with the host computer (Ethernet).  A temperature controlled case, compact and light.  Controls FWD/HWD operation.  Performs scanning, conditioning and further processing of the transducer signals (1 load + up to 15 deflections).

  • Page 17: Performance Specifications

    (in terms of load) is 0.03 to 0.2 kN (7 to 45 lbf), magnitude dependent. 1.4.2 Reproducibility The reproducibility of successive FWD/HWD tests run on the same elastic materials is typically 1% in terms of the load/deflection ratio, for a given falling height and mass configuration.

  • Page 18: Tow Vehicle Installation

    The vehicle should be fitted with a trailer hitch with a 50 mm (or 2”) diameter hitch ball, the centre of which should be located 480-500 mm (18-20”) above ground level when LOADED with some 100kg (see also Note 2.2.1). The hitch must be rated for towing of the FWD/HWD trailer max. permissible weight.

  • Page 19: Battery Separation Relay (Provided If Needed)

    A battery separating RELAY should be used (see below). 2.1.7 Battery Separation Relay (provided if needed) IF (and ONLY if) the FWD/HWD System is powered from the EXISTING vehicle alternator (or its replacement), a special, heavy duty battery separation RELAY should be installed (see Note 2.2.3).

  • Page 20: Cable Access Opening

    2.1.15 Cable Access Opening The towing vehicle should be fitted with some kind of an opening in the rear, so that the network cable can be easily passed from the Computer to the Trailer (see Note 2.2.5). 2.1.16 Placing the Computer The towing vehicle should be fitted with some kind of a small table or the like for the Computer (see Note 2.2.6).

  • Page 21: Notes For The Vehicle Installation

    The Trailer Hitch should be approved for the FWD/HWD trailer max. permissible weight (see “Trailer Specifications”). The Dynatest FWD/HWD Trailer can be delivered with a coupler intended for a trailer hitch ball diameter of either 50 mm (1-31/32”) OR (optionally) 2” (50.8mm).

  • Page 22: Trailer Tail Lights Wiring

    The trailer lights are connected to the car by means of a cable typically equipped with a 13- pin plug (European Standard, other plugs/connections are optional). The towing vehicle should be equipped with a corresponding SOCKET (provided). The trailer lights wiring diagram for a specific trailer can be obtained from Dynatest on request. 2-10...

  • Page 23: System Powering

    Many vehicles are factory fitted with a 65 Amp. alternator which MAY be sufficient (FWD only, not for the HWD), if it can be adjusted and if the FWD is not used very extensively and the need for 12V supply for other devices (like warning flasher lights, etc.) is rather limited, but we strongly recommend to get the existing vehicle alternator upgraded/replaced to achieve the recommended 90 Amp.
  • Page 24 All in all, the EXISTING alternator MUST be POWERFUL (and be adjusted as explained below) to be able to provide an adequate and stable power supply for the FWD/HWD Test System. Diode Unit and Alternator Voltage Adjustment A so-called DIODE UNIT or Battery Separation Relay (provided if needed) should be installed for battery separation if the existing alternator is used - see diagrams on a following page.
  • Page 25 2-13 2017.06.19 FwdMan2.8.17.docx...
  • Page 26 2-14 2017.06.19 FwdMan2.8.17.docx...

  • Page 27: Plate-Low Alarm Connection

    FWD/HWD plate has been raised from the ground during the measurements, or if the plate lowers while driving between test points. In both cases the plate will be raised automatically.
  • Page 28 The mechanical switch in example No 3 may be replaced by a proximity switch (optional). A suitable proximity switch may be ordered from Dynatest. A proximity switch of the same type as used for the System status sensors (described in a later section) may be used (NPN output type, active low output).

  • Page 29: Cable Access Opening

    PARK/ALARM Override Plug Use this Plug to check out the PARK/ALARM functioning in servicing situations. Connecting this plug to the ALARM socket asserts the “Vehicle in PARK” signal (causing the PRK LED on the Compact15 front panel to be lit). WARNING! NOTE that this PARK/ALARM Plug should NOT be used in the field, but ONLY for servicing purposes (in the workshop or laboratory).

  • Page 30: Warning Signs / Flasher Lights

    2.2.7 Warning Signs / Flasher Lights The FWD/HWD System usually does not include any warning signs and/or flasher lights. Due to the limited height of the FWD/HWD Trailer, warning lights should be mounted on top of the towing vehicle for maximum visibility.

  • Page 31: Computer Configuration

    The computer must be considered an integral part of the data collection equipment. It should not be used for any other purposes. Therefore we recommend that Dynatest supply and configure the computer for the equipment. If the customer supplies the computer, then it must be open for modifications to Computer Name, Workgroup/Domain membership, Security Setup, User accounts, Network Setup, Power Options and Virus Protection.
  • Page 32 If this installation requests that a Dynatest program be uninstalled, then please do so (equipment information and setups are preserved) and then re-run the installation.
  • Page 33 Your desktop should now have an icon for the Dynatest Data Collection (DDC): Windows Firewall may show a message saying it is blocking certain functionality of the DDC. You will have the option to remove the blocking. Please do so (see below).

  • Page 34: Network Settings

    Compact15 and the computer. This can in some cases “Stall” the computer. To avoid this you should: EXCLUDE the C:\Dynatest folder and all sub-folders from automatic protection. EXCLUDE the following image/picture file types from automatic protection. Extensions: *.JPG, *.BMP 3-22 2017.06.19 FwdMan2.8.17.docx...

  • Page 35: Backup

    Sections.MDB Roadway Sections 3.5 Software Upgrades Updates and upgrades to the Dynatest DDC program suite are periodically posted to, and may be downloaded from, the following location (simply type the address in your internet browser or click the hyperlink): f tp://ftp.dynatest.com/downloads/DDC...

  • Page 36: Cameras

    Shut down the capture program and check that the camera appears in the Camera Applet’s “Pick Camera” list. 3.6.2 HCamera Applet This applet is used with the Dynatest MFV (Multi Function Vehicle) and all preparations are performed by Dynatest prior to delivery. 3-24...

  • Page 37: Program Configuration

    4.1 Dynatest Data Collection (DDC) When the “Dynatest Data Collection” is first started, this screen appears: This sample shows that you will run tests with FWD S/N 8002-080 and run the DMI, Thermometers and GPS “Applets”. There are various controls on this screen that affect program functionality. These controls and their functions will be discussed in the next few sections.

  • Page 38: User

    4.1.3 User Initially there are four users each having different levels of access. Administrator allows changes to layout and calibrations Dynatest is for Dynatest personnel, only Operator is for general data collection SysOp is for the trained operator These four accounts cannot be deleted To create another Operator, SysOp or Administrator entry, first choose the appropriate level from the list and then type the desired name (replacing the level).

  • Page 39: Entering The Main Program

    u tostart Check u tostart to make DDC start FwdWin and applets as soon as communication with the attached hardware is established. Auto-EXIT Check Auto-EXIT to close the opening window when the main program is terminated. Last COM Port Some Serial COM port drivers (Blue Tooth) can be extremely slow to determine if hardware is available or not.

