DYNATEST FWD/HWD

TEST SYSTEMS

OPERATING INSTRUCTIONS
Version 2.6.26

2014.09.05

FWDOPERATION2.6.26

This document is subject to change without notice.

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!IMPORTANT SAFETY REMARKS!

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.

Hydraulic oil may leak at high pressure.

Hydraulic leakage may DROP the loading plate assembly onto the ground.

A few simple rules for the operator:

Stay clear of the FWD/HWD if at all possible.

Make sure nobody else gets close.

Never place objects like e.g. tools at or near the buffer hit plate.

Do not leave the weight raised to drop position.

Do not leave the subassembly raised and unlocked.

Support the weight or subassembly during maintenance.

During demonstrations, training etc.:

Announce what you are about to do before you press any buttons.

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iii

Table of Contents
1.

Leaving Base ................................................................................................................ 1-1

1.1 Maintenance Checks .................................................................................................. 1-1
1.1.1 Tire Pressure ........................................................................................................ 1-1
1.1.2 Hydraulic Oil Level ............................................................................................. 1-1
1.1.3 Battery Acid Level............................................................................................... 1-1
1.1.4 Loading Plate Swivel........................................................................................... 1-1
1.2 Connect Trailer to Tow Vehicle................................................................................. 1-2
1.2.1 Hook to Hitch ...................................................................................................... 1-2
1.2.2 Rear Lights Connection ....................................................................................... 1-2
1.2.3 Front Support Wheel ........................................................................................... 1-2
1.2.4 Power Cable ........................................................................................................ 1-2
1.2.5 Ethernet Cable ..................................................................................................... 1-2
1.3 Functional Check ....................................................................................................... 1-2
1.4 Just Before Leaving.................................................................................................... 1-3
1.4.1 Transport Locks (Automated or Manual) ............................................................ 1-3
1.4.2 Raise/Lower Bar Locking Pin ............................................................................. 1-3
1.4.3 Trailer Handbrake................................................................................................ 1-3
1.5 During Driving ........................................................................................................... 1-3
2.
Preparing for Measurements ..................................................................................... 2-5
2.1 Functional Checking of the FWD/HWD trailer ......................................................... 2-5
2.2 Lock error and Plate not low error ...................................................................... 2-9
3.
Performing the Measurements ................................................................................. 3-11
3.1 Warnings .................................................................................................................. 3-11
3.1.1 Emergencies ...................................................................................................... 3-11
3.1.2 Stopping a Sequence ......................................................................................... 3-11
3.1.3 Driving .............................................................................................................. 3-11
3.2 Running the Field Program ...................................................................................... 3-12
3.2.1 Switch ON ......................................................................................................... 3-12
3.2.2 Dynatest Control Center .................................................................................... 3-12
3.2.3 User interface .................................................................................................... 3-13
3.2.4 Test Setups ........................................................................................................ 3-15
3.2.5 Test Location ..................................................................................................... 3-21
3.2.6 Data Files........................................................................................................... 3-23
3.2.7 Running a Test .................................................................................................. 3-24
3.2.8 Closing the Data File ......................................................................................... 3-25
3.2.9 Opening a Data File ........................................................................................... 3-25
3.2.10
Exporting Data ............................................................................................... 3-26
3.2.11
Monitoring the System Status ........................................................................ 3-27
3.2.12
Manual Control .............................................................................................. 3-29
3.2.13
Exit ................................................................................................................. 3-29

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1. Leaving Base
This section describes a procedure which we strongly recommend to always be performed before
you leave your "home" base, to ensure that the entire FWD/HWD Test System is properly
prepared and set up for field testing, and to also ensure that any possible deviations and/or error
conditions can be detected and dealt with more conveniently at your base.
SAFETY NOTE:

IF deviations occur, which you yourself cannot easily correct without

any safety risks, then a trained technician with your own organization
or with Dynatest or a Dynatest representative should be called in.

1.1 Maintenance Checks

The steps of this paragraph are particularly important if the equipment has been out of operation
for an extended period of time.

1.1.1 Tire Pressure

Check tire pressure of both/all wheels (2.8 bar / 40 psi, cold) and adjust if necessary.

1.1.2 Hydraulic Oil Level

Check the hydraulic oil level, when - and ONLY when - the plate (i.e. the drop weight
subassembly) has been raised completely! Refill with the prescribed quality of HYDRAULIC oil
if necessary.

1.1.3 Battery Acid Level

Check the acid level of all cells and refill if necessary (with distilled or de-mineralized water
ONLY).

1.1.4 Loading Plate Swivel

Make sure that the loading plate swivel bearing can move freely. This is done by checking that
the edge of the loading plate can be pressed downwards by a foot a couple cm (an inch or so)
with limited effort. (The FWD swivel should be greased regularly. The HWD swivel is
maintenance free except for some old models).
Please NOTE that a "frozen" loading plate swivel can cause destructive damage to the load
cell!!

