TITAN Motor Truck Scale
Contents
1. Lift the center or base Module to a location above the four load cell base plates 9 03 10 Rev 5 OPTION 1 Set the module directly on the locating tools and the blocks will act as safety stands Install a load cell bearing cup with O rings into the upper receiver of each corner on the module Grease will help hold the cup in place Insert the upper end of the locating tool into the upper cup on the module Lower the module while holding the locating tool upright and guiding the bottom of the tool into the lower cup When the base module is set on all four locating tools keep tension on the cables until the module is centered and straight Use hydraulic jacks to lift the unit slightly and shift the base plates to get the locating tools plumb and the top and bottom flanges flush with the sides of the cup OPTION 2 Set the modules on the blocks first then on to locating tools The module is set on the blocks keep tension on the cables until the module is properly aligned Use hydraulic jacks to lift the unit slightly then install the locating tools Shift the base plates to get the tools plumb and the top and bottom flanges flush with the sides of the cup e Measure from each side of each end of the module to the end walls to be certain the module is plumb and square before removing tension f Once the tension on the lift cables is released remove the lift brackets and or hooks Setting End Modules e Module Pl2. To prevent this first tighten the inner nut securing the gland in the hole then 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 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 Scale house 50746 12 50745 15 03 10 Rev 5 Intalogix installations utilize a specific numbering 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 see Image 50745 12 Improper grounding will prevent the surge voltage protection from adequately protecting the scale d Grounding Smart Sectional Controllers Intalogix systems must have two 2 ground rods in the foundation for proper connection Pit power supplies use a ground separate from the weighbridge ground rod e 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
3. 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 the side of the Titan modules 50745 6 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 50745 14 03 10 Rev 5 c Smart Sectional Controller Wire cells into each section s 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 Note The Titan has been designed to provide protection from the effects of moisture The load cells have been calibrated with the cable attached and 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 and 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
4. 70 80 90 105 27 30 35 60 70 80 90 105 27 30 35 60 70 80 90 105 27 30 35 60 70 80 90 105 Ww feet 10 10 10 10 10 10 10 10 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 14 14 14 14 14 14 14 14 CLC Cap KIbs 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 ton 75 75 75 125 125 150 150 150 75 75 75 125 125 150 150 150 75 75 75 125 125 150 150 150 75 75 75 125 125 150 150 150 s Sec N A A A OO OID IQ iu hao A O0 ONNNAAAO0UONNNARAAOONDN 03 10 Rev 5 Section 3 Installation Installation consists of the following e Foundation check layout and base plate setting e Tools materials documentation and a crane e Setting the modules e Setting the modules on load cells A Preparations for Installation Tools Equipment and Materials Required 1 Certified Prints 2 Amobile crane of sufficient capacity to safely lift and place the weighbridge modules e Approximate Steel Deck Module maximum weight 8 tons 3 Four 4 equal length 20 ft lifting chains or cables with hooks to safely attach to the modules lifting channels located on the sides of the modules Note The lifting straps MUST be requested in advance from the Crane Service Company 4 Machinist s levels Starrett 134 amp 132 6 5 Hand tools 6 Hammer Drill