  • Page 40: Applet Overview

    Operator. This page shows the typical appearance of each. TIP: If you need a second DMI display (e.g. on a secondary monitor) “clone” CS_DMI.EXE as follows: In C:\Program Files (x86)\Dynatest\Elements Copy CS_DMI.EXE to CS_DMI2.EXE 4-28...

  • Page 41: Completing The Setup

    4.3 Completing the Setup This section shall address setup of the FWD/HWD hardware components. These components include the following (note that some of the components are optional and may not be present on your FWD/HWD):  Loading Unit  System Controller ...

  • Page 42: Entering The Data Collection Screen

    DMI, GPS etc. The data collection screen opens automatically when the user clicks the Start button on the introductory screen. This screen is the primary user interface for operating the FWD/HWD. The data collection screen interface, in its simplest form, is shown below.
  • Page 43 For example, if for some reason the FWD/HWD requires more than 15 seconds to lower the plate to the pavement surface (lower plate = 15.0), an error message is generated by the program, indicating that some malfunction has occurred.

  • Page 44: Compact15 System Controller

    In the Deflector Circuits area, the user can indicate the Number of ACTIVE Channels. Note that to the right the user can also specify the maximum range of the deflectors. Dynatest produce two types, 2000 and 2450 microns (80 or 100 mils). You should consult your delivery documents and specifications to verify the type of deflectors provided.

  • Page 45: Deflectors

    This information is supplied by Dynatest for new FWD/HWD units. Changes to the values in this screen should only be performed by knowledgeable personnel.

  • Page 46: Program Options

    Access (MDB) format. You can chose to save load and deflection histories (recommended). The remaining formats are all text based. The first three (F25, F20, FWD) are earlier Dynatest ASCII formats. ‘Pavement Deflection Data Exchange’ (DDX) was developed by AASHTO in 1998. Microsoft Access (MDB) The Access file format is the ‘working’...
  • Page 47 7 Defl., 32/80 chr. (.FWD) This file format is one of the oldest developed by Dynatest for PC driven FWD/HWD equipment. It is the least versatile format and will only accommodate seven deflectors. A number of back calculation programs (Modulus, Evercalc, Modcomp) were designed for this file format, only.

  • Page 48: Air Temperature Sensor

    4.3.7 Air Temperature Sensor Dynatest provides an optional ambient temperature sensor for the FWD/HWD. If your unit is so equipped, FwdWin will monitor the output of this sensor and automatically record the information in the data file for each test point.

  • Page 49: Surface Temperature Sensor

    4.3.8 Surface Temperature Sensor Dynatest provides an optional pavement surface temperature sensor for the FWD/HWD. If your unit is so equipped, FwdWin will monitor the output of this sensor and automatically record the pavement surface temperature in the data file for each test point.

  • Page 50: Distance Measuring Instrument

    4.3.9 Distance Measuring Instrument Right click the DMI applet and choose Calibration. This window shows the Model, Serial Number, Pulses per Revolution (Advertised PPR), measured tire diameter, Calibration figure and a Calibration Procedure. The calibration figure for the DMI is shown in the box labelled Counts per 10 km. This represents the expected total number of counts that would be accumulated over a distance of 10 km.

  • Page 51: Global Positioning System (Optional)

    4.3.10 Global Positioning System (Optional) Right click the GPS applet and choose Setup. This window shows the Model, Serial Number, Source options, geometric parameters and GPX option: Embedded means that the GPS device is connected to CP15 electronics. Local is for a GPS connected directly to the computer.

  • Page 52: Preparing For Measurements

    Four pushbuttons and several LEDs (Light Emitting Diodes) at the Compact15 front panel may be used for manual control and check of the FWD/HWD operation. The pushbuttons are enabled by turning and holding the MAN.KEY switch in the clockwise position (which in turn will disable remote control from the computer in the towing vehicle).

  • Page 53: Drop Heights Adjustment

    Keep the RP button pressed until the plate subassy. has reached its top position. If the FWD is not at the measuring location, then lock and settle the plate subassy.: Make sure the transport locks are engaged in BOTH sides, and then press LP/RW until motor stops.

  • Page 54: Weight Setup

    300 mm dia. plate. For 450 mm dia. plate, the kPa values should be divided by 2.25). Tables 1 and 2 below apply for the FWD only. Tables 3 and 4 below apply for the HWD only.
  • Page 55 Table 2 ( F WD ONLY!) MASS of WEIGHT Load Range (approx.) (lbs) kPa/300 (770) 565-1700 40-120 9,000 -27,000 (550) 380-1200 27-85 6,000 -18,500 (330) 225-700 16-50 3,500 -11,000 (110) 100-270 7-20 1,500 -4,400 Table 3 (HWD ONLY!) MASS of WEIGHT k (approx.) (lbs) kPa/300...
  • Page 56 which results in a drop height ESTIMATE of 250 kg: h = (Pmax/k) = (11,000/ 935) = 138 mm (/25.4 = 5-1/2”) 350 kg: h = (Pmax/k) = (11,000/1,350) = 66 mm (/25.4 = 2-5/8”) At system delivery, the drop heights will normally have been factory pre-adjusted to: h1 = 50 mm, h2 = 100 mm, h3 = 200 mm and h4 = 390 mm (h1 = 2”, h2 = 4”, h3 = 8”...

  • Page 57: Lock Error" And "Plate Not Low Error

    5.3 “Lock error” and “Plate not low error” If you forget to release one of the plate subassembly transport locks and you press the LP/RW button to lower the plate, then the lowering will stop, when the PL LED turns off (while PH LED is still on), i.e.

  • Page 58: Weight Setup

    (refer also to 5.2, “Drop Heights Adjustment”). The FWD drop weight consists of a basic 50 kg (110 lbs) weight, to which may be added four, eight or twelve detachable 25 kg (55 lbs) weights and two, four or six detachable rubber buffers with shafts and fixing bolts to constitute a 50, 150, 250 or 350 kg (110, 330, 550 or 770 lbs) weight assembly.
  • Page 59 Repeat steps 14) to 17) with maximum drop height (or, in case of a weak pavement or floor, with maximum allowable load level). If the FWD should be moved before measuring, then press the RP button until the subassembly reaches its top position and lock all transport locks.

  • Page 60: Changing The U U F Wdu U Weight Setup

    6.2 Changing the H WD Weight Setup By changing size (mass) of the HWD drop weight, any of 4 loading ranges can be selected (refer also to 5.2, “Drop Heights Adjustment”). The HWD drop weight consists of a basic 240 kg (535 lbs) weight, to which may be added two, six or ten detachable 50 kg (110 lbs) weights.
  • Page 61 6-49 2017.06.19 FwdMan2.8.17.docx...
  • Page 62 4) Remove the outer 25 kg subweight and place it on the ground (i.e., NOT on a stud!). 5) Move the inner 25 kg subweight from its standby stud to the corresponding basic weight stud (or vice versa). 6) Add again the outer 25 kg subweight. 7) Apply the tubular nut and tighten it firmly.

  • Page 63: Connecting The Electronics

    7. Connecting the Electronics 7.1 Connecting Transducers/Cables When the FWD/HWD equipment has been installed as described in section 2, “Tow Vehicle Installation”, then connection of the Electronics (the Compact15 System Controller and the Computer) should be performed as outlined in the step-by-step procedure below.

