Load Disc 3xi/LD3xiC Installation Manual
Contents
1. 1 A mantal NETT T 1 ELTE m i OJADE a aTa SA E OA OE EE i Chapter 1 Description of the Load Disc 1 1 TAME O AUC EL OM ete ag tes ess edu dos ast aber er EIN 1 1 Description of Measurement Systerm 1 1 Applicatiobs sec Lern steuert trie coit 1 1 Installation Option ee 12 Universal Top Adaptor Plate 0 rt rtr iro Uer ERA ene 1 2 Leveling Top Plate Adapter torti IEEE dk 1 3 HEN P EET 1 3 Leveling Base Adapter Plate i cet estre tenete eres eed eda ata 14 LD3x1 Assembly Op OI 2 7 oerte sets Peter rot tado c abt pee vans force in Dec EERE us tes Pus 14 Chapter 2 Preparing for the Load Disc Installation 2 1 EE EST 07 0 0E D A Tet 2 1 Load Disc Order iust Sede nists Seid epe erae dia 2 A A A 2 1 Measuring Sensor OUIpUL scere ER E ERE ERR E GE GET ORG 22 Prepare Installation Equipriett erri ron ARR Ee utes 23 Installation Equipment Needed esee eee ere es rn eei eee 2 3 Vessel Preparation diets2. MULTIMETER ala rape EIS YELLOW SUPPLY WHITE P KM METI 5 RED BROWN OAD DISC NS UM y BLACK BLACK 22 Chapter 2 Pre Installation Prepare Installation ee ied The following equipment is needed to install Load Discs Lifting equipment Tape measure Level Pry bar Marking pen Wrenches ASTM A 325 bolts or anchor bolts or equivalent strength lock washers and flat washers to secure Load Disc to vessel support or foundation if applicable Signal processor Shims if applicable Grout if applicable Digital Multimeter FLUKE or equivalent See TI drawings in Appendix D for the appropriate bolt size Note KM recommends the use of a trim box for applications which need to be certified for trade Vessel Preparation There are two aspects to successful use of Load Discs properly functioning Load Discs and appropriate vessel support characteristics Review the following list of error sources and make the recommended corrections before you install the Load Discs An inadequate vessel foundation can allow excessive movement Ensure the foundation is concrete or steel Hidden load bearing structures such as discharge chutes or plumbing supported by the floor can reduce loads on the vessel supports Install flexible couplings to minmize this problem Cross connecting structures such as catwalks and manifolds can transfer loads from adjacent vessels
3. 1 2 S S FLAT WASHER 1 2 13 ANCHOR BOLT cry CUSTOMER SUPPLIED 0 LD3xiC 3xiMJ Load Cell Assembly KM SUPPLIED S S FLAT WASHER STOMER SUPPLIED NG BAS PI ATF This unit consists of the LD3xiC 3x1MJ load cell assembly load cell and installed set screws and a cage assembly The load cell has the loading head on top and they both slide into the cage assembly They are held in place with three set screws The set screws are pre installed into the load cell at the factory The load cell assembly slips down into the holes of the cage assembly The LD3xiC assembly does not include jacking bolts the LD3xiMJ does include jacking bolts 14 CAD LAU i 8 OY BOTTOM VIEW OF LOAD CELL Ne LOAD CELL 5xiMJ CAGE Chapter 2 Pre Installation Chapter 2 Preparing for the Load Disc Installation Check Shipment This chapter describes the pre check procedures for the LD3xi LD3xiC Checking the load discs before installation will ensure properly working equipment that will provide accurate monitoring of vessel contents Perform the following prior to installing the Load Disc Check Load Disc Order Items The following items are included with a typical order for each vessel quantities dependent on application LD3xi LD3xiC Load Cell Junction Boxes or molded junctions Top or Bottom Hardware LD3xi only If any i
4. Route the cable from the last junction box through conduit to the signal processor Refer to the signal processor manual for wiring the junction box to the signal processor One vessel takes up one channel in the signal processor the channel shows the average value from all the load discs under the vessel Kas f T N QD K J e is 4 O 1 NIIS D Qj DM S Nn t A E m LOAD DISC CABLES SIGNAL PROCESSO e N nt gt FROM VESSEL LEGS OR OTHER J BOX Figure 3 8 Wiring Stainless Steel Junction Boxes Together and to Signal Processor 3 9 Chapter 3 LD3xi LD3xiC Mounting Trim Box Mounting and Wiring Mounting Trim Box 1 6 56 166 63mm TCE d Em 1 48 Ihm 8 M g 3 Figure 3 9 Summing Stainless Steel Junction Box Mounting 1 See Figure 3 9 Hold the junction box at the desired mounting location Mark the four mounting holes Mount the junction box with 78 32 socket head cap screws and flat washers Tighten the screws until snug Wiring Load Discs to Trim Box i See Figure 3 10 The summing stainless steel junction box accom modates up to eight Load Discs Follow this procedure Thread the Load Disc
