50753 - Fairbanks Scales
Contents
1. in Ibs Tighten all gland nuts to secure D Pit Power Supply Replacement 50753 Remove power from the system at the instrument Remove PPS cover and disconnect all wiring Remove screws securing power board Remove old PCB secure ground wire to new PCB Remake all connections install the new PCB and secure all screws Secure cover with all screws torqued to 10 12 in lbs Tighten all gland nuts to secure 15 12 12 Issue 5 Section 6 Parts A Parts List Part No Description 75458 1 1 8 x 4 1 2 wl nut module module 54788 1 1 8 lock washer module module 54255 1 1 8 flat washer module module 80955 Load Cell Base Plate 61743 Clamp Bar Washer base plates 62857 5 8 x 6 Anchor Bolts 55010 Ground Rod Kit B Load Cells and Load Cell Hardware Part No Description 80453 Load Cell 6 RC 100K 1000 ohm 2mv v 73682 Shim receiver cup 1 16 64338 Shim receiver cup 1 8 64334 Shim receiver cup 3 16 72274 O Ring INSIDE of Cup ANSI 222 64340 O Ring OUTSIDE of Cup ANSI 4228 70511 Receiver Cup LOWER w anti rotation pin 70512 Receiver Cup UPPER 64382 Roll Pin 1 2 x 272 anti rotation baseplate 63981 Anti Rotation Pin LOWER Receiver Cup 3 8 x 2 72 71717 Locating Tool 57 UPPER L C RECEIVER CUP B CABLE HOLES FOR INITIAL INSTALLATION USE 1 1 8 SHIM _ LOWER L C RECEIVER W CUP OO BASE PLATE LOAD CELL CABLE HANGER INSI2. 8 Verify that there is equal dead load on all load cells dead load will be higher on middle load cells of 60 70 and 80 scale installations Add or remove shims as needed to adjust the dead load 9 Adjust side and end checking per certified prints 10 Proceed to the electrical installation section to complete the installation 50753 9 12 12 Issue 5 Section 3 Electrical Instz A Introduction The Titan PV scale was designed to be used with Intalogix systems Intalogix systems utilize smart sectional controllers SSC and pit power supplies PPS for load cell excitation and signal processing B Description There is one 1 SSC per section and one 1 PPS for the entire platform unless the number and resistance of the cells require a second pit power supply Smart sectional controller boxes have four 4 terminals two 2 for load cells and two 2 for interfacing to other SSC boxes or terminating to a pit power supply All cell section scale adjustments are made via the Intalogix system instrument C Installation a Boxes The box has mounting brackets which allow mounting to adapters located inside each load cell access hole of the Titan modules b Wiring Cable used in all wiring must be a minimum of 18 AWG Use cable 17204 or 17246 Use appropriate service manual for the indicator being installed or refer to the Appendix for typical wiring information c Smart Sectional Controller Wire cells into each s
3. DE FACE Z j OF SCALE 6 LOAD CELL O RING 50753 16 12 12 Issue 5 v IPD peor indingo ea indino PISIyS UOE1 2X3 UOHl1DX3 ON Om tn O P 00 IPD peo1 Z 25 peo1 Am tn O P 00 N m sri ON 00 N m tn ON 00 L 12D peo1 indingo indingo plays Ww m in 0 M om UOHP 1DX3 st ca GN m st in ON CDSS indino jndino indino indino pi us PISIUS U011e32X3 U01e42X3 UOI1e45X3 UOH 3I X3 p q 93UM PISIUS onjg u i ela 21405 ovzZ1 ON m spi ON 00 UOHle1DX3 Pasm ION x N m sri ON 00 N m sb uy Q P 00 m S8v SH S8v Sd PIPIS UJMoy 5g SHOA 0 8T ON m tn OKO LDSS SMOA 0 8 ON m tn OKO ON m sb tn OC P 00 86S0S m Xd XL PIPINS 420 Sdd Am sb tn OC DN 00 JO3e2ipu 12 12 Issue 5 17 50753
4. FF 12 12 Issue 5 Section 4 Calibration A Preliminary Checks 1 Seat the suspension components Drive the test truck across the scale stopping and starting several times across the scale Repeat this procedure at least three times to assure that all parts are properly seated 2 Refer to the appropriate technical manual for the particular Intalogix Technology indicator for the setup and calibration procedures B Repeatability and Return to Zero performance tests Position the test truck in the center of the weighbridge and note the weight reading Pull the truck off the scale and note the return to zero Repeat this procedure at least three times to assure consistency If the scale does not repeat the readings within tolerance check for mechanical obstructions or alignment problems Check to see the scale is assembled properly and the load cells are aligned level and the load is equally distributed on each load cell Add or remove shims as required to improve deadload distribution C Section test and adjustment The section test should be conducted centering the test load weight cart or test weights directly over each section Record the weight indication of each section The sections should be adjusted so that the weight indications of all sections match within the tolerances set forth by the National Institute of Standards and Technology Handbook H 44 50753 14 12 12 Issue 5 Section 5 Maintenance A Maintenan