  • Page 64: Note On Load Cell Cable Connection:

    7.1.1 Note on Load Cell Cable connection: Step 3 is usually factory performed and the cable for the Load Cell should be left connected, also when the equipment is not in use, and should only be disconnected in case of servicing or the like.

  • Page 65: Connecting The Computer

    7.2 Connecting the Computer 7.2.1 Interface connections To interface the Compact15 System Controller to the Computer, connect the Ethernet RJ45 socket on the Compact15 System Controller to the “CP15” RJ45 socket on the Remote Control Box using a standard CAT5 patch cable. If you use a Router (or ‘Switch’): Connect a Cross-Over Ethernet cable from the “PC”...

  • Page 66: Leaving Base

    / required. 8.2.2 Rear Lights Connection Connect the plug of the FWD/HWD rear lights cable to the appropriate socket on the rear of the towing vehicle and check the function of all lights.

  • Page 67: Just Before Leaving

    everything is operational when you arrive to the test site. If you are in a hurry, you may continue below at step 8.4 “Just Before Leaving...”. To perform a functional check, you need to be familiar with Section 9, “Running the Program”.

  • Page 68: Running The Program

    Compact 15 sounds another beep). Windows Firewall The first time you run “Dynatest Data Collection” the Windows Firewall may show a message saying it is blocking certain functionality of the DDC. You will have the option to remove the blocking. Please do so.

  • Page 69: Dynatest Data Collection (Ddc)

    9.3 Dynatest Data Collection (DDC) When the “Dynatest Data Collection” is first started, this screen appears: This sample shows that you will run tests with FWD S/N 8002-080 and run the DMI, Thermometers and GPS “Applets”. Check Vehicle ID, Driver Name and User Name If the FWD Serial Number stays pale, then check the 12V power on the Trailer, Network cables, Router/Switch and Park/Alarm circuit and then re-sequence power.
  • Page 70 9.3.1.1 Network The Network applet manages Section information. If section information is preloaded into the Sections database, then the operator can easily pick the right section each time a new file is created. The information is divided into Facility Section Details Structure for each section...

  • Page 71: Speedometer

    9.3.1.3 Speedometer The Speedometer applet displays the current driving speed The unit can either track the unit used in FwdWin (Default) or be set to kph or mph. 9.3.1.4 Thermometers The Thermometer applet displays three temperatures and colorizes Air and Surface temperature relative to the Asphalt temperature.

  • Page 72: Camera

    This example shows 1 image stored every 10 meters. Station Offset: Adjustment of your distance reading. (Part of the image file name). Session ID: Ad Session ID No to image file name. (For FWD and Survey testing only). File Type: BMP, JPG, TIFF or PNG. Quality: 100% is least compressed ~bigger files.

  • Page 73: Ground Penetrating Radar

    Idle state Yellow: Prepared to start Green: Started Setup: Shut down the GPR system when DDC is closed Encoder pulses per meter Offset from FWD loading plate to GPR antenna (negative if the antenna is behind the FWD) 9-61 2017.06.19 FwdMan2.8.17.docx...

  • Page 74: The Data Collection Screen

    9.3.2 Simulation Mode If the opening window cannot detect the presence of FWD hardware, you can still run the system in Simulation Mode. Simulation mode allows the user to run FwdWin even when the equipment is not connected. In this mode artificial data is fed into the program at the appropriate times to create the appearance that an FWD/HWD is actually connected.

  • Page 75: The Data Collection Screen

    NOTE: Some of the features shown in the following may not apply to your system. 9.4 The Data Collection Screen The data collection screen opens when the user clicks the “Start” button in “Dynatest Data Collection”. The screen consists of a Main window, sub-windows and applets. The large Main window is the primary interface or “mission control”...

  • Page 76: Main Window

    9.5 Main Window As mentioned earlier the Main window is the “mission control” for operation of the program. From this window the additional sub-windows can be toggled on and off by clicking the i ew menu item on the menu bar. Applets can be turned off from their individual menus. Greyed text boxes cannot be edited directly.
  • Page 77 Each control in a window has been assigned a tab order, so that when the user presses the TAB key the focus rectangle is moved to the next control in the tab order, and when TAB is pressed while simultaneously holding down the Shift key the focus rectangle is moved to the previous control in the TAB order.

  • Page 78: Special Keys

    navigate in the drop-down list simply use the up- and down-arrows. When an item in the drop-down list is highlighted the user can select it by pressing the Enter key.  The user can navigate the menu bar using short-cuts. Each of the items in the menu bar has an underscored letter in their name.

  • Page 79: Sub-Windows

    9.6 Sub-Windows The sub-windows listed here are FWD/HWD dedicated windows. General functions are handled by the previously described applets.  E D Panel  Time i stories Plot  u rface Modulus Plot  Surface o duli Chart The additional display components can be toggled on and off by clicking the i ew menu item at the upper left corner of the data collection screen.
  • Page 80 9.6.1 LED Panel This window gives feedback for proximity and pressure sensors and also the state of the MOS output drivers 9.6.2 Time Histories This window shows the time histories of the last drop. The peak stress and peak center deflection rules the auto scaling.

  • Page 81: Performing The Measurements

    You can create a Test Setup for each job type and store them for easy retrieval next time a similar job comes up. Note that the Test Setup screen is divided into different areas that control specific operational aspects of the FWD/HWD. These will be discussed in detail below. 10-69 2017.06.19 FwdMan2.8.17.docx...
  • Page 82 Correlation trials have proved the value of this option. Nevertheless, use of this feature is left to the discretion of the operator or responsible engineer. For further information, please contact Dynatest. Preserve Temperatures Some agencies manually measure asphalt temperatures at time of test in addition to or in-lieu of the surface temperature measurements.
  • Page 83 Station This item is mostly used when the FWD/HWD is equipped with a third party odometer that is not physically connected to the system. The operator would then read the distance from the dash and enter it into the dialog box that appears at each test point.
  • Page 84 Cracking Pavement surface cracking can influence the measured deflections making it difficult to analyze the deflection data. If cracking is turned on, the operator can record the severity of cracks in the vicinity of the test point. This will aid the analyst in properly processing the deflection data.
  • Page 85 Overflow Most deflectors delivered with Dynatest FWD/HWDs are capable of measuring deflections of up to 2000 microns (80 mils). Deflectors delivered with some systems are rated at 2450 microns (100 mils). If the range is exceeded, the deflectors may exceed their stated accuracy and the quality of the data may be in question.
  • Page 86 Prior to testing, the operator must define the sequence. A sequence is a series of programmed tasks to be performed by the FWD/HWD at each test point. The sequence box allows the operator to specify the number of steps, step types, and step parameters utilized at each test point.

  • Page 87: Test Section

    Once all of the items in the “Test Setup” screen have been modified as needed, the operator can then click the OK button to save the data and return to the data collection screen. p ply The Apply button serves the same function as the OK button except that the “Test Setup”...
  • Page 88 Districts Most highway agencies subdivide their networks into Districts for more efficient management. For the operator’s convenience, a list of Districts is compiled from the database contents Facilities Certain attributes of the facility under test can be defined and recorded by the operator. Again, it is possible to create and maintain a database for use on future projects.