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1-1

1.2 Connect Trailer to Tow Vehicle

1.2.1 Hook to Hitch
Hook up the FWD/HWD trailer tongue coupler to the tow vehicles trailer hitch ball. MAKE
SURE THAT the coupler indicator shows that it has been properly locked to the ball.
Attach the inertial brake breakaway security wire to the vehicles towing hitch assembly.
ALTERNATIVELY, (OR in addition), attach heavy safety chains from the trailer to the vehicle.
For additional breakaway (and theft!) prevention, the supplied tongue coupler key lock can be
applied.

1.2.2 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.

1.2.3 Front Support Wheel

Raise and secure the FWD/HWD front supporting wheel, using the heavy split-pin. (Tighten the
clamp VERY well).

1.2.4 Power Cable

Connect the heavy, 2-pin male plug of the trailer power cable to the matching, female power
output socket on the rear of the towing vehicle (or to an optional gasoline power generator if
applied). (Be CAREFUL NOT to SHORT the pins in the plug, as these are connected to the
trailer buffer battery!).

1.2.5 Ethernet Cable

Connect the Ethernet cable from Compact 15 to the Remote Control Box in the vehicle. If this
connection is made up of several cables, then check all connections. Assure that cables and
connectors are not stressed.

1.3 Functional Check

At this point in the FWD/HWD preparation it is strongly recommended to perform a functional
check of the complete Test System BEFORE driving to the test site, to make sure that everything
is set up and operating correctly. This is done by performing the procedures outlined in the two
following Sections: "Preparing for Measurements" and "Performing the Measurements".
IN ANY CASE, i.e. AFTER the Functional Check OR if you e.g. due to urgency should decide
not to perform this Check before leaving, MAKE SURE to ALWAYS FINISH UP WITH
performing the REMAINDER OF THIS SECTION.

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1.4 Just Before Leaving...

1.4.1 Transport Locks (Automated or Manual)
Please NOTE that this step MUST ALWAYS be performed, no matter whether the transport
locks are automated or manually operated!
Switch ON the Compact 15 by turning the Power key at the front panel (do not use the Remote
Control Box) and wait until you hear a beep (30 seconds).
Make sure that the plate subassembly is in its topmost position and that ALL of its transport
locks have been brought properly into their locking position in BOTH SIDES!
After having done this, the subassembly MUST MANUALLY be LOWERED again TO
SETTLE on the locks by pressing the LP/RW button (at the Compact 15 Front Panel) and
keeping it pressed until the motor stops automatically. The subassembly should settle firmly
on the locks after having lowered a couple cm (some 1) MAX. IF NOT, then corrective action
MUST be taken before driving!

1.4.2 Raise/Lower Bar Locking Pin

Make sure that the guide rod of the raise/lower bar front end support mechanism has been locked
in its top position by the appropriate locking pin.

1.4.3 Trailer Handbrake

IMPORTANT! Make sure that the Trailer handbrake is fully released!

1.5 During Driving

WARNING!
NEVER switch ON or OFF or perform Computer HARD-RESET WHILE DRIVING!!
This MAY initiate uncontrolled Trailer hydraulics activity!

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2. Preparing for Measurements

The functional checking procedure as outlined in the following subsection should be performed
in the following cases:
Before leaving the (home) base for a testing job:
- in this case you must perform at least all bold face numbered items, meaning that you
may skip all item numbers in parenthesis ( ). Additionally, it is strongly recommended to
perform at least one complete, automated testing sequence subsequent to the checking
procedure, as described in a following section titled Performing the Measurements.
If the equipment should be malfunctioning during a testing job:
-

in this case the entire functional checking procedure should be performed.

SAFETY NOTE:

IF any deviations from the expected operation - as described in the

following procedure - should occur, which cannot be corrected easily by
yourself without any safety risks, then a trained technician with your
own organization or with Dynatest or a Dynatest representative should
be called in.

2.1 Functional Checking of the FWD/HWD trailer

One key switch, six LEDs (Light Emitting Diodes) and four pushbuttons of the Compact 15
front panel may be used for manual control and check of the FWD/HWD operation:
Key Switch:

MAN.KEY

Pushbuttons:

LP/RW
RP
LC
DROP

LEDs:

PS1
PS2
PH
WH
PL
TRG

ON: Enable pushbuttons

Lower Plate / Raise Weight
Raise Plate
Lower Catch
Drop in combination with LP/RW button
Pressure Switch No.1
Pressure Switch No.2
Plate High
Weight High
Plate (not) Low
Trigger

Turning the MAN.KEY switch enables the pushbuttons.

The preparation and functional checking of the FWD/HWD Trailer is then performed as outlined
in the procedure in the following.

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Please NOTE that if the trailer hydraulics at ANY time does not function as outlined in the
procedure when operated by the manual pushbuttons, OR if any other deviation from the
expected and described operation occurs, then for safety reasons, a specially trained and
authorized technician must be called in for rectification of the problem(s).

! SAFETY NOTE !
Whenever somebody is close to the moving parts of the FWD/HWD Trailer,
MAKE SURE that all POWER has been switched OFF!
(ONLY the green 12V LED at the Compact 15 front panel may be lit, all others off)

Prior to performing the procedure in the following it must be ensured that the loading plate
(i.e., the drop weight subassembly) is in its topmost position and has been locked securely by
the transport locks. If not so, then perform items 9, 25 and 26 of the procedure to accomplish
this.
The transport locks must remain engaged during the first 11 steps of the procedure.
1.