5. Installation Manual MIA Z SWE Titan Series Portable Vehicle Scale Model 6020 A w tet eee d ye 7 AA de US p ix X A A CIE niak TU Se iinet 5 T vw EA 4 ax DEM APA lup ara OA WO a fs as d 2 ACE AA fts SN ye AA fere by ME fo a m DRAC M 2012 by Fairbanks Scales Inc 50753 All rights reserved Issue 5 12 12 50753 Issue 1 Issue 2 Issue 3 Issue 4 Issue 5 03 2004 08 2005 07 2006 11 2010 12 2012 Amendment Record Titan Series Portable Vehicle Scale 50753 Manufactured by Fairbanks Scales Inc 821 Locust Kansas City Missouri 64106 New product Revised installation instructions Revised installation instructions Revised instructions with regard to on site construction Revised specifications on page 5 2 12 12 Issue 5 Table of Contents Section 1 General Information A Introduction i D dI EARS SONS 4 B Description uoto site eke oa tu deo e Sess a i aeo 4 C Specifications sessio oo eb tests dab Set ENS 4 D ACCESSONeS nro dou ete imet ere doe eee odio 5 Section 2 Installation KA Introduction uses AER ta ere ds es 6 B Site preparation 6 Section 3 Electrical Installation A IB troductio ny z u rusa ea sweet Pes 10 B D soriDti lyr uias di aor apre D alate Eres 10 C Installation 10 Ae BOXES ane e VOY aus taka oat Qa TA ri 10 eV IIS uta a EO a Ma ioa oc Od ed ei 10
6. ackfill for proper drainage A slope away from the scale is recommended 5 Allow concrete to cure for 28 days or until a test cylinder indicates the concrete has reached its design strength before allowing traffic on the scale Remove the wood shipping blocks from between the frame and weighbridge Caution Module Assemblies are heavy and awkward to handle Exercise extreme care when lifting a module assembly to avoid personal bodily harm or damage to any equipment When lifting the modules ensure that the lifting chains are equally loaded secure and that an angle of greater than 30 degrees is maintained b Installing Modules All installations types Using a chalk line mark the foundation to determine the center line of the foundation and position of the anchor bolts concrete piers using the Certified print 1 Using a suitable and safe crane lift and set a 35 foot module assembly in place on the support area The end of the module with the step plates needs to be positioned away from the first approach end Always attach the lifting chains to the scale weighbridge Do not attach the chains to the subframe The subframe is secured to the weighbridge and will lift together as a complete module assembly A 35 foot module assembly weighs approximately 10 tons or 20 000 pounds 50753 7 12 12 Issue 5 2 If installing a single module scale proceed to step 5 The installation of a mutiple module scale varies slightly from the in
7. c Smart Sectional Controller 10 E OEOURGIDIQ se a PES We eee KI E ES 12 e Indicator to Pit Power Supply 12 f SSC Dip Switch 13 Section 4 Calibration A Preliminary Checks 14 B Repeatability amp Return to Zero performance tests 14 C Section test and adjustment 14 Section 5 Maintenance A Maintenance Inspections 15 B Load cell Replacement 15 C Smart Sectional Controller Replacement 15 D Pit Power Supply Replacement 16 Section 6 Parts 24322260512 Oboe Ced 17 Appendix I Wiring 18 Disclaimer Every effort has been made to provide complete and accurate information in this manual However although this manual may include a specifically identified warranty notice for the product Fairbanks Scales makes no representations or warranties with respect to the contents of this manual and reserves the right to make changes to this manual without notice when and as improvements are made 50753 3 12 12 Issue 5 Section 1 General Information A Introduction The Titan Portable Vehicle Scale PLT 6020 XXX is a uniquely designed truck scale combining the proven reliability of a hermetically sealed load cell system with the added benefit of an above grade low profile portable steel deck design scale T
8. ce Inspections Ensure that the system is maintaining proper ground connections Check module to module bolts for tightness Check that the frame has not shifted that all bolts are secure Check for give or washout under any temporary pier structures Check load cells for a level condition Examine load cell cables and module interconnect cables for problems Ensure that the SSCs and the PPSs covers are secure B Load cell Replacement Remove power from the system at the instrument Jack the scale at the bad load cell location Remove the old load cell Apply a small amount of grease to the load cell buttons top and bottom then install the new load cell Gently lower scale assembly ensuring proper placement of load cell Loosen the gland nut unwire the defective load cell from the SSC record the wire color code Wire the new cell into SSC tighten the gland nut around the cable Close the SSC and tighten all screws to 10 12 in Ibs Reapply power to the instrument Check operation calibrate as necessary C Smart Sectional Controller Replacement Remove power from the system at the instrument Remove cover disconnect all wiring noting colors and terminal locations Remove screws securing PC board Carefully remove prom and insert in new PC board note DIP switch settings Set DIP switches for proper address on new PC board Install PCB and secure with all screws Connect all wires Secure cover with all screws torqued to 10 12