5. Instruction Manual TITAN Motor Truck Scale Model 6020 Series 2004 2010 by Fairbanks Scales Inc 50745 All rights reserved Revision 5 03 10 Amendment Record Titan 6020 Series Motor Truck Scale 50745 Manufactured by Fairbanks Scales Inc 821 Locust Kansas City Missouri 64106 Issue 1 New product Issue 2 Revised cable routing drawings formatting Revision 3 Updated the Parts List Revision 4 Updated drawings and Parts Lists Revision 5 Updated Specifications and drawings 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 50745 2 03 10 Rev 5 50745 Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 APPENDIX I Table of Contents General Information Description Installation A Preparations for Installations B Foundation C Setting the Modules Electrical Installation A Introduction B Description C Installation Maintenance A Scale Maintenanc
6. Rings Actual Size 2 1 4 D 2 1 2 O D Part No 64340 1 8 Thickness ANSI 228 Outside of all load cell cups 1 1 2 I D 1 3 4 O D Part No 72274 1 8 Thickness ANSI 222 Inside of cup 50745 7 50745 19 03 10 Rev 5 Section 7 Accessories A Field Installed Rub Rail Installation e Disconnect all loadcells Electrically isolate the load cells from the platform e Use the print with the accessory for actual measurements e Clean remove primer the areas to be welded for good penetration e Weld stiffeners to the side weldments e Bolt the gussets to the stiffeners and end weldments e Weld pipe to the gussets e Clean and paint paint provided all weld areas Warning Fairbanks does NOT recommend using foundation or ground installed guide rails along the sides of a truck scale platform Damage may occur to the scale if a truck hits the guide rail transferring damaging forces to the platform and the checking system Use of this style guide rail will void product warranty Va 3 DIA PIPE GUSSET STIFFENERS 50745 2 NOWELD T TYP VERTICAL UP WELD 50745 20 03 10 Rev 5 Appendix l Foundation Check 50745 TAURO Foundation Inspection FAIRBANK i EMM L uuu FOUNDATION FIELD CHECK LIST ONDES Field Form A Foundation Inspection should ALWAYS be performed prior to scale installation and to confirm correct foundation construc
7. a Lines TOP VIEW Lateral Layout Load Cell Data Line FF 2267 Issue 1 50745 22 03 10 Rev 5 iring Ww IX Append 1189 peo indino indino PISIUS UONENOXJ UONENOXJ 189 PEOJ c IIO PEOJ mdino pieius pieius UOIENOXJ UONENOXA Nomo FDLOT oo Mm TNOFVDLOOMO UONENOXJ UONEJNOXJ L Ie PEOJ indino pjeius UONENDX J lt a pun pori SUM pPISIUS enig US9JO TAMMY OONO yoelg 21989 9vZZI TNOFVDLOOMO TAMMY OONO UONENOXJ pesn JON cal val 8 T CN C lt 010 OF H G8 S4 G8 Su Xu pieius XL umy oa pjeius H oq N3 SHOA 0 8 02 DO SHOA 0 8 TAMMY 010 OF T QN CO s 10 R oo Mm Hv Nomo FDOTT oM A8e OV Joyeoipu 03 10 Rev 5 23 50745
8. acement Guide the modules into place with the supporting blocks on the end of the module coming to rest on the supporting blocks of the center module Lower the other end of the module onto the load cell locating tools or blocks 50745 3 50745 10 03 10 Rev 5 4 Before releasing cable tension e Check the alignment of the end modules to the center or base module and to the end wall e Using the provided shims fill any gaps on the supporting blocks and get the modules properly aligned 5 Connecting the Modules e Bolt the modules together using the 11 s x 8 threaded rod lock washers flat washers and nuts provided Tighten the bolts snugly but do not tighten them completely Shim the supporting blocks if necessary to align the modules Warning Module to module bolts MUST be installed correctly and torqued properly after all lifting is completed Do Not substitute or omit bolts 6 Checking Adjustment a Adjust End Checking e Adjust the End Checking Bolts until they touch and prevent movement b Install the side checking brackets e Bolt the brackets to the end checking plates embedded in the end walls per certified prints Adjust the bolts until they touch the channels they bump against 50745 11 03 10 Rev 5 7 Base Plate Completion e Check that all locating tools are properly aligned and flush with the receiver cups Drill the holes for the base plate anchors