  • Page 89: Data Files

    Access 2000, which is the most versatile and HIGHLY recommended. The remaining formats are all text based. The first three (F25, F20, FWD) are earlier Dynatest ASCII formats. ‘Pavement Deflection Data Exchange’ (DDX) was developed by AASHTO in 1998. For further information see 4.3.

  • Page 90: Running A Test

    Prior to running a test, it is assumed that the following functions have been performed (in addition to driving to the site and positioning on the first test point):  The program has been configured for the appropriate FWD/HWD unit  A proper test setup has been created (or loaded).

  • Page 91: Remarks

    10.5 Remarks It is sometimes desirable to enter additional Remarks after testing or while moving on to the next test station. Pressing the “Remarks” button (or F4 or Alt+R) opens the following window: Stored Station and Remark DMI Reading Reading when “Remarks”...

  • Page 92: Closing The Data File

    10.7 Closing the Data File The operator can close the data file by selecting lose from the i le menu item. The Microsoft Access (MDB) file closes and optional e tup – ASCII files as selected in p tions are subsequently written (se also 10.9 Exporting Data).

  • Page 93: Monitoring The System's Status

    10.10 Monitoring the System’s Status The program provides an interface that can be used to monitor the status of the FWD/HWD systems including voltages, deflector drifts, and statistics regarding the number of tests performed. These screens are accessed from the nformation menu item in the data collection screen.
  • Page 94 In other words, if you use the same computer to run two or more FWD/HWDs, the program will keep separate statistics for each. Note that the operator can overwrite the numbers shown in the Sequences and Drops fields.

  • Page 95: Manual Control

    The manual control screen consists of 6 objects: a drop button, a stop button, a raise weight lever, a lower plate lever, a graphical schematic of the FWD/HWD subassembly, and a schematic of the pavement structure. The RP lever lifts the plate when it is moved...

  • Page 96: The Dynatest Fwd/Hwd Hardware

    11. The Dynatest FWD/HWD Hardware 11.1 General Description The Dynatest 8002 FWD and 8082 HWD are trailer mounted Falling Weight Deflectometers of balanced and durable construction, having a low tongue load and a front supporting wheel. A low centre of gravity ensures stable towing at highway speeds.
  • Page 97 - One Ethernet cable connects the Compact15 System Controller to the Remote Control Box. - One “Trailer Power Cable” connects the 12V system of the FWD trailer to the alternator in the towing vehicle (or to an optional, trailer mounted Power Unit).

  • Page 98: Trailer Specifications

    11.2 Trailer Specifications 8002 FWD Trailer 8082 HWD Trailer 1200 kg (2,600 lbm) (single axle) 2,000 kg (4,400 lbm) Max. permissible weight 1300 kg (2,800 lbm) (tandem axle (standard)) (tandem axle) Tire size 165-13” 185 R14 C Tire pressure 2.8 bar (40 psi) cold 2.8 bar (40 psi) cold...

  • Page 99: Fwd/Hwd Hydraulics

    11.3 FWD/HWD Hydraulics 11.3.1 General Description The hydraulic system incorporates the following main items (refer to drawings on the following pages):  A hydraulic cylinder (“Main Cylinder”) for raising/lowering of the weight catch  Two (parallel connected) cylinders (“Side Cylinders”) for raising/lowering of the falling weight subassembly ...
  • Page 100 11-88 2017.06.19 FwdMan2.8.17.docx...
  • Page 101 FWD Hydraulics (without Automated Transport Locks) 11-89 2017.06.19 FwdMan2.8.17.docx...
  • Page 102 FWD Hydraulics (with Automated Transport Locks) 11-90 2017.06.19 FwdMan2.8.17.docx...
  • Page 103 HWD Hydraulics (with Automated Transport Locks) 11-91 2017.06.19 FwdMan2.8.17.docx...
  • Page 104 At all times, MAKE SURE that all power is OFF and KEPT OFF while anybody is close to the trailer mechanics/hydraulics! FWD ONLY: Now it should be possible to press up the ring “C” (see figure) by hand. The ring should stay in the upper position.

  • Page 105: Adjusting The Hyd. Pump Excess Pressure

    Tighten the A and B screws and remove the Allen wrench. Turn the MAN.KEY, lower the catch completely and raise the plate. It may be necessary to repeat the entire bleeding procedure after e.g. one day of FWD testing. 11.3.2 Adjusting the Hyd. Pump Excess Pressure The hyd.
  • Page 106 HWD: 75-85 bar (1050-1200 psi). This setting must at all times exceed the P1 setting, which is: FWD: approx. 40 bar (560 psi) HWD: approx. 60 bar (850 psi) which in turn must be higher than the pressure needed to raise the drop weight subassembly with maximum weight set-up, even under cold conditions (this pressure is normally at least 10 bar (150 psi) lower than the P1 settings listed above).

  • Page 107: Electrical System

    ELSE turn CLOCKWISE 1/8 revolution. Now the excess pressure should be equal to or very close to the P1 trip point pressure: FWD: approx. 40 bar (560 psi) HWD: approx. 60 bar (850 psi) best indicated by a flickering P1 LED (while the LC button is pressed).

  • Page 108: Fwd/Hwd Control Circuits

    11.4.2 FWD/HWD Control Circuits The remaining electrical circuits of the FWD/HWD unit are exclusively used for operational control, powered via the 12V trailer buffer battery. The Compact15 front panel incorporates 4 pushbuttons for manual operation of the FWD/HWD unit, and 6 LEDs for monitoring of the trailer proximity- and pressure switches.

  • Page 109: Hyd. Unit Connections

    150A fuse and to the TRAILER POWER CABLE via an 80A fuse, both placed in a heavy fuse box. The negative terminal of the battery supply is connected to a common GND point on the FWD/HWD frame. For powering of all other circuits than the motor, separate wires are connected directly from the battery supply to the bottom of the Compact 15 System Controller.

  • Page 110: Fwd/Hwd Trailer Mounted Power Unit (Generator - Optional)

    11.5 FWD/HWD Trailer Mounted Power Unit (Generator - Optional) The Dynatest 7071 Rapid Charge Generator has the following specifications:  Custom built 12VDC, with 120 Amps output, rapid charge generator driven directly (no belt) by a 4-stroke, 5.5HP Honda combustion engine ...

  • Page 111: Generator Operating Instructions

    11.5.1 Generator Operating Instructions Turn “ON” choke (Lever pushed to the far left). Turn “ON” fuel (Lever pushed to far right). Choke and Fuel Plug the charging connector Note: You can leave the plug connected even when the generator is not operating. IMPORTANT: NEVER DISconnect the plug while the motor is spinning!!!
  • Page 112 The YELLOW light will be on if the alternator is not capable of supplying sufficient current and keeping charging output voltage level of approx. 14.1 volts. Momentary lighting can be expected during normal operation of the FWD or HWD. This does not indicate any problem with the generator.
  • Page 113 Spillage of fuel on any part of the hot generator, including the exhaust, could result in fire and injury. • Please consult your company’s Safety Representative for your company’s safety procedures. In doubt on any of these procedures or if difficulties are encountered whilst operating the generator please contact Dynatest. 11-101 2017.06.19 FwdMan2.8.17.docx...