5. outer eer tata gens ve aad ede ento nad essi ee 23 Factors Affecting Performi tiCe Ed ck BESTEN ERE VE CER REY Be dk De 24 Chapter 3 Mounting the Load Disc ceres 2 1 General MOnato Loris rt eo 3 1 LD3xvLED3 xi General Installation rna rete ace acs tenderet 32 Leveling and aoc deti eec freier reU RC ee retinet eee ib esse 3 5 Leveling Shimming using Universal Top Adapter Plate sse 3 5 Leveling Shimming using Leveling Top Adapter Plate eese 3 6 Leveling Shimming using Leveling Base Adapter Plate esee 3 6 Leveling Shimming using Anyadapter Plate 3 6 Junction Box Mounting and Wiring etre pete te ee ee rave Deere Ee denso concedes 3 7 Trim Mounting and Wire oe ie rr tetro oo rei t rere 3 10 Appendix A Contact Information eee eeee eee eterne seen esse esos ee essceeessceesse Appendix B System Calibration 5 05 lt s cccsscansssossesscevsstvesseseenscreasvoceasasveacserexesceasssesasesetiess Di Appendix C liii rM Appendix D Technical Drawings ccccossonsssossssseessssvesosensssseastoaeasasevsssecatesceassoesesesernases D 1 Table of Contents Introduction Welcome About this manual Introduction This chapter
6. System Calibration B2 Appendix C Troubleshooting Appendix C Troubleshooting the Load Disc System This section describes an output check and some common problems For each problem one or more possible explana tions are listed For each explanation suggested solutions are provided Functional Check Measuring Output while wired to Signal Processor Note The no load 1 condition is when the Load Disc stands 2 alone without any weight applied 3 4 Mesure the output of the load cell using procedure from page 2 2 Verify the output to be between OmV and 1 mV stable Repeat Steps 1 and 2 for each LD3xi If the load cells are ins talled under the vessel verify stability of each load cell Functional Check Measuring Resistance The following will be true between 0 F and 100 F iF 2 Measure between the disconnected excitation wires and verify the resistance to be 700 ohms 4 15 ohms with a stable reading Measure between the disconnected output wires and verify the resistance to be 700 ohms Note When using the 61 6036 01 trim box and a sensor fails the sensor must be replaced When the sensor wires are removed from the junction box the jumper must be soldered back in place C 1 15 ohms with a stable reading Appendix C Troubleshooting Problem Problem Details Solution Small Amplitude Fluctuations can be caused Check condu
7. gt KM Load Disc 3x1 LD3x1C Installation Manual caution It is essential that all instructions in this manual be followed precisely to ensure proper operation of the equipment 97 1137 02 Rev F July 2003 NOTICE The content of this document is the intellectual property of Kistler Morse Corporation Any reproduction or translation of this document without the written authorization of a Kistler Morse corporate officer is prohibited CAUTION Follow these rules if welding is done on the vessel after installation of the Load Disc The electrical current of the welder may pass through the Load Disc causing damage to the transducer and possibly to the signal processor To avoid damage follow these precautions 1 Disconnect the Load Disc cables from the signal processor 2 Ground the welder as close to the welding joint as possible The welding ground must be between the Load Disc and the weld joint to prevent the welding current from going through the Load Disc to earth ground Note High temperatures can damage the Load Disc If you are welding in the vicinity ofa Load Disc monitor the temperature of the metal adjacent to the Load Disc If it becomes too hot to touch stop welding immediately and remove the Load Disc before continuing Prior to reinstalling the Load Disc verify that no damage has occurred by referring to the measurement procedures in Troubleshooting Appendix C Table of Contents Table of Contents