9. e B Mechanical Faults C Replacing an RC Load Cell Parts List A Parts List B Load Cells and Load Cell Hardware C O Rings Actual Size Accessories A Field Installed Rub Rail Installation Foundation Check List APPENDIX Il Wiring 03 10 Rev 5 Section 1 General Informatior This Instruction manual provides installation instructions for the Fairbanks Titan Modular Steel Deck Truck Scales For assurance of correct Titan scale installation s use e Methods and Procedures FF 2267 101732 See Appendix e The Certified prints setting plans supplied with the scale e This Instruction Manual 50745 The concrete foundation work must be performed according to the certified prints issued for the specific customer and order number The name and order number for the particular customer will be on the certified prints 50745 4 03 10 Rev 5 Section 2 Description The Titan Modular Steel Deck truck scales are available in various lengths from 27 to 105 feet and widths from 10 to 14 feet The scale is made up of modules of 27 30 and 35 feet in length All modules are assembled and welded at the factory e The scale should be located so that vehicles can approach and exit the scale as easily as possible e The platform should be visible from the instrument location e Drainage of surface water must be such that water does not collect under the scale e Smooth and level approaches are required at each end of the pla
10. ed O ring on the edge of the the upper foundation next to each base plate 5 Place the load cell locating tool next to each base plate LOAD CELL ASSEMBLY DETAIL UPPER L C RECEIVER CUP PART 87482 CABLE HOLES FOR INITIAL INSTALLATION USE 1 1 8 SHIM PRE TAPPED BAR 0 LOWER L C RECEIVER CUP FOR JUNCTION BOX PART 87481 LOAD CELL CABLE HANGER 6 LOAD CELL INSIDE FACE OF SCALE BASE PLATE PART 80453 O RING ON EACH RECEIVER CUP PART 50745 1 50745 8 03 10 Rev 5 C Setting the Modules 1 Preparing The Modules For Lifting The module s are complete with channel pieces welded to the sides for attaching lifting hooks No lifting bolts are required 2 Setting the Center or Base Module a 50745 The center or base module is always set first The center or base module will have four 4 load cells to install all other modules will have two 2 load cells The modules must be placed in the proper order and aligned in the foundation so that all modules fit correctly These scales HAVE a definite orientation because of the junction box mounts are welded to one 1 side only The junction box mount side of the base module should face the conduit of the main interface homerun cable Place the safety blocks under the modules which will set the modules at a height slightly lower than the finished height
11. ghten the module to module bolts e The bolts should be torqued to 500 ft Ibs f Load cell cables e Route the load cell cables to the conduits that go through the scale and also over the top of the module diaphram plates Coil excess cables on the cable hanger on the interior side of the I beams see Image 50745 11 5 6 10 5 8 4 7 3 8 CABLE HANGER 3 4 10 X 3 FULL THD BOLTS PART 54559 6 REQ D EACH ND WALL SIDE CHECK BRACKET BASE PLATE CHECKING DETAIL ELEVATION 50745 11 9 Final Checking Adjustment a Adjust End Checking e Adjust the End Checking Bolts to allow 1 6 to 1 8 clearance b Adjust side checking bolts to allow 146 clearance from block 50745 13 03 10 Rev 5 Section 4 Electrical Installat A Introduction The Titan 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 Analog instruments cannot be used with this platform The sensitivity using a analog indicator would be approximately a half 5 microvolt Most analog instruments have a minimum sensitivity of one 1 microvolt 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
12. p amp position the anti rotation pin Carefully lower the hydraulic jack s until the cell is set into the lower cup Remove the cover of the sectional controller then loosen the gland bushing to free the cable Remove the old cell wires and connect new cell wires in the sectional controller Latch the cover Tighten all gland nuts with a wrench to secure Test and adjust scale as necessary 17 03 10 Rev 5 Section 6 Parts List A Parts List Part No Description 75458 11 8 x 41 2 w nut module module 54788 11 8 lock washer module module 54255 11 8 flat washer module module 80956 Load Cell Base Plate 61743 Clamp Bar Washer base plates 62857 5 8 x 6 Anchor Bolts 55010 Ground Rod Kit 144562 Check Bolt 1 1 8 x 8 75398 Check Bracket 60312 Side Check Bolt 1 x 6 1 2 B Load Cells and Load Cell Hardware Part No Description 80453 Load Cell 6 RC 100K 1000 ohm 2mv v 73682 Shim receiver cup the 64338 Shim receiver cup 1 8 64334 Shim receiver cup 3 6 72274 O Ring INSIDE of Cup ANSI 222 64340 O Ring OUTSIDE of Cup ANSI 228 87481 Receiver Cup LOWER w anti rotation pin 87482 Receiver Cup UPPER 64382 Roll Pin 72 x 272 anti rotation baseplate 63981 Anti Rotation Pin LOWER Receiver Cup 3 e x 272 107118 Locating Tool 6 Jf manufactured before 07 01 07 then order part no 70511 If manufactured before 07 01 07 then order part no 70512 50745 18 C O