  • Page 114: Transducers/Cables

    Despite the low profile, the high range and the low cell deflection, the FWD load cell features a high electrical output of approx. 36 mV at max. FWD peak load and 15V excitation.

  • Page 115: Key Features

     High Output 12.2.2 Description The DYNATEST HWD LOAD CELL 86205 is a low profile shear web design strain gauge type load cell. Despite its range of 400 kN (88 kips), it features a height of only 63 mm (2.50”). Due to the shear web design, the cell will deflect less than 50 microns (2 mil) at max.

  • Page 116: Seismic Detector 86211

     Requires no power 12.3.2 Description The DYNATEST SEISMIC DETECTOR 86211 (SD, also sometimes named “deflector”, “deflection sensor” or “geophone”) is a very robust, high precision, light weight, seismic velocity transducer in a sealed aluminium housing with an internal electrical shield. It has a natural frequency of approx.

  • Page 117: Calibration

    Hence this Relative Calibration Procedure is so very important. The procedure is the same for FWD, HWD and Fast FWD. The system should be charged during testing.

  • Page 118: Analysis

    The Test-Setup for the Relative Deflector Calibration consists of 2 sets of 42 drops (2 seating and 40 recorded) separated by a pause. Thus a total of 85 steps. The recorded deflection must be 350µm ± 100µm. Place the Calibration Column with the deflectors in a vertical position close to the load cell and press it firmly to the ground.
  • Page 119 Choose ”Enable content”. Open the “Drops” tab and copy all content. 13-107 2017.06.19 FwdMan2.8.17.docx...
  • Page 120 Go to [C:\Dynatest\Data] and open “PrEN-5 RelCal.xlsx”. Choose the “Drops” tab and paste the copied data from the .mdb test file. Now copy the content from the “Transducer” tab in the .mdb test file to the “Transducer” tab in the .xlsx file, in the same manner as the drops content.

  • Page 121: Gain Adjustment

    Relative calibration should be performed again 2% Range: The means ratio must be within the range of 0.980 and 1.020. Contact Dynatest for evaluation of the deflection sensor if it is out of the 2% range. 13.1.3 Gain Adjustment As described in previous section a means ratio greater than ±0.005 requires an update of the...

  • Page 122: Air Temperature Sensor Calibration

    13.2 Air Temperature Sensor Calibration Before delivery of a Dynatest Air Temperature Sensor, the best-fit calibration line for this sensor has been established from linear regression on a set of 9 values obtained from a reference calibration procedure performed by means of a high-accuracy, certified, dry-block calibrator traceable to international standards.

  • Page 123: Surface Temperature Sensor Calibration

    13.3 Surface Temperature Sensor Calibration Before delivery of a non-contact Dynatest IR (Infra-Red) Surface Temperature Sensor, the best-fit calibration line for this sensor has been established from linear regression on a set of 9 values obtained from a reference calibration procedure performed by means of a high- accuracy, certified, dry-block calibrator (with a special adapter giving the desired emissivity of 0.95) traceable to international standards.

  • Page 124: Dmi Calibration

    13.4 DMI Calibration Dynatest provides a simple user-friendly method for calibrating the DMI. It does require however, that the user has access to a smooth straight pavement section (of say 1 km or 1 mile of length) which has been accurately measured and whose endpoints have been marked.

  • Page 125: Setup Details

    14. Setup Details 14.1 GPS 14.1.1 Prefetch Maps If you don’t have Internet connection during data collection, then you may prefetch map imagery when the Internet is available. This can be done by connecting your laptop to an office network and run DDC in simulation mode. Right click the GPS applet and chose “Map Setup”...

  • Page 126: Trimble Ag262 Setup

    14.1.2 Trimble Ag262 Setup We will setup the Ag262 through port B and later use the device through port A Install Trimble’s AgRemote software Connect signal cable to port B Connect RS232 plug to computer Apply power Start AgRemote and choose File – Connect, then select the right COM Port: Connection is established if this comes up: >...
  • Page 127 Click to enter Port A configuration: > Click until cursor reaches O in 8O1, then click once to make it N (no parity) > Click until cursor reaches TSIP, then click until you get NMEA If the baud rate is not 9600, then change it Press ←...
  • Page 128 Click to get to: Then click ESC to return to idle display Then Choose [File] – [Disconnect] and exit the AgRemote program. Switch off the GPS Connect signal cable to port A Check the GPS with DDC 14-116 2017.06.19 FwdMan2.8.17.docx...

  • Page 129: Trimble Bx982, Ver. 85992-01 (Basic Version) Setup

    14.1.3 Trimble BX982, Ver. 85992-01 (Basic Version) Setup Download WFC-BD9xx-V494.exe from this web site: http://intech.trimble.com/support/oem_gnss/trimble_bd982 Install on a computer on the usual 192.168.1.xxx network. Connect a Serial cross over cable to PORT4 at the BX 982 Connect an Ethernet cable to the BX 982 “Dongle” Start WinFlash and set the COM port for your computer: Chose “Configure Ethernet settings”...
  • Page 130 The default setting is DHCP Change that to “Static IP address” and enter IP Address: 192.168.1.19 Press OK and the BX 982 will reboot Exit WinFlash Open an Internet browser and enter 192.168.1.19 in the address line User name: admin Password: password 14-118 2017.06.19 FwdMan2.8.17.docx...
  • Page 131 In I/O Configuration click one of the TCP/IPs Chose: NMEA, Listen port: 15919, GGA at 10 Hz Press OK Chose Serial COM1 and setup for NMEA, 38400 Baud, GGA at 10Hz And Press OK Close the browser 14-119 2017.06.19 FwdMan2.8.17.docx...
  • Page 132 Start DDC with GPS applet colored Right click the GPS window and chose [Setup] Set Server to 192.168.1.19 and Listen port 15919 Enter figures for antenna position (there will be two Distance from Antenna fields, one for FWDs and one for RSPs) For standard GPSs the “Reference Point”...

  • Page 133: Upgrading A Bx982 To Ver. 85992-02

    14.1.4 Upgrading a BX982 to Ver. 85992-02 To upgrade a ver. 85992-01 (which has been set up as described above) to a ver. 85992-02, do the following: 1. Use the equipment laptop PC (or a computer with the usual 192.168.1.xxx network) 2.

  • Page 134: Cameras

    14.2 Cameras 14.2.1 Mounting Camera Suction Disc Mount Clean the window Clean the suction disk Pull back the plastic housing to protrude Press the rubber suction disk firmly against the rubber suction disk the window. Apply suction with the lever and lock in Adjust focus and aperture.

  • Page 135: Exposure

    14.2.2 Exposure Aperture Adjustment Shutter Speed and Field of Depth depends on the F-stop setting, the size of the aperture opening. The lens aperture ranges from F 1.4 to F 22 typically Smaller F-stops numbers = larger opening. Larger openings = more light. Larger openings = faster shutter speed.