Make sure that only the green 12V LED at the Compact 15 front panel is lit, all others off.

2.

Check that the rod of the centre deflection device (deflector holder) sticks out through the
centre hole in the bottom of the loading plate a distance of some 10-20 mm.

3.

Make sure that all the geophone holders are tightly connected to the beams of the
raise/lower bar (in the correct distances from the loading centre).

4.

Check the springs, foam rubber guides and movable parts of all deflector holders to
ensure they are functioning properly.

5.

Make sure that all geophones are properly in place and that all measuring rods/tips are
tight (i.e. not bent, loose or missing!).

6.

Check also that all geophone cables are tied properly to the raise/lower bar beams without
being strained.

7.

Check that the (steel) cable for the raise/lower bar is properly positioned on all guide
pulleys.

8.

Make sure that the loading plate swivel bearing can move freely. This is done by checking
that the edge of the loading plate can be pressed downwards by a foot a couple cm (an
inch or so) with limited effort. (The FWD swivel should be greased regularly. The HWD
swivel is maintenance free except for some old models).
Please NOTE that a "frozen" loading plate swivel can cause destructive damage to the
load cell!!

9.

Switch ON the Compact 15 and wait for the initial beep (approx. 30 seconds).

(10)

Now the LEDs must be ON (i.e. lighted) or OFF as follows:

2-6

PS1(red)

PS2(yellow)

PH(green)

WH(red)

PL(yellow)

TRG(green)

ON

(ON or OFF)

ON

OFF

ON

ON

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11.

Turn MAN-Key and press shortly the RP (Raise Plate) button, so that the plate (i.e., the
drop weight subassembly) is raised to its topmost position to clear the transport locks.
Press the RP button shortly a couple more times and make sure that the PS1 LED turns
OFF each time while the button is pressed (because the motor & hyd.pump will create
maximum (i.e. excess) pressure). The PS1 LED must be ON whenever the motor is not
spinning.

12.

Unlock the transport locks. (In case of automated locks, this is done by pressing the LC
button for approx. 1 second).

13.

Remove the locking pin from the guide rod of the raise/lower bar front end support
mechanism.

14.

Lower the plate (i.e., the drop weight subassembly) to the ground by pressing the LP/RW
(Lower Plate/Raise Weight) button and check that the raise/lower bar is lowered
concurrently with the plate. Keep the LP/RW button pressed until (and only until) the PL
LED turns off (see also the WARNING below!).
(NOTE: IF the motor stops before the PL LED turns off, and the LP/RW button becomes
inactive, then press shortly the RP button (until the TRG LED comes ON) and repeat the
plate lowering, this time by pressing the RED button and the LP/RW button
simultaneously, but again, only until the PL LED turns off!!).

! WARNING !
PLEASE be aware that IF the LP/RW button is kept activated for an extended
period (i.e. some 5-10 seconds) AFTER the settling of the loading plate on the
ground, then the drop weight will be raised, and IF it reaches the top position,
then it WILL BE RELEASED AUTOMATICALLY!!

(15)

Now the LEDs must be ON or OFF as follows:

PS1(red)

PS2(yellow)

PH(green)

WH(red)

PL(yellow)

TRG(green)

(ON or OFF)
OFF
OFF
OFF
ON
ON*)
*) IF the TRG LED is OFF at this point, then press shortly the LC button until PS2 turns
OFF, after which TRG must be ON.
16.

Check that all the geophone holders of the raise/lower bar are now resting properly on the
ground, and that the measuring tip of each holder is resting directly and freely on the
ground through the hole in the bottom of the holder.

(17)

Keeping the above WARNING in mind, and watching the WH LED, press the LP/RW
button and ensure that the WH LED will blink whenever a pre-adjusted drop height is
passed, but STOP after 3 blinks or well before maximum height. The 4th height will
normally be so close to maximum drop height that it will be difficult to check without
dropping the weight, so do NOT check this 4th height IF a drop from full height is
undesirable. IF the weight is dropped from maximum height, then raise it again (by
pressing the LP/RW button) at least 50-100mm (2-4).

(18)

With the drop weight raised to any height in excess of 50mm (2), the LEDs must be ON
or OFF as follows:

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(19)

PS1(red)

PS2(yellow)

PH(green)

WH(red)

PL(yellow)

TRG(green)

ON

ON

OFF

(ON or OFF)

OFF

OFF

The DROP function can now be checked by pressing simultaneously the LP/RW button
AND the RED button, BUT PERHAPS first lower the weight to a smaller drop height (by
pressing the LC button) if you wish to limit the impact load in the actual test location.
The weight must drop within 1 to 2 seconds when the LP/RW & RED buttons are
pressed.

(20)

Raise the catch (without the weight) by pressing the LP/RW button, and keep the button
pressed until the PS1 LED turns OFF (due to excess pressure) when the catch reaches the
top position. PS1 must turn ON again when the LP/RW button is released.