8. 1 Appendix A Contact Information 4r Note Load Disc installation field wiring conduit installation and junction box and signal processor mounting must be performed by the customer The AC power must be connected to the signal processor but not energized prior to KM beginning work On Site Consultation Field Service staff can provide additional services at your request Contact KM at the closest office for rate and scheduling information for the following services Technical application startup and troubleshooting assistance on site Training on site or at our corporate office Service calls Equipment updates to our latest configuration General descriptions of some of these standard services follow Of course if your service needs vary from those described we are available to discuss them with you Installation Startup Assistance and On Site Training The system will be powered up and checked for proper electrical operation For best results KM requires moving a known amount of material such as a truckload for Live Load calibration Live Load calibration will be performed if actual material or weight devices can be moved If it is not possible to move material a Manual calibration will be performed Recommendations for the optimal performance ofthe system will be provided On site training will include simulation of the Live Load calibration process if Live Load calibration can not be performe
9. 28 32 socket head d cap screws and flat washers per your application 5 171 5mm n Tighten the screws until snug Wiring Load Discs to Junction Box Figure 3 6 Plastic and Stainless Steel Junction Box Mounting See Figure 3 7 The stainless steel junction box accommodates up to eight Load Discs with up to two Load Disc wires at each terminal Note that the junction box has no pre cut holes for conduit or fittings Follow this procedure CAUTION Only use 1 Install liquid tight fittings Sikaflex 1A polyure thane sealant or Dow 2 Seal fittings with Sikaflex M or electrical grade Corning 739 or sealant RTV 738 Other sealants may contain 3 Thread the Load Disc cable through the desired conduit acetic acid which is fitting See Figure 3 7 har miful to sensors and 4 Estimate the required length of cable to the terminal strip electronics allowing a little extra for strain relief Cut the excess cable 2 Strip back 3 76mm of the cable sheathing to expose the four wires and the shield inside Strip back 4 6mm of Nas ivan hoet insulation from the end of each of the wires Note If you have a 61 6036 01 Stainless Steel J Box with 6 Connect the Load Disc wires to the selected TB2 5 trimming pots refer to page terminals on the left side of the junction box red or 3 10 brown wire to EX white wire to SIG and black wire to
10. Install slip joint or flex couplings to minimize this problem Shock loads can damage the Load Disc Install protective barriers or stops to prevent vehicles from hitting the vessel supports 2 3 Chapter 2 Pre Installation Factors that affect Performance An independent isolated vessel with no connection to any other vessel or adjacent structure provides the most accurate results for a weight measurement system Examples ofthis type of application are floor scales and truck scales Connections to other vessels or structures affect accuracy because the transducers interpret strain changes caused by the connecting structures as being caused by changes in the material weight FI Horizontal run length is ok for Some typical causes of error related to x coupling cross sectional area of pipe connecting structures and where applicable No horizontal run y methods for reducing the errors follow Catwalk Hidden load bearing members Vessel goes through roof Tripper conveyors or deck plating Rigid piping connection between vessel and another adjacent structure Poor Foundation No horizontal run Flexible Structure Horizontal run too short for cross Uneven Loading sectional area of pipe Figure 2 1 Examples of typical causes of error 24 Chapter 3 LD3xi LD3xiC_ Mounting Chapter 3 Mounting the Load Disc General Information This chapter describes installation and wiring of th
11. and Wiring on page 3 10 Live Load calibration requires you to move a known quantity of material into or out of the vessel while performing the procedure The quantity of material moved must be at least 25 of the vessel s total capacity to provide the best accuracy Live Load calibration is also based on the material weight currently in the vessel Manual calibration allows you to start using the system as soon as the load discs junction boxes and signal processor are installed and wired even if you cannot move any or enough material now Manual calibration values are based on system parameters including rated load and signal processor A D converter sensitivity These values are known can be calculated or can be obtained from the signal processor Manual calibration is also based on the material weight currently in the vessel Note that manual calibration does not take into account the actual response to changes in weight Theoretically a change in weight results in a proportional change in digital counts However the structure s actual response to weight and interaction with piping catwalks roof discharge chutes etc prevents the system from achieving theoretical values Manual calibration is a good start but to obtain the highest accuracy perform a Live Load calibration when scheduling permits you to move material into or out of the vessel Refer to the indicator manual s for detailed calibration instructions Appendix B