  • Page 136: Unibrain Camera

    14.2.3 Unibrain Camera Unibrain Fire-i™ 780c 1394b SXGA, 2/3" CCD camera with a 12.5mm Fujinon C-mount “Megapixel lens”. Right click the Camera applet and chose “Picture Format” Values shall be: Pixel Format: YUV 4:2:2 Image Size: 1280 x 960. Fire-i 780c Frame Rate 7.5 (Frames/Sec). Unibrain Fire-i 980c Max resolution 2448 x 2048 pixels.
  • Page 137 For “Shutter” as well as for “Gain”, check the “at” box. Expo: Regulates the total amount of light. Can be used to regulate the overall “lightness / darkness” of the pictures. Shutter: and Gain: With check marks in Shutter Gain “at”...

  • Page 138: Unibrain Troubleshooting

    14.2.4 Unibrain Troubleshooting Camera has not been recognized by Windows. Is the LED on the camera on? Check all cable connections. Power and connection ok and still empty Empty Image Holder Image Holder? Right Click Image Holder. In the pop-up Menu Click “Pick Camera”.
  • Page 139 Fire-I 780: Values should be: Pixel Format: YUV 4:2:2 Image Size: 1280 x 960. Frame Rate 7.5 (Frames/Sec). Frame Rate 14-127 2017.06.19 FwdMan2.8.17.docx...

  • Page 140: The Compact15 System Controller

    15.2 General Description The Dynatest Compact15 System Controller is a compact, PC based electronic unit, interfaced with the electrical components of the FWD/HWD unit as well as with the Computer. The main functions of the System Controller are:  controls the FWD/HWD system hydraulics.
  • Page 141 12VDC Power supply CP15 Ethernet cables IBM compatible PC Remote Control Box A standard CAT5 Ethernet patch cable connects the Comapct15 System Controller to a Remote Control Box (inside the vehicle) which in turn connects with another patch cable to an IBM compatible PC.

  • Page 142: Notes On Specifications

    15.3 Notes on Specifications Note that the temperature range of the connected Computer may be narrower than that of the Compact15. Note also that the upper limit of 50°C (120°F) will be exceeded at a lower ambient temperature when the unit is exposed to direct sunlight. With respect to moisture, condensing should be avoided.

  • Page 143: Description

    15.6 Description LED indicator lights Indicates any “forbidden” Status Sensor Signal combination. ALERT PARK Towing vehicle Park indicator BATT Trailer battery voltage indicators. +15V Internal, stabilized +15V supply. Internal, stabilized -15V supply. Internal, stabilized +5V supply. CP15 Front Panel Transducer Connections Sockets: Socket for air-temperature probe.
  • Page 144 CP15 Front Panel Pressure Switch 1 (Hydraulics) Pressure Switch 2 (Hydraulics) Plate High Proximity Sensor. Weight High Proximity Sensor Plate Low Proximity Sensor Trigger Proximity Sensor Power for fan in Air Temperature device. Solenoid AL (Automatic locks). Solenoid BL (Automated locks) 12V power outlet (Activated by pressing the RP/X button (See below) 12V power outlet (Activated by pressing the LC/Y button (See below) DMI1...

  • Page 145: Manual Operation

    15.7 Manual Operation  Turn the POWER key “ON” CP15 Push Button Panel: If the embedded computer has not been booted through the laptop, wait approximately 30 seconds for the booting sequence to finish. (CP15 sounds a short beep).  For safety reasons the spring disengaged “MAN”...
  • Page 146 “Air Temp. Fan” 12V power outlet for fan in Air Temperature device. “Brakelight” Alternative Park Alarm input from brake light. “El. Box Fan” 12V power outlet for (optional) fan in FWD Electronics Box. “Beacons” Two coaxial 12V outlet plus one additional 12V outlet for beacons.

  • Page 147: Maintenance

    3) Inner parts of catch surfaces may be lubricated using a DRY spray lubricate such as Teflon of silicon. 4) FWD ONLY: The two external weight guide rollers may be lubricated using a dry spray lubricate such as Teflon or silicon.

  • Page 148: Electrical/Electronic Parts

    16.4 Hydraulic System 1) Check hydraulic oil level: When the FWD/HWD loading unit is in its transport position (i.e. when the plate (subunit) has been raised completely) and when parked on a level surface, then the hyd. oil level should be within the upper half of the level indicator on the hyd.

  • Page 149: Trouble Shooting

    11. Check the two pressure switches (See 16.11, “Checking the Pressure Switches”). 17.1 Checking the Hydraulic Oil Level When the FWD/HWD loading unit is in its transport position (i.e. when the plate (subunit) has been raised completely) and when parked on a level surface, then the hyd. oil level should be within the upper half of the level indicator on the hyd.

  • Page 150: Switching Off All Power

    If so, check motor brushes. If not, then the relay contact must be defective, and the relay should be exchanged. Note that brush exchange should only be performed by qualified personnel (e.g. by Dynatest). 17.5 Revealing hyd. leakage error A hydraulic leakage can cause one or more of the following errors: The weight drops prematurely.

  • Page 151: General Functional Checking Of The Hydraulics

    The different operational modes of the Trailer Hydraulics are activated by powering of one or more of the four hydraulic solenoids (coils), denoted A, B, C and D, plus the motor starting relay solenoid denoted M, refer also to 11.3, “FWD/HWD Hydraulics”, from which the truth table is repeated here for convenience:...
  • Page 152 solenoids should never be on at the same time, and when both are off, the in- and outlets of all cylinders are cut off from the pump supply, which in turn is shunted directly back to the reservoir. The only difference between RAISE WEIGHT and DROP modes is additional powering of the C valve in DROP mode, which will cut off the return oil from the raise weight cylinder, creating an excess pressure below the piston of this cylinder, a pressure that will propagate through a centre bore in the shaft to a small release piston in the catch, which will then release...
  • Page 153 17-141 2017.06.19 FwdMan2.8.17.docx...
  • Page 154 FWD Hydraulics (without Automated Transport Locks) 17-142 2017.06.19 FwdMan2.8.17.docx...
  • Page 155 FWD Hydraulics (with Automated Transport Locks) 17-143 2017.06.19 FwdMan2.8.17.docx...
  • Page 156 HWD Hydraulics (with Automated Transport Locks) 17-144 2017.06.19 FwdMan2.8.17.docx...

  • Page 157: B) Checking The Hydraulic Modes

    The D valve is only used to “convert” LOWER CATCH mode to RAISE PLATE mode (which will also lower the catch). Note that if plate is not low, then RAISE WEIGHT as well as DROP mode will cause the plate to be lowered and the two side cylinder shafts to be fully extended, before the relevant mode becomes active.

  • Page 158: Checking The Lower Plate/Raise Weight Mode

    Now press the LP/RW AND the red button until the weight drops (red button first in, last out). If it took more than 2 seconds to get the weight to drop, then the raise weight cylinder may need bleeding. (Refer to bleeding instructions in Chapter 11.3 FWD/HWD Hydraulics, the paragraph “Bleeding the Hydraulics”).

  • Page 159: Checking The Lower Catch Mode

    (refer to instructions in a previous section). If the catch will still not work, then it may be defective and should be repaired or replaced. In that case, contact Dynatest for further advice and instructions. 17.9 Checking the LOWER CATCH mode Lower the plate, raise and drop the weight.