(21)

Now the LEDs must be ON or OFF as follows:

PS1(red)

PS2(yellow)

PH(green)

WH(red)

PL(yellow)

TRG(green)

ON

(ON or OFF)

OFF

OFF

OFF

ON

(22)

Now WATCH the PS2 LED and KEEP watching it ALL THE TIME while the catch is
lowered again by pressing the LC button: the PS2 LED must be ON continuously UNTIL
the catch reaches and engages with the weight, shortly after which it must turn OFF again
(at which time you should release the LC button).

(23)

Press again shortly the LC button a couple times and check that the PS1 and PS2 LEDs
are both OFF each time while LC is activated. When LC is deactivated, PS1 must turn
ON again, while it does not matter if PS2 turns ON or not.

(24)

Check that the LEDs still fulfil step (21) above.

25.

Raise again the plate (i.e., the drop weight subassembly) by pressing the RP button.
Check that the raise/lower bar is raised concurrently with the plate. Keep the RP button
pressed until the drop weight subassembly has reached its top position.

26.

If the FWD/HWD is equipped with MANUAL transport locks (and is not at the
measuring location), then lock the drop weight subassembly. Make sure the transport
locks are engaged in all 4 supporting points. If not, then press shortly RP and check again.

27.

Now the drop weight subassembly should be lowered again TO SETTLE on the locks for
optimum support, by EITHER pressing the B-valve with an appropriate rod OR by
pressing shortly (less than 1 second) the LP/RW button.

28.

Now the LEDs must be ON or OFF as follows:

PS1(red)

PS2(yellow)

PH(green)

WH(red)

PL(yellow)

TRG(green)

(ON or OFF)
OFF
ON
ON
ON*)
ON
*) PL may be OFF, if LP/RW was pressed more than approx. 1 sec. in the previous step.
This is OK, but will create an annoying beep.
29.

Secure the rod of the guide mechanism of the far (front) end of the raise/lower bar with
the appropriate locking pin.

30.

You may now switch OFF the Compact 15.

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2.2 Lock error and Plate not low error

If any of the drop weight subassembly transport locks is/are not properly unlocked and therefore
preventing the subassembly from lowering when you press the LP/RW button, then the lowering
will stop automatically, when the PL LED turns off (while the PH LED is still on), i.e. the
LP/RW button will become inactive. The RP button will still be active, so that the plate can be
re-raised to enable releasing of the lock(s).
Also, for smaller drop weight setups, the weight MAY start raising (slowly) during lowering of
the plate using the LP/RW button. If this causes the TRG LED to turn off while the PL LED is
still ON, then it will not be possible to lower the plate further. In that case, use the LC button to
return the weight and try again (perhaps use DROP (LP/RW + red button) to lower the plate,
until the PL LED turns off).
So, if the LP/RW button will not work, then always check that the PH, PL and TRG LEDs do
NOT fulfil any of the following, erroneous combinations (x means dont care):

PH

PL

TRG

Lock Error:

on

off

Plate Not Low Error:

on

off

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3. Performing the Measurements

3.1 Warnings
3.1.1 Emergencies
If you have to move away from the test site swiftly:
1) Go OUT OF PARK or RELEASE the HAND BRAKE. This will instantaneously initiate a
Raise Plate operation (beeper will sound).
2) WAIT until the Plate AND the deflectors are OFF GROUND (beeper still on).
3) Drive away.
The beeper will stay ON until the plate has been raised COMPLETELY.
(The automated Raise Plate action in step 1 is on condition that Park/Alarm circuits have been
installed properly!).

3.1.2 Stopping a Sequence

If e.g. someone approaches the equipment it may be necessary to Stop or Pause an ongoing test
sequence. Pressing ESCape or any function key from F1 to F3 will pause the test and bring up a
screen with the following options:
In any case, be very careful what you do next!
If you stopped because you suspect some
malfunction, do NOT continue the sequence.
Instead, lower the weight manually and do
trouble shooting.

3.1.3 Driving
Things you should NOT do while driving:
NEVER switch the Computer OFF or ON
NEVER perform Computer HARD-RESET as this may cause UNCONTROLLED
HYDRAULICS ACTIVITY

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3.2 Running the Field Program

3.2.1 Switch ON
IMPORTANT: DO NOT DRIVE while you or your co-pilot switches on the system!
The recommended preparations are detailed in section 1, Leaving Base.
You must switch on the computer and Compact 15 as follows:
1.
2.
3.
4.

Make sure everything is switched off (Check Power key at Compact15 front panel).
Switch ON the computer and wait until it is ready (hard disk idle).
Make sure that the PARK/ALARM signal is active (PARK LED ON).
Switch ON the Compact 15 by pressing ON at the Remote Control Box (after approx 30
seconds the Compact15 sounds a beep).
5. Wait at least one minute (watch LEDs for network activity at the RJ45 socket).
6. Start Dynatest Control Center (Shortly after the Welcome screen is shown the Compact
15 sounds another beep).

3.2.2 Dynatest Control Center

When the Dynatest Control Center is first started, the following screen appears:

This sample shows that you will

run tests with FWD S/N 8002080 and run the DMI,
Thermometers and GPS
Applets.
If the FWD Serial Number stays
pale, then check the Park/Alarm
circuit and Network cables, then
re-sequence power.