13. supplies Connect the indicator interface cable to the instrument in the scale house per the instructions in the appropriate indicator service manual 50745 16 03 10 Rev 5 Section 5 Maintenance A Scale Maintenance 50745 1 4 9 Check for accumulations of solid material under the scale which may affect the accuracy i e ice frozen mud debris Have the customer clean under the platform regularly Inspect load cells for damage to the ends cables check cups and O rings for damage The load cell bearing cups should be inspected cleaned and greased periodically Inspect and adjust all checking to proper tolerances Mechanical Faults E Check all clearances around the scale for any obstructions or interference with the movement of the platform Check all check bolt clearances both with and without a concentrated load over each section individually Check all load cells for plumb and level Inspect the boxes for leaks the interior should be clean and dry If there is moisture inside clean then dry it out thoroughly Check all connections at the terminal blocks Replacing a load cell 1 2 Remove power from the instrument Lift the scale using a proper sized and rated hydraulic jack s at the corner s close to the defective cell location Check upper and lower receiving cups and O rings for damage Replace as necessary and reapply grease Insert the new cell into the upper receiving cu
14. tform to reduce loading shock and facilitate testing of the scale e Approaches must conform to the requirements of the law in the state in which the scale is being installed In the absence of such laws the approaches must conform to paragraph UR 2 6 National Institute of Standards and Technology Handbook 44 which states that the first 10 feet must be level and on the same plane as the scale platform NTEP CC 96 089 CMA AM 4949 50745 5 03 10 Rev 5 50745 Titan Steel Deck Truck Scale 6020 Series 100K CLC Model PLT 6020 T04 PLT 6020 T05 PLT 6020 T06 PLT 6020 T08 PLT 6020 T09 PLT 6020 T10 PLT 6020 T11 PLT 6020 T12 PLT 6020 U04 PLT 6020 U05 PLT 6020 U06 PLT 6020 U08 PLT 6020 U09 PLT 6020 U10 PLT 6020 U 11 PLT 6020 U 12 PLT 6020 V04 PLT 6020 V05 PLT 6020 V06 PLT 6020 V08 PLT 6020 V09 PLT 6020 V 10 PLT 6020 V 11 PLT 6020 V12 PLT 6020 W04 PLT 6020 W05 PLT 6020 W06 PLT 6020 W08 PLT 6020 W09 PLT 6020 W10 PLT 6020 W11 PLT 6020 W12 Scale 89801 89802 89803 89804 89805 89806 89807 89808 89809 89810 89811 89812 89813 89814 89815 89816 89817 89818 89819 89820 89821 89822 89823 89824 89825 89826 89827 89828 89829 89830 89831 89832 Weight 12800 14200 16500 28400 33000 38400 42600 49500 14100 15600 18200 31200 36400 42300 46800 54600 15400 17100 19800 34200 39600 46200 51300 59400 18000 19900 23100 39800 46200 54000 59700 69300 L feet 27 30 35 60
15. the scale will not fit correctly to low could result in excessive shimming O 6 In pit foundations check walls to verify they are straight Straight walls are very important but are even more critical for modular scales like the Titan Series O7 Verify conduit locations and pull strings if needed Os Verify ground rod locations LI 9 Verify that drains and sump openings are piped correctly and are clear of debris 10 Check the end coping to ensure they are centerline and that the coping is correct for the scale being installed 10 11 or 12 width etc Check all coping side and end for hollow areas LIm Verify location of any and all required embeds or pre installed baseplates i e Hwy System RR scales etc All of these dimensions will be located on the Certified foundation prints 112 Layout To help in locating pre installed baseplates embeds load cell centerlines etc refer to Methods and Procedures section on Layout See other side for foundation amp Layout charts FF 2267 Issue 1 21 03 10 Rev 5 Length 8 Width Check Measurement B to B A Measurement A to A Diagonal Measurements Check B Pier Height Check Side View concrete Longitudinal Layout nails A Coping Length e Concrete Nails B 1 2 of the coping length OR Centerline G Centerline of of Scale C Distance from Centerline to Load Cell Dat