9. ction 2 Installation A Introduction The Titan Portable Vehicle Scale can be set almost anywhere it s needed The soil bearing under the scale sub frame must be firm and unyielding i e 3000 P S F concrete piers are the best method of assuring a solid level base for the sub frame to be anchored to However the sub frame may be set on firm level ground a leveled gravel area or heavy wood supports If concrete work is performed use only certified prints For example a 35 module would be a complete two 2 section scale A seventy 70 foot scale will use two 2 modules with the sub frames bolted together e Standard practice for onsite construction of earthen ramps for Portable Vehicle scales uses compacted graduated limestone fill or caliche fill provided by others Either of these choices typically will provide a solid non yielding base if installed and compacted correctly Concrete berms along the sides of the ramps may be used to keep the material from spreading out during the compacting process but this is typically not necessary The scale is shipped fully assembled with stands suspension hardware with load cells installed There are eight 8 shipping bolts for each 35 module which MUST BE REMOVED once the modules are set and secured See drawing 50598 4 B Site Preparation All foundation types 1 Help the customer select a site which allows easy access to and from the scale ensuring enough area for straight and le
10. ections sectional controller per the appropriate service manual Refer to the Appendix for typical wiring information Load Cell Wiring Designations Color Description Black Excitation Green Excitation Red Signal White Signal Yellow Shield 50753 10 12 12 Issue 5 Notes The Titan PV scale has been designed to provide protection from the effects of moisture The load cells have been calibrated with the cable attached therefore the cable should NOT be cut The cable is connected directly to the sectional controller through a sealed gland fitting which MUST be tightened properly to keep water moisture out of the box All cabling should have a drip loop at the cell or box entry location to help prevent water entry On all boxes the load cell cable gland fittings have O rings that can be forced out of position if tightened improperly To prevent this first tighten the inner nut securing the gland in the hole insert the cable and carefully tighten the gland Do not over tighten where the gland turns The cover MUST be secured with ALL screws tightened properly 10 in Ibs for protection against moisture Note Smart Sectional Controllers have connections for two 2 load cells TB1 and TB2 The odd numbered cell connects to TB1 and the even numbered cell connects to TB2 Example of three 3 section cell numbering Intalogix 50598 2 System Inst Note Intalogix installations utilize a specific numberin
11. g system for load cells because of digital addressing of the SSCs Number the load cells as follows With respect to the following starting position face the platform from where the indicator is located The cell at the upper left or far side of the platform is Cell 1 The cell positions along the far side will be odd cell numbers the near side locations will be even cell numbers 50753 11 12 12 Issue 5 d Grounding Smart Sectional Controllers Intalogix systems must have two 2 ground rods in the pit for proper connection Pit power supplies use a ground separate from the weighbridge and sectional controller ground rod For accurate operation and protection against damage from lightning strikes all of the components of the system must be properly grounded The grounding system contains ground rods for the scale pit location The following steps must be taken to correctly ground the system It is recommended that the grounding be done with 8 AWG or larger wire or braided ground straps All of the ground connections should be 2 feet or as short as possible The case of the SSCs and PPSs must be attached in a clean electrical connection to the platform frame The platform frame is then connected to a pit ground rod The insulated WHITE wire from the PPS connects directly to the separate ground rod not to the same rod as the weighbridge The 117 VAC SVP unit must be connected to a known good ground at the instru