You will normally not need to change anything here. Just check that the FWD/HWD serial
number is correct, enter or select the driver and operator names. A password may be required for
Administrators.
Click Start to proceed to the data collection screen.
Click Exit to stop execution at this point.

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3.2.3 User interface

FwdWin functions much like any other Windows based programs so users accustomed to
working in Windows should feel right at home with the program. FwdWin is mouse driven, but
wherever possible keyboard shortcuts (Alt + underlined letter) help reduce the requirement for
mouse operation.
The main component of the FwdWin interface is the data collection screen as shown next.

This window appears after the operator clicks the Start button on the welcome screen. This is the
primary window or mission control for operation of the FWD/HWD, i.e. everything is
controlled from here.
Greyed text boxes cannot be edited directly. Some are filled automatically (temperatures) others
may open sub-windows for data entry.
In addition to the data collection screen and the Applets, the FwdWin interface is composed of a
number of components (sub-windows) that the user may choose to display or hide. The
additional components are:

LED Panel

Feedback signals from hydraulics and proximity switches

Time Histories Plot

The shape of load and deflection signals

Hysteresis Loop

Center deflection versus force (energy loss)

Surface Moduli Plot

Graphic presentation of surface moduli

Surface Moduli Chart

Shows surface moduli from several tests

Back Calculation

Tabulated estimates of layer moduli

Back Calculation Chart

Shows layer moduli from several tests

Printer Paper

Print preview

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The data collection screen and the additional components can be arranged freely on the monitor
or onto a secondary monitor. Most components can also be resized freely.
Next is an example setup showing most of the components:

The additional display components can be toggled on and off by clicking the View menu item at
the upper left corner of the data collection screen. This is illustrated in the figure above.
The check marks in the drop down list indicate that all items should be visible. Note that the
user can move the various components around using the mouse, so the operator should take care
that one component does not cover another.
At this point, if any setup changes are required to the trailer, the processor, the deflectors, etc.
they should be made now through Main Menu item Setup.

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3.2.4 Test Setups

The next step in the process is to establish a test setup that meets the procedures required by the
particular project. Accessing the test setup screen can be done in several ways:
1. Click the Test Setup menu item at the top of the data collection screen.
2. Hold down the Alt key and then press the T key (Alt-T shortcut).
3. Click on the Test Setup label in the middle of the data collection screen.
4. Click in the greyed text box to the right of the Test Setup label.
Once the Test Setup window is opened the user will be presented with the following screen.

It may be useful to the operator at this point to define what a Test Setup is. It is a collection of
software settings that tell FwdWin the type of loading plate, the positions of all deflectors and
what actions to take during each test cycle. For example, you might want FwdWin to collect four
drops at each test point, all from different heights. A Test Setup can be created to do this.
Moreover, you might have several different deflector spacings commonly used on different types
of jobs. 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 next.

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New
Creates a new test setup based on the present test setup, so, BEFORE you press
this button you should select the Test Setup that best matches your needs from
the drop down list to the right of the Setup Name label. The operator must
specify a new name in the Setup Name field then click the Apply button. The operator can then
make changes to the test setup. Once changes are complete, the operator should then click the
OK button to save the changes.
Delete
This deletes the present Test Setup. The operator will be prompted to confirm
that he/she wishes to delete the setup.
Rename
This allows the operator to rename the present Test Setup. The operator must
enter a new name in the Setup Name field, and then click OK.

Setup Name
This is a drop down list that contains all of the test setups that have been created by the operator.
If you click on this box, a list of all setups stored in the program will appear. Clicking on one of
the setups loads it into the FwdWin program. It is useful to include descriptive information in
the setup name for easy identification (when you operate an FWD/HWD for a while, youll
create MANY setups).

Comment
The operator can use this line to include additional descriptive information regarding the present
test setup.
Options
The options box contains three program controls:
Sampling Window
For each drop the system samples the load and deflection signals
for a period of typically 60 milliseconds. This parameter also
controls the range of the time axis on the time-history plot (see
Time History Plots later in this chapter).
Smoothing
The Smoothing (or Smoothed Peaks Option) is a special feature, which ensures that the influence
on the load and deflection peak values from possible undesired, high frequency components in
the load cycle will be reduced to a minimum. 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.

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Preserve Temperatures
Some agencies manually measure asphalt temperatures at time of test in addition to or in-lieu of
the surface temperature measurements. These measurements are labour intensive, so they cannot
be done at each test point. If this box is checked, FwdWin will record the last entered asphalt
temperature at each successive test point until a new temperature measurement is recorded and
entered into FwdWin.
Loading Plate
The FWD/HWD is provided with two sizes of load plates a 300
mm (5.9 in.) and a 450 mm (11.8 in.) diameter plate. You must
indicate which plate is presently installed on the FWD/HWD. If
the plate is segmented (split) the Segmented box should be
checked as well. A quick visual inspection of the load plate will
reveal its size and whether it is segmented.
Automated Prompts
Automated prompts provide an interactive way for the operator to enter or verify certain
information at each test point prior to storage in the data file. Automated prompts should be used
sparingly as they contribute heavily to operator fatigue and slow production.
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.
Slab ID, Test Position
This prompt is only used on jointed Portland Cement Concrete
pavements. It is common practice to assign numbers to slabs so
that they can be positively identified during the data analysis
phase of the project, which almost always occurs in the office
away from the test site. If this option is checked, FwdWin will
prompt the operator to enter the slab number and position (corner,
joint, midslab, etc.) of the load plate.
Asphalt Temperature
This option is activated on projects where the operator or technician is manually measuring
(average) asphalt temperatures (e.g. at mid-depth of layer). This provides a way to record these
manually measured temperatures in the data file.
Surface Temperature
Same as Asphalt Temperature except that the temperatures are measured at the surface as
opposed to mid- or third- depths. This item is greyed (irrelevant) in the Test Setup screen when
an automated surface temperature measurement system is installed.

