RoughDeck CS Operator Installation Manual Coil Scale ®

RoughDeck CS
®
Coil Scale
Operator Installation Manual
114975 Rev B
Contents
1.0
Installation ................................................................................................................................... 1
1.1 Recommended Equipment and Tools (Steel Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Lifting and Handling (Steel Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Temporary Setting Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0
Load Cell Mount Installation........................................................................................................ 3
2.1 Install Baseplate and Load Cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Mount Block and Grout Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.0
Load Cell Wiring .......................................................................................................................... 5
3.1 Trimming & Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.0
Load Cell Replacement................................................................................................................ 7
5.0
Troubleshooting ........................................................................................................................... 8
Technical training seminars are available through Rice Lake Weighing Systems.
Rice Lake continually offers web-based video training on a growing selection
Course descriptions and dates can be viewed at www.ricelake.com/training
of product-related topics at no cost. Visit www.ricelake.com/webinars.
or obtained by calling 715-234-9171 and asking for the training department.
© 2010 Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America.
Specifications subject to change without notice.
Rice Lake Weighing Systems is an ISO 9001 registered company.
Version 1.0, October 2014
i
Technical training seminars are available through Rice Lake Weighing Systems.
Course descriptions and dates can be viewed at www.ricelake.com/training
or obtained by calling 715-234-9171 and asking for the training department.
ii
RoughDeck® CS Operator Installation Manual
Introduction
This manual is intended for use by technicians responsible for installing and servicing the RoughDeck® CS.
Authorized distributors and their employees can view or download this manual from the Rice Lake
Weighing Systems distributor site at www.ricelake.com.
Site Consideration: The opening of the V-Top coil cradle option runs parallel with the load cell pocket
CAUTION cover plate. See Figure 2-3 on page 18
Package includes: Assembled weighbridge module and weighbridge fasteners; load cells; load cell mounts with
leveling bolts and anchor bolts; junction box; homerun cable to indicator (20' long).
1.0
Installation
The general assembly order is summarized below:
1. Set deck module into position on setting blocks.
2. Install load cell mounts in pockets and anchor bolts in baseplates.
3. Run cabling and connect electrical wiring to J-box.
4. Connect indicator and peripheral devices.
1.1
Recommended Equipment and Tools (Steel Deck)
•
•
•
•
•
•
•
•
•
•
•
•
•
•
1.2
Crane with a minimum 5000 lb. capacity
Four chains or cables (8' minimum length each) with hooks or clevises
3/4" rotary hammer drill
3/4" x 24" masonry carbide bit
One low-profile 4-ton bottle jack
3" minimum setting blocks
Torque wrench to 100 ft-lb
Socket wrenches to 1 1/2" (drive compatible with torque wrench)
Box end wrenches to 1 1/4"
Open end wrench set (7/16" – 1 1/4")
4' bubble level
Small torpedo level
Hammers, maul, pry bar
Hand tools for pulling and connecting electrical wiring
Lifting and Handling (Steel Deck)
Deck modules are lifted using four chains or cables attached to the four lifting straps mounted on the top of the
weighbridge. The lifting straps provide balanced lifting of the modules.
Note A set of lifting lugs are provided with the scale.
Lifting straps must always be inserted into the top of the scale. Lifting should always occur
WARNING with the top plate facing up and the lifting straps securely attached through the nuts welded to
the bottom side of the top plate. Lifting from the bottom of the plate could cause nuts to break
loose and the scale to fall.
Installation
15
1.3
Temporary Setting Blocks
Most installers use setting blocks that are approximately 3" high for the initial placement and connecting of the
deck module. Use leveling bolts in base plate to level the scale. Setting blocks are only used in the corners of the
module where the load cell mounts are installed.
Weighbridge Module
7.5"
3"
Figure 1-1. Setting Blocks Under Weighbridge Module
When placing module on setting blocks, place blocks in locations close to, but not at, the pocket (to allow
Note room for mount).
It is important to consider the orientation of the scale if using the V-Top coil cradle option. The V-Top coil
Note cradle runs parallel with the load cell pocket cover plate. See Figure 2-3 on page 2.