12. applications adjust plate to lowest position by lowering jam nut to top of LD3xi and tighten Then lower leveling nut to the jam nut 1 or 1 4 2 lt j whichever is less 1 2 3 Note Concrete founda tion and grouting shown for reference only The concepts apply to all foundation types Anchor bolts supplied by 4 customer eveling Nuts a Grout after level i or 1 4 whichever is less Figure 3 1 Angular misalignment 32 Chapter 3 LD3xi LD3xiC Mounting 5 Raise the vessel 6 Inspect the foundation and vessel mounting surfaces that will mate to the LD3xi LD3xiC plates a Check the mounting hole locations and size on both the foundation base and the vessel foot pad Refer to the TI drawings Appendix D b Also check the surfaces for flatness and angular misalignment A baseplate with leveling nuts is recommended See Figure 3 1 7 Mount the LD3xi LD3xiC assembly to the foundation See TI drawings Appendix D a Lower the LD3xi LD3xiC to the foundation Take care to align the mounting holes with the foundation mounting holes studs b Install the bolts and nuts as required DO NOT fully tighten the bolts at this time Leave a 1 4 inch gap between the nut and the washer to allow for positioning of the Load Discs See Figure 3 2 Repeat Steps 7 and 7b for the remaining Load Discs 8 Record the voltage output at
13. cable through the desired conduit fitting See Figure 3 10 Seal fittings with Sikaflex or electrical grade sealant Estimate the required length of cable to the terminal strip allowing a little extra for strain relief Do not cut the excess cable Strip back 3 76mm of the cable sheathing to expose the four wires and the shield inside Strip back 1 4 6mm of insulation from the end of each of the wires The trim box is designed for two three or four load cells Determine the number of load discs that will be wired to the trim box and cut the JU jumpers for any unused inputs The wire coding for the load disc Red or Brown Black EX White 51 Blue or Yellow SI Wire each load disc to the terminals leaving the cord grips loose until the trimming has been complete The terminals have quick connect levers that open when pushed A screwdriver or ballpoint pen can be used to open or close jaws The terminals can accommodate wire gauges 14 through 26 Set all the potentiometers fully clockwise for inputs being used This will give the maximum output from each load disc 3 10 Chapter 3 LD3xi LD3xiC Mounting 8 A calibration of the electronic indicator is needed before before trimming functions can be done Refer to the electronic indicator manual for the calibration procedure 9 Place test weights above each load cell and record the weight value displayed on the electronic indicator The tes
14. cover 2 See Figure 3 8 Route the 4 conductor cable through the fitting into the junction box farthest from the signal processor Connect wires from the cable to the TB1 terminalin the junction box red or brown wire to EX white wire to SIG and black wire to EX and blue or yellow wire to SIG 3 Route the cable through conduit to the next junction box Estimatethe required length of cable to the terminal strip allowing a little extra for strain relief Cut the excess cable Connect wires from the cable to the TB1 terminal in the junction box red or brown wire to white wire to SIG and black wire to EX and blue or yellow wire to SIG 4 Route another cable through the fitting into this junction box and attach wires to the TB1 terminal red or brown wire to TEX white wire to SIG and black wire to EX and blue or yellow wire to SIG 5 Repeat Steps 3 and 4 until all junction boxes on vessel are wired together 3 8 LOAD DISC CABLES VESSEL LEGS FROM CAUTION Only use Sikaflex 1A polyure thane sealant or Dow Corning RTV 739 or RTV 738 Other sealants may contain acetic acid which is harmful to sensors and electronics p S S qp EJS 35 els 2 ES 20200 20200 Chapter 3 LD3xi LD3xiC_ Mounting