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Air Temperature
Same as Asphalt Temperature, except that the technician or operator is measuring and
recording the air temperature. This item is greyed (irrelevant) in the Test Setup screen when an
automated air temperature measurement system is installed.
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.
Comment
If this option is activated, the operator can enter a comment at each test point.
Reject/Accept
This option allows the operator to review, then reject or accept the measured deflections at each
test point. This option is most commonly used on structures where irregular deflection basins are
prevalent. This includes severely distressed pavements or structures with extensive underground
utilities, pipes or culverts.
Positions
This area is used to record the positions of the deflectors. The number of
deflectors shown is determined by the number of active sensors as indicated
in Setup - Processor - Deflector Circuits.
Note that the deflectors are referenced by channel number. To view a list of
deflectors and assigned channels, select Setup then Deflectors from the
main menu.
Each channel is assigned an X position and a Y position. The values
displayed are a function of the display units selected, in this case
millimetres. Both the X and Y positions represent the distance from the
deflector to the centre of the load plate.
A positive X value indicates that the deflector is in front of the load plate.
The X axis is assumed to be parallel with the travelled lane.
The Y axis is assumed to be oriented perpendicular to the travelled lane.
The meaning of a positive Y value may differ depending on location. The
local agency should establish the convention. (If no convention, we suggest
positive towards the roadway centreline).

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Data Validity Checks

Data validity checks are a quality assurance feature which
alerts the operator to irregularities in the deflection data
immediately during the testing cycle. There are three simple
types of validity checks, Decrease, Roll off, and Overflow
and the more complex Repeatability.
Each type of test can be:
Disabled: The test is not performed
Enabled: If the test fails, then the test cycle will stop and
prompt the operator to decide whether to keep the data or
throw it away and repeat the test.
Relaxed: If the test fails, then the results in the data grid will
be flagged somehow but the test cycle continues.
Smart: If the test fails, then the program will automatically
repeat the last drop to obtain data that pass the test.
Decrease
It is commonly accepted in pavement engineering that the measured pavement deflections should
decrease as the distance from the centre of the load and point of measurement increases. In other
words, the farther a deflector is positioned from the centre of a load, the smaller deflection it
should measure. This is true in theory, but sometimes not in practice.
Pavement cracks, joints, and other irregularities (such as defective deflectors) result in nondecreasing deflections whereby some outermost sensor records a higher deflection than its
neighbour who might be closer to the load impact point. This results in data that is extremely
difficult or impossible to analyze.
Roll Off
At the end of the sampling interval (60 msec), the program expects the deflection time history to
return to less than 90% of the peak value. Roll-off errors may occur when a deflector is lowered
onto a piece of gravel or some other unstable surface, then falls off when the weights drop. A
roll-off error can also occur if the pavement is experiencing excessive vibrations due to heavy
traffic in an adjoining lane. Finally, a roll-off error may be caused by a defective deflector.
Overflow
Most deflectors delivered with Dynatest FWDs 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. Overflows can occur on soft pavements, near joints and corners on
Portland Cement Concrete, or may be caused by defective deflectors.
Repeatability
Some agencies (most notably the FHWA LTPP group in the USA) utilize a repeatability check as
an additional quality assurance measure. Repeatability specifications require that a series of
consecutive similar drops give similar results. These specifications are intended to alert the
operator in the event that the testing is in some way affecting the physical properties of the
pavement structure, or that the surface of the pavement is unstable. They also alert the operator
to variations in loads or deflections caused by defective equipment.
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The program allows the operator to specify the allowable variation in load and/or deflection, both
in terms of the actual measurement units as well as in percent. Seating drops can also be
included in the repeatability check. Note that the test only applies to a series of drops that are
conducted from the same drop height (or the same target value).
Sequence
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. It also allows the operator
to enable on-display plotting (D) and filing of time history data
(F) for each applicable step.
A step can be any one of the following types:
1. No Op

No Operation (fill)

2. Pause

Waits for user action

3. Seating

A drop from a specified height, data will not be stored to disk

4. Height

A drop from a specified height

5. Loading

The drop height is adjusted to achieve a specified target load

6. Deflection

The drop height is adjusted to achieve a specified centre deflection

7. Resettle

The plate is lifted of the ground and then lowered again

8. Weight Up

The weight is raised to a specified height (but not dropped)

9. Catch Dn

The catch is lowered (returning the weight to the hit plate)