16
RoughDeck HE AutoLift
2.0
Load Cell Mount Installation
Load cell mount components (baseplate, mount blocks, anchor bolts, link, load cell, and upper mount blocks) are
shipped in the hardware box and need to be assembled while in the load cell pocket. Remove the printed load cell
Certificate of Conformance (CC) forms (included with load cells) and store them in a safe place for future
reference.
The following sections contain step-by-step instructions on mount installation, including the baseplate, load cells,
upper mount blocks, ground straps, and anchor bolts.
2.1
Install Baseplate and Load Cell
Use the following steps for installing the mount baseplate and load cell in the load cell mount pockets:
1. Remove load cell mount components from the packing box and position one set at each mount location.
Figure 2-1. Baseplate
2. Remove load cell pocket covers.
3. Working with the baseplate first, lower baseplate through pocket opening and onto concrete foundation.
4. Place the load cell link over the end of the cell and install load cell/link assembly onto the top of the
baseplate.
5. Place the load link on top of the load cell and the upper mount block on top of the load link.
6. Place the load cell and load link assembly onto the two stands of the base stand and screw in the load cell
mounting bolts (finger tight). The loose bolts allow freer movement for better weighing accuracy.
7. Adjust the load link so it is vertical and centered side to side (in a balanced condition). If the load link is
not vertical and centered side to side, adjust the base stand.
8. Apply anti-seize compound to threads of load cell bolts before installing. Torque load cell bolts 55 ft-lb.
Figure 2-2. Cut-Out View of Load Cell Access Area Shown with Optional Flexible Conduit
2.2
Mount Block and Grout Installation
Use the following steps to install mount blocks and baseplate grout.
It is important to consider the orientation of the scale if using the V-Top coil cradle option. The V-Top coil
Note cradle runs parallel with the load cell pocket cover plate. See Figure 2-3
Load Cell Mount Installation
17
.
Figure 2-3. V-Top coil cradle option showing orientation
9. Adjust leveling bolts until radius of block comes in contact with rocker link radius.
10. Jack the weigh module and remove setting blocks.
11. Slowly lower the weigh module until it rests on the load cell links.
After the weigh module is lowered into final position, check each load cell mount assembly to ensure that the
Note link is plumb and that there is no binding or misalignment.
12. Use an industrial hammer drill to drill a 3/4" hole into the concrete at least 6" deep on one side of the
mount frame.
13. Drill a second anchor bolt hole on the opposite side of the mount frame.
14. Each mount requires two anchor bolts to prevent longitudinal motion of the baseplate. Anchor bolts (7" x
3/4") with expansion heads are supplied with the scale.
15. Insert bolts into holes drilled in foundation.
16. Install one washer and one nut on each anchor bolt. Place a driver pipe on top of the anchor bolt and use the
long punch to seat anchor bolts against baseplate.
Note
Do not apply excessive force to the anchor bolts-- bending of the baseplate could occur.
When installing anchor bolts, make sure that there is adequate bolt length to extend into the concrete
foundation.
17. Attach one end of the ground strap to the upper block.
18. Insert a bolt through the wire terminal on the loose end and thread the bolt into the hole on the baseplate.
Tighten the bolt securely with a wrench.
19. Pour 9000 PSI, non-shrinking, epoxy or cement grout under and around the baseplate. A funnel with a
long tube can be used to pour grout under and around the baseplate while working from above the access
hole.
20. Grout should be allowed to set for at least 24 hours before removing the wooden forms.
21. After grout has hardened, tighten anchor bolt nuts.
18
RoughDeck HE AutoLift
3.0
Load Cell Wiring
Before the weigh module wiring can be completed, all load cell cables have to be routed through the conduit
beginning at the load cell outlet. Use the following steps to route load cell cables through conduit to the J-box:
1. Before routing load cell cables, mark each load cell cable at the end to help identify each load cell.
2. Working from the J-box corner, insert a fish tape or similar tool and pull each load cell cable through the
rigid conduit until all excess cable is taken in.