15. describes the organization manual conventions and provides specification information This manual describes the installation of the Load Disc 3xi 3xiC load cell and its various hardware options It includes procedures for leveling and shim ming of the vessel if it is neccessary Instructions for wiring the load cell to the junction boxes and wiring the junction boxes together and to the signal processor are also included Refer to the signal processor manual for specific information on wiring the junction boxes to the signal processor Contact KM at 1 800 426 9010 if you have any questions regarding the installation For outside the USA and Canada call 425 486 6600 The chapters are organized in the following way Chapter 1 Description ofthe Load Disc 3xi 3xiC Chapter 2 Preparing the Load Disc 3xi 3xiC for Installation Chapter 3 Mounting the Load Disc 3xi 3xiC Appendix A through D include contact info system calibration troubleshoot ing charts and technical drawings TI s Manual Conventions Three kinds of special explanations appear throughout the manual Warning Caution and Note The format and significance of each is defined below amp WARNING Possible danger to people Injury may result if this information is ignored CAUTION Possible risk to the product The Load Disc or other equipment may be damaged if this information is ignored Note Contains additional information about a step
16. may reach Kistler Morse corporate headquarters at the following Mail Kistler Morse 19021 120th Ave NE Suite 101 Bothell Washington USA 98011 9513 Telephone 1 800 426 9010 425 486 6600 Fax 425 402 1500 E mail sales kistlermorse com Website http www kistlermorse com European Office Mail Kistler Morse Rucaplein 531 B 2610 Wilrijk Belgium Telephone 32 3 218 99 99 Fax 32 3 230 78 76 E mail kistler morse skynet be A complete unabridged copy of our product warranty is available upon request from KM A summary ofthe warranty subject to the terms and conditions listed fully in the warranty follows KM warrants the equipment to be free from defects in material and workmanship for one year from date of shipment to original user KM will replace or repair at our option any part found to be defective Buyer must return any part claimed defective to KM transportation prepaid KM maintains a fully trained staff of field service personnel who are capable of providing you with complete product assistance Our field service staff is based in Bothell Washington USA corporate headquarters and Wilrijk Belgium European office Phone Consultation Our Customer Service staff provides the following services by telephone via our regular and toll free number toll free in U S A and Canada only Technical application and troubleshooting assistance Spare parts assistance Warranty replacement assistance A
17. no load condition now that it 15 in position a Assign a number 1 2 3 etc to the load disc and make a note of it b Measure the output of load cell c Repeat steps a and b for all the Load Discs Figure 3 2 Leave I 4 inch gap for positioning Load Disc No Load Output Dead Weight Output Output Change mV mV mV Dead Weight Output No Load Output pog Lo o3 NEC Figure 3 3 Weight Distribution Chart Record YOUR system 5 Load Outputs 33 Chapter 3 LD3xi LD3xiC Mounting Figure 3 4 Lower vessel onto top plate Note output changes should be positive If you observe a negative output change check wiring polarity and vessel load shifting 9 Mount the vessel to the LD3xi LD3xiC a Lower the vessel gently onto the Load Discs Alignment pins may be used to help guide and position the vessel See Figure 3 4 Center the Load Disc top mounting holes with the vessel mounting holes using the clearance available from the bottom mounting holes Note If the vessel hole pattern does NOT match up with the Load Disc hole pattern modify the mounting holes on the vessel DO NOT hammer or force the Load Disc into position by tightening the mounting bolts The vessel holes will need to be resized or relocated Place the four top bolts customer supplied through the ve