10. Terminate

Leaves the plate on the ground

3, 4, 5, 6 and 8 require a Step Parameter. A step parameter is a modifier associated with the
step type. For example, Seating and Height requires that the desired height (1,2,3 or 4) is
chosen.
To define a sequence, the operator first enters the number of desired steps in the No of steps
box. The number of rows in the table expands or shrinks to accommodate the specified number
of steps. The leftmost column shows the step numbers.
Next, for each step, the operator must select the action to be performed. In the example above,
the operator has specified that three drops from a specified height will be performed at each test
point.
The operator then assigns a step parameter for each step type. In the example above, the
parameters are 1, 2 and 2. This will perform one drop at drop height 1 and two at drop height 2
at each test point.
The fourth and fifth columns act as toggle (on/off) switches. If a check mark appears in the D
column for a given step, the time history data (O-Scope) will be plotted to the screen during the
test cycle. Similarly, if a check mark appears in the F column the load/deflection time history
for that step will be written to the data base file.

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OK
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.
Apply
The Apply button serves the same function as the OK button except that the Test Setup
window remains open. Note that the button shown here is greyed out indicating that the button
is disabled. This button is disabled by default and is only enabled when a change is made
anywhere in the Test Setup screen.
Cancel
The Cancel button discards any changes made in the Test Setup and returns the user to the
data collection screen.

3.2.5 Test Location

The data collection screen provides a wealth of opportunities to incorporate section information
in your data files. In addition, many attributes, such as your start location, end location,
pavement type, lane, and other useful bits of information can be included as seen below.

All fields default to plain text entry mode, however there are a few features that make it easier for
the operator to incorporate location and other information in the datafile.
Select the Section field and press Alt + Down to
get a list off all known Sections.
All fields behave like this, showing available
choices. Facility, -Code and Section, -Code are
special in that they load all fields with data from
the underlying database.

The system saves new and modified sections in a database. This database may also be populated
through the Network Applet or directly in MS Access.

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Districts
Most highway agencies subdivide their networks into Districts for more efficient management.
For the operators 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. A Facility can be
anything from roadways, runways, streets to parking lots or even railways. Often a facility is
identified by both its common name and a roadway code which links into a pavement
management system database.
Section
A single facility is often composed of sections of varying construction. This Sectioning can be
both longitudinal and transverse. The latter is appropriate for multilane roadways where traffic
load varies across the construction.

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3.2.6 Data Files

Once the operator has configured the test setup, and made the necessary changes or additions to
the network information, it is time to test. It will now be necessary to create a file for storage of
the deflection data. Prior to opening a file, a few words about file formats are necessary.
Specifying File Formats
From the main menu, select Setup then Options, which reveals that FwdWin can store data in
several formats. The native format is Microsoft Access
2000 (MDB), 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. Extensible Markup
Language (XML) is a structured format developed by the
World Wide Web Consortium (W3C).
Creating a Data File
A data file is created by clicking the
File menu item from the data collection
screen, then choosing New. A file
dialog box appears.
This dialog box allows the operator to
navigate to an existing subdirectory for
file storage. It also allows the operator
to create a New Folder.
To create a new file, the operator
merely needs to type the data file name
in the File Name field.
This window also informs the user
which system of units will be employed
for storage of data. The user is also
given a last chance to sort out the
facility information and choose a
suitable test setup. Buttons are
provided for convenient navigation to
the Section window and the Test
Setup window.
Once the information on the screen has
been entered, the operator should click
the Save button. The program will now
prepare the disk file and then return to the data collection screen.
We are now ready to test!

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3.2.7 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 trailer

A proper test setup as been created (or loaded).

The location information has been entered.

A file has been created (or opened).

The data collection screen serves as the primary control interface. At first glance, it may seem
complicated, but after a short time the operator will become quite familiar and comfortable with
it.
Current DMI

Surface Moduli
GPS
coordinates

Time history
Camera

Surface
Moduli
Chart

Trailer LEDs

Thermometer

Temperatures

BackCalculation
Chart

Location

Structural Info
Station Info

Start a
Test
Backcalculation
results

Load and
Deflection data
DMI direction control

Test Setup

The testing process is fairly simple. When the vehicle is located in the appropriate test position,
the operator merely clicks the Action button to start a test sequence. When the sequence
completes, the computer will issue one of a variety of sounds indicating that the plate has been
raised to the transport position and it is OK to move to the next test point.
If an error or other problem occurs during the test sequence, a pop-up window will appear
indicating the nature of the problem or error. If so equipped, the computer may also issue an
audible version of the error message.

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During the test sequence, there is generally nothing for the operator to do until it is complete.
This is a good time to scan the surroundings to make sure persons stay clear of the equipment
and that traffic is not posing a hazard.
After each drop, the load and deflection data are written to the data collection window. This
provides a convenient method for monitoring the progress of each test sequence.

3.2.8 Closing the Data File

The operator can close the data file by selecting Close from the File
menu item. The Microsoft Access (MDB) file closes and optional ASCII
files as selected in Setup Options are subsequently written (se also
3.2.10 Exporting Data).
Closing the program (Exit) will automatically close the data file properly
before shutting down.