1
2
Pocket 1 Conduit
Pocket 2 Conduit
J-box corner
Pocket 2 Conduit
4
3
Pocket 3 Conduit
Figure 3-1. J-box location
3. Wire each load cell to the J-box terminal strip in accordance with the wiring code contained in the
Certificate of Conformance.
4. Cable should not be routed near heat sources greater than 400°F. Do not shorten any load cell cable. The
load cell is temperature compensated with the supplied length of cable. Cutting the cable will affect
temperature compensation. Coil and protect excess cable so it will not be mechanically damaged or sit in
water.
5. Provide a drip loop in all cables so that water or other liquids will not run directly down the cables onto
either the load cells or the junction box.
6. If conduit protection is necessary against mechanical or rodent damage to the load cell cables, use flexible
conduit and conduit adapters at the load cells.
Note Flexible conduit and conduit adapters are an optional item and not included with the standard setup.
7. Connect cables for load cells to the summing board in the junction box according to the guide shown
below and the labels on the terminal strips of the junction box. To verify the wiring scheme, see the
certification shipped with each load cell.
8. For better performance, use positive and negative remote sense lines if the wiring running from the
junction box to the indicator is longer than 25 feet
Load Cell Wiring
19
Drip Loop
Figure 3-2. Load Cell Wiring Drawing
Load Cell Wire Color
Function
Red
+ EXC
Black
- EXC
Green
+ SIG
White
- SIG
Gray or Bare
Shield
Table 3-1. Load Cell Wiring
3.1
Trimming & Calibration
Refer to the JB4SS TuffSeal™ Signal Trim Junction Box manual for trimming details.
Refer to indicator manual for connection and calibration details.
20
RoughDeck HE AutoLift
4.0
Load Cell Replacement
Use the following steps to replace load cells in the RoughDeck® CS coil scale:
1. Position jack on the concrete
foundation beneath one of the
weighbridge’s main frame members
close to the load cell mount. (Allow
Upper Mount
Block
room for load cell removal and
installation.) Raise jack approximately
1/2" and put setting block(s) under the
scale deck.
Shim
As a safety precaution, always use
Note setting blocks when jacking scale
Load Cell Bolts
Load Cell
Link
Anchor
Bolt
Load Plate
Baseplate
module.
Grout
(optional)
2. Disconnect the load cell terminal
connections in the junction box. Pull
the load cell cable out of the conduit.
Attach a pull cord to the load cell
Note cable at the junction box before
pulling the cable through the conduit.
Figure 4-1. Load Cell Mount
3. Remove the two load cell bolts and lift
out load cell and link assembly.
4. Install link over new load cell. Reinstall load cell and link assembly onto the baseplate. Install load cell
mount bolts. Torque bolts to 55 ft-lb.
5. Pull load cell cable through conduit using pull cord.
6. Remove setting blocks and lower scale module so that it rests on the link. Check link to verify that it is
centered and plum.
7. Connect wiring to terminals in junction box.
Load Cell Replacement
21
5.0
Troubleshooting
If the system powers up and gives some type of stable digital readout that varies with the load on the system, any
system problems are probably caused by factors other than the load cells. The load cells are often blamed for a
malfunctioning system, but the majority of the time, the problem lies elsewhere. Look for mechanical causes for
your problem first.
If the system can be calibrated but doesn't return to zero, loses calibration, or demonstrates non-linearity or
non-repeatability, see the following chart for possible causes and do the following checks.
Symptom
Possible Cause
No return to zero
Mechanical binding or debris in seals or under load cells; may have lost system calibration.
Non-linearity
Thermal expansion or deflection under load causing binding or side load.
Non-repeatability
Loose load cell mount; drifting caused by moisture, load cell overload or shock damage;
mechanical binding.
Lost calibration
Out of level or plumb; moisture problem; mechanical binding.
Drifting readout
Moisture in junction box, cables, or load cell; mechanical binding.