18. 5x rated load compression Electrical Excitation Voltage Operating Range 5 15 VDC Recommended Supply Voltage 10 VDC Maximum Current 16mA 10 VDC excitation 0 F Output Resistance 700 ohms 2 Output Non linearity Hysteresis combined 0 03 rated output Return to Zero over 30 min 0 026 rated output Creep over 30 min 0 028 rated output Creep over 20 and 30 min 0 008 rated output Zero Balance 1 rated output Rated Output 2 mV V 0 1 Environmental Temperature Range Standard 14 to 104 10 to 40 C Temperature Zero Shift 0 0013 F 0 0024 C Temperature Sensitivity Change 0 00094 F 0 0017 Storage Temp Range 4 to 176 F 20 C to 80 C Humidity 100 Physical Construction sensor 17 4 PH 900 stainless steel cage 304 stainless steel Cable Length 168 5 m with tinned pigtail termination Rating IP68 100h at 1m water column Shipping Weight 18 7 165 8 5 kg Approvals CE OIML R60 Chapter 1 Description Chapter 1 Description of the Load Disc Figure 1 1 LD3xi Compression Load Cell with optional NEMA 6P cable system LD3xi LD3xiC weight 4 x4 junction box weight 4 weight 4 1 1 ___ Signal weight 4 Serial Output N Setpoints for signal signaling a processor change in staus such as high and
19. EX and blue or yellow wire to SIG 7 AR N QD el CIS S ed x SS s m S se T 5 IS D NL sd Sl V LOAD DISC CABLES NS FROM VESSEL LEGS Figure 3 7 Wiring Load Discs to Stainless Steel Junction Box 3 7 Chapter 3 LD3xi LD3xiC Mounting 7 Perform Steps 3 through 6 for each Load Disc you wire to this junction box 8 Replace the junction box cover if not ready to begin wiring the junction boxes together Wiring Junction Boxes Together and to Signal Processor The procedure below assumes the conduit fitting and conduit for wiring the junction box to the other junction boxes and to the signal processor has been installed Seal all conduit fittings against water entry Install drain holes at conduit s lowest elevation s to allow condensation to drain Use Belden 4 conductor shielded interconnect cable or equivalent to wire junction boxes together and to the signal processor For lengths up to 50 feet 15 2 m use Belden 8723 For 6 wire cable of distances up to 100 feet use Belden 9773 All spliced wiring routed between junction boxes and signal processor must be soldered and encapsulated in waterproof heatshrink Remove the junction box
20. SE NG NUT NU Anyadapter Plate This option consists of the unique Anydapter Plate which has a MOUNTING BO universal bolt pattern to fit a variety of vessel leg flanges and a hex 3 head bolt The plate attaches to the load disc with the bolt and washers T d The Anyadapter plate then bolts to a vessel gusset or a flat plate Fd 3 4 SPRING WASHER welded to the vessel leg using customer supplied hardware e a This hardware arrangement allows 360 degree movement PLATE of the top plate and angular misalignment of up to 3 degrees Additionally there is a leveling feature that allows vertical height adjustments This arrangement also incorporates a locking jam nut to insure that the SPHERICAL WASHER SET height remains unchanged 7 LEVELING NUIT JAM NUT P CARRIER ASSEMBLY vw LD3xi ASSEMBLY Note Adapter plate not shown in illustrationat right This kit requires an adapter plate for proper installation Chapter 1 Description Leveling Base Adapter Plate This kit consists ofa Leveling Base Adapter Plate and four hex bolts four flat washers and four lock washers 1 03605 bolts onto the leveling base adapter plate This plate rests on four leveling nuts and washers screwed onto anchor bolts installed in the foundation By turning the leveling nuts the height of the load discs and thus the vessel can be adjusted for proper load distribution 1 2 S S BOLT KM SUPPLIED
21. al Multimeter DMM check Weight Reading or cause indicated weight to resistance for individual Load Discs System Requires shift up or down by large 1 Measure between the disconnected Frequent amount up to 100 of full excitation wires and verify the resistance Recalibration scale live load to be 700 ohms 15 ohms with a stable reading Measure between the disconnected output wires and verify the resistance to be 700 ohms 15 ohms with a stable reading Place one DMM lead on the LD s shield wire and take four measurements to each of the other wires The reading should be greater than 5 giga ohms Repeat Steps 1 through 3 for each suspect Load Disc until damaged Load Disc is located Sudden change in weight Check signal processor excitation voltage reading can be caused by and incoming AC voltage for accuracy and problems with signal processor stability refer to signal processor manual Appendix C Troubleshooting Appendix D Technical Drawings Appendix D Technical Drawings TI This appendix contains the following technical drawings for the LD3xi Drawing No Drawing Title TI LC LD3xi 01 Installation Arrangements 220 5500 Ib Load Disc 3x1 13 Pages Page Installation Instructions 1 4 LD3xi with Leveling Top Universal Adapter Plate 5 LD3xi with Universal Top Adapter Plate 6 LD3xi with Anyadapter Plate 7 Mounting hole patterns for Anyadapter 8 LD3xi with Leveling Base Adapter Plate 9 LD3xi M