3.2.9 Opening a Data File

You can use File Open to re-open an MDB file in order to store another data collection
session. Note that you cannot re-open an ASCII file, i.e. the program cannot append data to such
files. Instead, additional sessions generate additional ASCII files with sequenced file names (se
also 3.2.10 Exporting Data).

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3.2.10 Exporting Data

Use the File - Export facility to generate ASCII files based on MDB files at a later time (in the
office). This option means that you can safely un-check all ASCII options in Setup Options
(leave MS Access 2000 (MDB) checked).

Sessions Keep generates

multiple files from multiple
sessions.
Sessions Join merges
multiple sessions (from reopened files)
Smooth Post-smooth saved
histories
The selection of formats here
is independent of the chosen
real-time Setup - Options.
Note that you may select
multiple source files from the
same folder.

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3.2.11 Monitoring the System 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 Information menu item in the data collection
screen. Three menu items are available in the list box: Voltages, Drift/Vibration, and
Statistics.
Voltages
The voltage screen is shown at
right. The list of voltages
appearing along the left side of
this window corresponds to the
various deflectors. If a deflector is
stationary, the voltage should be
very close to zero. If the voltage
is varying with time, it either
means the deflector is
experiencing vibration from some
source, or is defective.
Clicking on a button on this
screen causes the reading to be
displayed on the large readout at
the top of the screen as well as on
the face of the button. This aids in
troubleshooting as the reading can be seen from some distance.
Where applicable the tooltip shows the typical voltage range for the component.
The Administrator can set the Trailer Battery Warning Limit.
Pressing the OK button closes this screen and returns to the data collection window.
Drift/Vibration
Selecting this menu item will bring up a continuously updating time-history plot of the load cell
and deflector outputs. This screen is used mainly for
troubleshooting suspected problems. Time in milliseconds is
plotted along the X-axis while voltages are plotted for each device
on the Y-axis. Load reading is plotted with positive in the up
direction, while deflections are plotted as positive downward.
Prior to activating the drift screen, the operator should lower the
plate and deflectors to the pavement surface. The pavement
should be free of vibrations (due to traffic or other sources).
The base line for each transducer is adjacent to the respective
label Ld, D1 D9.

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The Y axis scale for load and deflection is shown at the top of the plot. In this case, each
horizontal line represents and increases of 2 lbs/in2 of pressure for the load cell. Each horizontal
line represents 0.5 mils of deflection for the deflectors.
If the FWD/HWD is working properly, the lines should be fairly flat and coincident with the each
components base line. If one or more lines are tracking away from their origins, this is indicative
of a problem with the system.
Statistics
FwdWin can track certain statistics such as the
number of test sequences and drops completed by a
given machine. These statistics are stored in a
database and are serial-number specific. 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. Pressing OK saves the changes and
closes the window. Pressing Apply saves the
changes but leaves the window open. The Apply
button is greyed-out (disabled) until some change
is made in one of the fields. The Cancel button
discards any changes and closes the window.
The program also monitors and records the plate pressure, pavement centre deflection, and length
of time required to raise the weights to a specific height. This information pertains only to the
last drop completed at each fixed drop height. The program also calculates the velocity with
which the weight is raised. Velocity information is required since the height stops may be
occasionally moved thus changing the time required to lift the weights to a certain height.
This information is useful for troubleshooting such problems as e.g.:

Inadequate charging systems - as trailer batteries discharge, weights are lifted

progressively slower.

Effects of cold weather on trailer hydraulics thickening of the fluid due to cold
temperatures will slow the system down

Air accumulation in trailer hydraulics air in the hydraulic fluid will slow the system
down

It is a good idea for the operator to record typical values for RW Duration and Raise Weight
Velocity when the system is new or known to be in good operating condition. This will provide
a baseline for later comparisons.

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3.2.12 Manual Control

Occasions will arise when it will be convenient or necessary for the operator to take manual
control of the trailer systems. For example, if a testing sequence terminates abnormally and it is
necessary for the operator to raise the plate prior to vehicle movement, he/she can do so from
within the program. This eliminates the need to exit the vehicle to operate the manual control
box.
Manual control of the FWD/HWD is accomplished through the
Manual Control menu item near the top of the data collection
screen.
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
upwards and lowers the plate when moved to the
downward position. The RW lever is indexed so
that the operator can lift the weight to a specific
height.

Raise Weight
Lever (RW)
Raise/Lower
plate lever (RP)

The subassembly diagram will respond visibly to the controls so

that the operator knows what position the trailer subassembly is
in.
The drop button causes the weight to fall. The stop button will
cause an immediate abort to any operation in progress (well, it
wont stop the weight from falling).
Errors are issued if conflicting commands are given, for example, if the operator tries to lift the
weights while the plate is lifted off the pavement surface.

3.2.13 Exit
The operator can close the program by selecting Exit from the File menu item. Windows can
now be shut down in the usual way.
IMPORTANT!!
Before driving away from the test site, the operator should:
1. Secure the trailer. Transport locks and locking pins must be in position (see section 1.4,
Just Before Leaving..., )
2. Switch OFF the Compact 15.
3. Switch OFF the computer.

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