  • Page 160: Checking The Pressure Switches

    If a switch will not turn on at all (and fuses are OK) then perhaps disconnect a WORKING switch (they are all identical) from its DIN socket on the CP15 front panel and connect the suspicious switch instead and check again. IF the switch now works, then the CP15 internal circuitry for the original switch socket may be defective, otherwise the switch itself is defective.

  • Page 161: P2 Check

    3) If step 2) was fulfilled, then P1 is probably OK. Perhaps also check that P1 LED remains ON during raising of the plate even with maximum weight set-up. If this is OK too, then you may proceed with P2 check below. If step 2 failed, this may be due to any of three causes: 4) Defective Wiring: Disconnect one of the two P1 wires directly on the switch.

  • Page 162: Optional Accessories

    18. Optional Accessories 18.1 Optional Hardware A variety of optional accessories are available for the Dynatest FWD and HWD Test Systems. Unless otherwise stated these will apply for the FWD as well as for the HWD. 18.1.1 Distance Measuring Instrument Distance information may be generated by the CP15 or by devices connected directly to the PC.

  • Page 163: Rear Extension Bar

    The standard colour of a Dynatest FWD or HWD trailer is bright blue (colour code: RAL 5017). At the time of ordering an FWD or HWD, any other colour with a RAL code can be specified at no or little extra cost (depending on actual colour). Colour matching to e.g., a towing vehicle colour may also be possible.

  • Page 164: Data Processing Software

    18.2 Data Processing Software 18.2.1 ELMOD For routine purposes, Dynatest can provide the ELMOD program (acronym for: Evaluation of Layer Moduli and Overlay Design). ELMOD is used to calculate the layer moduli and the remaining service life of an existing flexible pavement, and to carry out the structural overlay design.

  • Page 165: Data Formats

    19. Data Formats Data file extensions are shown in parentheses. 19.1 MS Access 2000 (MDB) This is the native format for FwdWin data files. Field data is stored in a number of tables as shown in the following relational diagram: The Sessions and Transducers tables record ‘Header’...

  • Page 166: Comma Delimited (F25)

    'Line-ID-Number' which is the 'key' to the contents of the line. File Type: SEQUENTIAL UASCII Text File (Line length varies). A file consists of 40 lines of "Header" information followed by TEST DATA, Comments etc. Optional Global Positioning data are stored BEFORE the related FWD/HWD test sequence data. Text items The width of a text field may vary Most text items are “Quoted“...
  • Page 167 Legacy 2016 Year Month 24 Day Hour Minute Legacy Load Cell 5200,”XX1 “,2,1.000,89.00, 0.02, 7.129 Serial Number Type 2:FWD 3:HWD 1.000 Relative Gain 89.00 Absolute Gain 0.02 Unbalanced Zero 7.130 Shunt Value Centre SD 5201,”0231 “,4,1.000,1.000 0231 Serail Number Type 4:2mm 5:100mil 1.000...
  • Page 168 Diameter of Plate and Y-Positions 5021, 300, ..Diameter of Plate D1, Center deflector 0 D2 “Other” Physicals 5022,0, 195, 386, Plate Type: 0=Standard 1=Split Plate Height ONE Height TWO Height THREE 386 Height FOUR Station and Lane Information 5023,1,3,0, 23.800, 31.200, 31.200,...
  • Page 169 Lines 34-35-36 presents the layout of “Station Information”. Station Id 5301,0,1,3,3, 31.500,1,1, 3,1991,06,05,20,07 0 1 3 Legacy Location unit 31.500 Station 1 1 Legacy Lane 2016 Year Month Hour 06 Minute Comments 5302,0,1,8,0,0,0,0,0,”Comment" 0 1 8 Legacy 0 Level of Cracking 0 0 0 0 Legacy Comment Temperatures...
  • Page 170 TEST data are stored chronologically from line 41 and up in groups of: “Station Information” as lines 34,35,36 above and one or more lines of Load and Deflection PEAK READINGS. Remarks and optional GPS information. Load and Deflection PEAK READINGS: 574, 434, 396,...

  • Page 171: Nondelimited, 7+ Deflectors (F20)

    File Type: SEQUENTIAL UASCII Text File with varying line lengths. A file consists of 36 lines of "Header" information followed by TEST DATA. Optional Global Positioning data are stored BEFORE the related FWD/HWD test sequence data. Items are located within fixed fields indicated by [X,Y], which defines the first and last character positions.
  • Page 172 [25,30] [31,36] [37,42] [43,48] ... "C:\DYNATEST\DATA\ .F200H20" [1,2] Working Disc Drive [3,28] \DYNA... Working Directory (26 characters max). [29,32] .F20 FWD Data file Extension. [33,33] 1 History Mode (NA) [34,36] MDB History stored in database "Generatorvej 21 ... [1,60] Roadway Identification.
  • Page 173 6=yards 7=Miles [10] 0 Pressure unit 0=kPa 1=psi [11] 0 Weight (mass) 0=kg 1=lb [12] 0 Distances 0=mm 1=in [13] 0 NA [14,15] 1 Lines per Station ID (ONE) [16,17] 1 Lines per Drop (ONE) [18,32] 23. " 0 0.0 0 0.0 ."...
  • Page 174 Steps stored 34. NA 35. NA 36. "SETUP Standard Setup " [1,8] SETUP First eight characters of setup name. [9,32] Setup Comment. ------------ END of HEADER ---------- 37. "*subsection ... Subsection Prefix character [2,61] User specified TEST data are stored chronologically from line 38 and up in groups of: Optional GPS data.
  • Page 175 STATION IDENTIFIER (the first one): "S 11506hvv 20.000 20 200209300110010112" Station_LaneAsphtCdSurAirLSHrMnWSPCEFGHsn Station prefix [2,9] 1150 Station (see [28]) [10,13] 6hvv Lane (text) [14,18] 20.0 Asphalt Temperature [19,20] “Condition” field (text) [21,23] Surface Temp (Optional) [24,26] AIR Temperature (Optional) [27] [28] “Location”...

  • Page 176: Nondelimited, 7 Deflectors (Fwd/Hwd)

    FWD/HWD Data File Type: RANDOM UASCII Text File (Fixed Line length). A file consists of 36 lines of "Header" information immediately followed by TEST DATA and Comments. Optional Global Positioning data are stored BEFORE the related FWD/HWD test sequence data.
  • Page 177 .FWD" [1,2] Working Disc Drive [3,28] \DYNA... Working Directory (26 characters max). [29,32] .FWD FWD/HWD Data file Extension. "Generatorvej 21 ... [1,32] or [1,60] Roadway Identification. "S 11506hvv 20.000 20 20020930" Copy of last STATION ID stored in file (see line 38).
  • Page 178 4=km extended 5=feet 6=yards 7=Miles 8=Miles ext. ext. 9=Miles.feet 0 Tmp. Prompt(s) 0=OFF 1=ON 1 Cnd. Prompt 0=OFF 1=ON 0 Roll off check 0=OFF 1=ON [10] 0 Pressure unit 0=kPa 1=psi [11] 0 Weight (mass) 0=kg 1=lb [12] 0 Distances 0=mm 1=in [13] 2 Station Step Mode, 0=No...
  • Page 179 [25,32] Drops 30. Not used 31. "A1aaB2bbC3ccD4dd... [1,89] Sequence step types (most recently used). A..D: Seating drops (never stored) 1..4: Drops at heights 1 to 4 (stored). e..n: “Target Sensing” drops (stored). Pause. Resettle loading plate. Stop (leave plate on the ground). [65,80] Reserved 32.
  • Page 180 Station_LaneAsphtCdSurAirLSHrMnWSPCEFGHsn Station prefix, No specific “direction” [2,9] 1150 Station (see [28]) [10,13] 6hvv Lane [14,18] 20.0 Asphalt Temperature [19,20] 00 “Condition” field (text) [21,23] Surface Temp (Optional) [24,26] AIR Temperature (Optional) [27] Station "Direction" I:Increasing or D:Decreasing [28] “Location” unit (as line 22.[6]) [29,32] 0930 Time of Day (HrMn) [33,36]...