Table 5-1. Troubleshooting
1. Check load cell mount for debris restricting load cell movement or debris between scale and structure.
2. Check that tank/vessel and mounts are plumb, level, and square at the critical areas.
3. Check all piping and conduit for connections that restrict movement.
4. If check rods are used, loosen all connections to finger tight only for testing.
5. Check load cell cables for physical or water damage.
If after all these checks the problem still cannot be isolated, reconnect all but one load cell. Replace the load cell
with a load cell simulator. Alternate so that each load cell is individually disconnected and replaced with a
simulator. If there is a problem with a particular load cell, the symptom should disappear when that load cell is
disconnected and replaced with the simulator.
22
RoughDeck HE AutoLift
RoughDeck Limited Warranty
Rice Lake Weighing Systems (RLWS) warrants that all RLWS equipment and systems properly installed by a
Distributor or Original Equipment Manufacturer (OEM) will operate per written specifications as confirmed by the
Distributor/OEM and accepted by RLWS. RoughDeck fabricated platforms and weldments are warranted against
defects in materials and workmanship for five (5) years. Load cells and all other components are warranted for two
(2) years.
RLWS warrants that the equipment sold hereunder will conform to the current written specifications authorized by
RLWS. RLWS warrants the equipment against faulty workmanship and defective materials. If any equipment fails
to conform to these warranties, RLWS will, at its option, repair or replace such goods returned within the warranty
period subject to the following conditions:
• Upon discovery by Buyer of such nonconformity, RLWS will be given prompt written notice with a
detailed explanation of the alleged deficiencies.
• Individual electronic components returned to RLWS for warranty purposes must be packaged to prevent
electrostatic discharge (ESD) damage in shipment. Packaging requirements are listed in a publication,
“Protecting Your Components From Static Damage in Shipment,” available from RLWS Equipment
Return Department.
• Examination of such equipment by RLWS confirms that the nonconformity actually exists, and was not
caused by accident, misuse, neglect, alteration, improper installation, improper repair or improper testing;
RLWS shall be the sole judge of all alleged non-conformities.
• Such equipment has not been modified, altered, or changed by any person other than RLWS or its duly authorized repair
agents.
•
•
RLWS will have a reasonable time to repair or replace the defective equipment. Buyer is responsible for
shipping charges both ways.
In no event will RLWS be responsible for travel time or on-location repairs, including assembly or
disassembly of equipment, nor will RLWS be liable for the cost of any repairs made by others.
THESE WARRANTIES EXCLUDE ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT
LIMITATION WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. NEITHER RLWS
NOR DISTRIBUTOR WILL, IN ANY EVENT, BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
RLWS AND BUYER AGREE THAT RLWS’ SOLE AND EXCLUSIVE LIABILITY HEREUNDER IS LIMITED TO REPAIR
OR REPLACEMENT OF SUCH GOODS. IN ACCEPTING THIS WARRANTY, THE BUYER WAIVES ANY AND ALL OTHER
CLAIMS TO WARRANTY.
SHOULD THE SELLER BE OTHER THAN RLWS, THE BUYER AGREES TO LOOK ONLY TO THE SELLER FOR
WARRANTY CLAIMS.
No terms, conditions, understanding, or agreements purporting to modify the terms of this warranty shall have any
legal effect unless made in writing and signed by a corporate officer of RLWS and the Buyer.
© Rice Lake Weighing Systems, Inc. Rice Lake, WI USA. All Rights Reserved.
RICE LAKE WEIGHING SYSTEMS • 230 WEST COLEMAN STREET • RICE LAKE, WISCONSIN 54868 • USA
Troubleshooting
23
230 W. Coleman St. • Rice Lake, WI 54868 • USA
U.S. 800-472-6703 • Canada/Mexico 800-321-6703 • International 715-234-9171 • Europe +31 (0)26 472 1319
ww.ricelake.com www.ricelake.mx www.ricelake.eu www.ricelake.co.in m.ricelake.com
© Rice Lake Weighing Systems
October 24, 2014
PN 114975 Rev B