12. he Titan Series PV scale uses a Rocker Column load cell system combined with Intalogix Technology B Description The Titan weighbridge consists of 35 factory assembled steel deck modules Each module bolts to the adjoining module With the scale installed completely above ground the load cell system suspension components and weighbridge are not subjected to the harsh corrosive environments found in a scale pit 1 Rocker Column load cell systems are hermetically sealed cells completely constucted out of stainless steel A stainless steel sheathing protects the load cell cable 2 Intalogix Technology offers the customer outstanding resolution surge voltage protection and built in diagnostics C Specifications 50753 CLC Capacity Load cell data Capacity Type Environmental Bridge Resistance Output Construction Module Design Module Understructure Lengths 100 000 Ibs 250 000 Ibs for a 3 section scale 300 000 Ibs for a 4 section scale 100 000 Ibs Rocker Column Stainless steel hermetically sealed 1000 W 2 mV NV Welded structural steel l beam Orthotropic Open bottom 30 35 60 70 and 80 12 12 Issue 5 Width Deck plate thickness Material Soil bearing required NTEP Certificate of Conformance Number D Accessories 50753 73164 Bulkheads 73170 Approach Coping 2 pieces 10 3 6 ASTM A 36 Steel 3000 psf 96 089A2 12 12 Issue 5 Se
13. ment location Use a voltmeter to test the electrical power source available for the Neutral to Ground voltage level it must be 0 2 VAC or less If you are unsure or if the testing reveals a higher than acceptable level 0 2 VAC maximum make provisions to install a separate ground rod at the SVP location Use braided cable or 8 AWG wire to make the SVP to ground rod connection Caution mproper grounding will prevent the surge voltage protection from adequately 50753 e protecting the scale Indicator to Pit Power Supply Cable Connection Prepare the cable ends in the standard manner Use the appropriate manual for wiring instructions for the sectional controllers and power supplies Connect the indicator interface cable to the instrument in the scale house per the instructions in the appropriate indicator service manual 12 12 12 Issue 5 f SSC DIP Address Switch In each of the smart SSC boxes there is an eight 8 position DIP switch labeled S1 This switch is used to identify the section in a binary code The switches must be set properly for the scale to operate Note Switches 1 2 and 3 are always OFF Do not change these switch settings Switches 4 through 8 are used to set the section address locations Set the section number according to the chart below 50753 Section number Switch settings 4 5 6 Sec 1 ON OFF OFF Sec 2 OFF ON OFF Sec 3 ON ON OFF Sec 4 OFF OFF ON OFF OFF OFF OFF OFF OFF OFF O
14. stallation of a single module scale Follow the steps as identified for the size scale you are installing 3 The 60 and 70 scales are two module scales With the first 27 30 or 35 module already in place lift and set the second 27 30 or 35 module assembly so that the end with the step plates is set on the first module step plates Place the module so both subframes are in line and touching Bolt the two subframes together 2 bolts and proceed to step 5 4 The 80 scales are comprised of three modules With the first 27 module already in place with the step block end away from the first approach near the next module lift and set the next module and place it at the end of the first 5 Remove the shipping bolts that retain the 27 30 or 35 weighbridges to the subframes 2 bolts per corner 8 bolts total per 27 30 or 35 module See drawing below 34 x 24 Hex Bolts Included as part of optional bulkheads Optional bulkhead option when ordered with scale 50753 8 12 12 Issue 5 6 Secure the subframes to the support piers using anchor bolts 1 per corner 4 total per subframe 34 x 24 Hex Bolts Included as part of optional bulkheads Optional bulkhead option when ordered with scale T Lift and set the steel bulkheads if purchased and bolt to the subframe ends Secure the steel bulkheads to the support piers using anchor bolts 4 bolts per bulkhead 8 total See drawing below
15. vel approaches and to meet all state and local Weights and Measures regulations WARNING Be aware of underground utilities and hazards CALL BEFORE YOU DIG 1 888 258 0808 2 The site should have good drainage away from the scale and surrounding areas must not drain into or through the scale site 3 Obtain all necessary permits and licenses prior to beginning construction 4 Using a transit sight in and mark with stakes the area where the placement is to occur and where supports forms or concrete are to be built 5 When constructing forms make sure they are plumb square and level 6 Place and compact gravel into the base of the forms if necessary 50753 6 12 12 Issue 5 a Concrete Pier Installations 1 Cut and position rebar into the form as per the schedule detailed on the certified foundation prints supplied 2 The scale is designed so the sub frame may be anchored to the foundation by using expansion anchors which are inserted into the concrete after it has cured Expansion anchors are recommended because of the flexibility allowed in final positioning of the scale Use certified prints for anchor locations 3 Pour concrete using a mix to yield a minimum 4000 PSI Vibrate the concrete into position to ensure consistency All concrete work MUST conform to standards set forth by the American Concrete Institute Code 4 Allow concrete to cure several days before erecting the scale Remove forms and b
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