  • Page 181: Pavement Deflection Data Exchange (Ddx)

    TemperatureUnits = Celsius SensorsLocationUnits = millimetre TestLocationUnits = kilometre, millimetre, millimetre GPSUnits = degree, degree, meter DropHistoryDataFrequencyUnits = Hertz [Device Information] DeviceDesignationName = Dynatest FWD DeviceModelNumber = 8082 DeviceSerialNumber = 8082-061 LoadCellSerialNumber = 86205-0071 SensorSerialNumbers = 86211-3701,86211-3702,86211-3703,86211-3704,86211- 3705,86211-3706,86211-3707,86211-3708,86211-3709 DeviceLoadType = impulse...
  • Page 182 [Data Configuration] NumberOfTestLocations = NumberOfDropHistoryDataSamples = 600 DropHistoryDataFrequency = 10000 [Test Location 1] TestLocation = 8.000, 0, 0 GPSLocation = 30.0000000, -82.0000000, TestLane = Right-1 TestTemperatures = 20.4, 24.1, 22.3 TestTime = 19:48:19 TestComment = DropData_1 = 596, 459.8, 414.6, 392.8, 355.6, 324.3, 254.1, 182.2, 111.8, 41.6 DropData_2 = 845, 649.2, 589.3, 559.9, 503.2, 453.2, 359.2, 255.6, 158.7,...

  • Page 183: Error Messages

    20. Error Messages The following is a list of equipment error messages. Error 536: Deflection OFF RANGE One or more deflections exceed the specified range ! (2000/2540 mu). Plot the test to check the shape of the Time History. Error 537: Repeatability check failed Pressure and/or Normalized Deflections of latest “Comparable”...
  • Page 184 the computer Network port verified by a technician. After this message you will have the opportunity to exit the program. Error 604: +/-15V supply OFF RANGE The system has measured a too high or too low +15V or -15V supply. Possible causes: Battery voltage off range.
  • Page 185 - Check trailer fuses. Error 620: Command echo The system did not recognize the last command. Error 621: Command fault The system did not accept the last command. Error 622: System Response The system response to the last command is not accepted. - Bad Numeric format.
  • Page 186 The Transport locks have not been unlocked. Defective PH and/or PL proximity switches. - Check ALL transport locks and optional unlocking hardware. - Check switch to LED correspondence in the Trailer. NOTE that a Deactivated PL switch (PL LED in Trailer OFF) means that the Plate IS Low.
  • Page 187 Error 643: Drop Timeout The time from initiation of the Drop mode until activation of the trigger (TG) proximity switch has exceeded a predetermined time limit (2 sec. typ.). Possible causes: TG proximity switch defective. Hydraulics need bleeding. Hydraulics failure. - If the weight actually dropped, then the TG switch MAY be defective.
  • Page 188 Error 647: Raise catch Timeout The time from initiation of the Raise Catch mode until activation of the P1 pressure switch has exceeded a predetermined time limit (5 sec. typ.). Possible causes: Pressure switch P1 defective or improperly adjusted. Hyd. pump excess pressure is too low. Hydraulics failure.
  • Page 189 Error 654: PL was ACTIVATED The PL (Plate Low) proximity switch was activated (i.e. Plate is NOT low!): Possible causes: The plate is NOT low (of course). PL proximity switch defective. P1 pressure switch defective or too sensitive. - The length of raise plate cylinder shafts limits the depth of "below ground" tests.
  • Page 190 Error 675: Load Cell Excitation A Load Cell Calibration found one or both of the following Voltages in error: Positive Excitation, typ +5.3V for FWD, +6.65V for HWD Negative Excitation, typ -5.3V for FWD, -6.65V for HWD Posible reasons: Load Cell cable not connected or defective.
  • Page 191 Error 677: Load Cell Calibration A Load Cell Calibration found one or both of the following Voltages in error: Calibration Level Shuntvalue type 3.5V for FWD, 3.25V for HWD Posible reasons: Load Cell cable not connected or defective. Connections exposed to moisture.
  • Page 192 - Check encoder mount - Check if Controller is ON. - Check if FPS600 is ON. - Contact Dynatest if the error persists Error 715: Excess Motor Controller Current The maximum allowed current in the controller was exceeded. Possible reasons:...
  • Page 193 The machine is tilted Switch OFF - Reduce the dropping mass if possible - Contact Dynatest if the error persists Error 719: Motor Undervoltage The induced voltage in the motor is bellow the required one to operate. The motor should receive 600V to work properly.
  • Page 194 - Check that the lock retracts when the LW1 plug is disconnected - Use button [Lock Weight] to check LW1 output and Lock function Error 749: Weight Release 1 (front) Micro Switch is NOT Activated The Micro Switch in Weight Lock 1 is not activated when it should be. Possible causes: Electrical break Lock malfunction...
  • Page 195 Error 754: Both TG and WH were ACTIVATED (ON) The TG (Trigger) proximity switch AND the WH (Weight High) were activated simultaneously. These sensors are mutually exclusive (only one can be active at a time). Possible causes: Trigger or Weight High malfunction - Check that "TG"...
  • Page 196 Error 759: TG was NOT activated The TG (Trigger) proximity switch was NOT activated when it should be. Possible causes: The weight WAS not resting at the base plate (of course). TG activator trouble. TG switch defective. - Check the TG activator (located at weight base plate). NOTE that the Trigger MUST be activated as long as the weight is raised less than 6 to 12 mm (1/4"...
  • Page 197 Switch OFF - Check the encoder cable and connectors - Check the motor cable and connectors - Check encoder mount - Contact Dynatest if the error persists Error 781: Homing Impossible The initial homing process failed. Possible reasons: Batteries are low...
  • Page 198 Lock malfunction Microswitch malfunction (feedback signal) Check: - Check Micro Switch connections, Cables, WR1 and WR2 (Weight Released) plugs - Check that the locks retract when the LW1 and LW2 (Lock Weight) plugs are disconnected - Use button [Lock Weight] to check LW1 and LW2 outputs and Lock function Error 792: Weight Released NOT Activated Weight Not Released.
  • Page 199 Error 795: WH was activated (ON) too early The WH (Weight High) proximity switch was activated too early during Raise Weight. This can happen if the Plate is locked in transport position AND the PH proximity signal is OFF. Possible causes: PH switch disconnected or defective.

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