16. tion If possible this should be done prior to scale shipment Tools required LI Certified drawings and site plan LI 2 to 4 level LJ 100 and 25 steel tapes CT Hammer and concrete nails L Laser or builders level if possible O String line construction string O Straight edge for pit foundations 2 x 4 very straight and 4 wider than pit walls L Construction paint up side down type for marking concrete Perform the following Foundation Checks Refer to Methods and Procedures for complete description of each step Recommended to copy check list and keep in job file ALWAYS familiarize yourself with the CERTIFIED foundation prints for the job you are working on as model numbers and specifications are subject to change Ll 1 Site Plan and Certified Prints should be thoroughly reviewed to confirm accurate locations to the scale and all extra items scoreboards lights poles etc that are included in the bid or contract O 2 Check for truck and crane access overhead wires fences green concrete etc L3 Dimensional length and width check check all 4 sides and record on chart other side L1 4 Diagonal measurements check to verify that the foundation is square and record on chart other side These measurements should be equal or within 1 2 Greater error could result in the scale not fitting in the foundation LI 5 Check ALL pier heights to make sure they are the proper elevation and record on chart other side To high and
17. using a hammer drill and the 5 8 drill bit Tap the anchors into clean holes and tighten the nuts securely 3e END WDMT 3 DECK PLATE OVERHANG le GAP BETWEEN t APPROACH amp SCALE DECK PLATE LOAD CELL CABLE HANGER EDGE DF APPROACH EDGE DF PANEL 1 1 8 BOLT 8 LG PART 144562 1 BOLT 6K LG BASE PLATE PART 80956 PART 60312 CHECK BRACKET PART 75398 CHECKING DETAIL PLAN Use eye protection 8 Installing Load Cells a Unpack the load cells and mark each calibration certificate with the cell location position b Starting at one end of the assembled platform place hydraulic jacks at the corners so the section can be lifted off the locating tool Two 2 hydraulic jacks may be required c Liftthe platform so the load cell locating tool can be removed from the upper and lower bearing cups Once removed fill both cups with grease 50745 12 03 10 Rev 5 d Onthe bottom of the load cells there are two flatsides which must be aligned with the flats in the lower cup Carefully lower the scale while seating the bottom of the cell into the lower cup Check the scale s level and height particularly at the approaches Use the load cell shims provided to adjust load cell cups for correct height and to ensure that all cells share the proper amount of load Center section cells will have up to twice the deadload of end section cells e When the modules are level and at the correct height ti
18. with 5 s bit 16 long 7 Hydraulic jacks 16 ton capacity 8 100 steel tape measure 9 Stringline and chalkline 10 Prybars 11 High quality grease and anti seize 12 Load cell locating tools Part No 707118 50745 7 03 10 Rev 5 B Foundation Before installing any part of the scale the foundation must be checked for accuracy using Foundation Inspection Field Check List FF 2267 101732 see Appendix 1 Layout and position the base plates in the proper locations using the Methods amp Procedures and certified prints Each base plate must be level and in full contact with the top of the pier Adjustments can be made by chipping the concrete or grouting under the base plates 2 Re check the locations of each base plate against the certified prints Insert two 2 roll pins into each base plate for anti rotation Position the plates with pins towards the outside This will leave the load cell cable exiting the load cell to the inside It is not necessary to install base plate anchors at this time 3 Grease and install the inner O ring in each load cell receiver cup On all load cell receiver cups grease the large outer O rings then install one in the groove on the outside of each cup Puta 1 8 shim on the lower cups grease the outside then insert the shim s into the base plates Lower cups for the load cells have a pin which must be aligned between the two roll pins in the base plate 4 Place the upper cup with greas
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