22. d while KM is on site and instruction covering operation and maintenance of the system Troubleshooting KM will troubleshoot systems for mechanical electrical calibration and wiring errors Normal component repairs will be made and wiring errors will be corrected including replacement of non repairable printed circuit boards To troubleshoot your own equipment see Appendix C for Equipment Troubleshooting charts Service Calls KM will perform on site repair replacement services Return Material Authorization If a part needs to be sent to the factory for repair contact KM s corporate office and request a Return Material Authorization RMA number The RMA number identifies the part and the owner and must be included with the part when it is shipped to the factory A 2 Appendix B System Calibration Appendix B System Calibration for the Load Disc This chapter describes general procedures for calibrating the Load Disc system Before calibrating install a signal processor Refer to the signal proces sor manual for the procedures to input calibration parameters Calibration Methods There are two calibration methods e Live Load calibration set lo span and hi span while moving material into or out of the vessel This is the preferred method e Manual calibration set scale factor counts scale factor weight and zero calibration value without moving material For use with Trim Box refer to Trim Box Mounting
23. e LD3xi LD3xiC and junction boxes Follow all instructions carefully to ensure proper operation of the system The load disc has a variety of mounting hardware options that accommodate almost all possible applications These general require ments apply to all applications CAUTION If you need to raise the vessel or one vessel leg after installation loosen the bolts on all Load Discs to prevent overloading Ensure the surfaces where the baseplates bolt down onto are clean smooth flat and level with less than 1 of slope in any direction Ensure vessel legs gussets are clean smooth flat and level with less than 1 of slope in any direction Position load disc so the cable cannot be snagged or chafed and can be easily routed to the junction box When raising the vessel for load disc installation use proper support to prevent the vessel from tipping or falling During installation carefully distribute the load to ALL load discs evenly PLACING THELOAD ON ANY ONELOAD DISC MAY CAUSE DAMAGE Hardware and Bolts 1 All bolts and hardware to attach the Load Disc to the vessel and to the foundation are customer supplied ASTM A 325 orequivalent See TI drawings Appendix D 2 Use specified hardware and bolt sizes Using other than the specified hardware can either reduce strength or overstress the load disc during installation voiding the warranty 3 All bolts are kept loose until shimming and leveling
24. ed onto the cage fixture you have more flexibility in mounting procedures If ever the cell needs to be replaced it can be unloaded without having to remove the cage fixture itself The LD3xiC is available in virtually all popular weight capacities from 220 lbs to 22 000 165 and is easy to specify due to identical dimensions and price General Description of Measurement System The deflection of the load cell by the vessel weight is measured by the foil gage sensor which is entirely sealed within the watertight cavity of the transducer The sensor converts the deflection into an electrical signal which is directly proportional to the increase or decrease of the vessel contents Material movement and changes in material repose will not affect the accuracy of the system Accurate weight information is then sent to a signal processor for display information transmission and storage See Figure 1 2 Applications Description The watertight design of the load cell makes it ideal for measuring bulk material in the sanitary and clean in place environments It is particularly suitable for use on mixing and blending vessels surge hoppers and agitated vessels Rugged solid bolt in place mounting assures vessel stability in outdoor storage vessels with gussets or legs used in all process industries 1 1 Chapter 1 Description Installation Option Descriptions Note Accomodates up to three degrees of tilt in the floor or vesse
25. is complete Securing LD3xi LD3xiC after Leveling Shimming Once the weight distribution criteria has been satisfied through leveling and or shimming complete the installation by tightening the required bolts for your application 3 1 Chapter 3 LD3xi LD3xiC Mounting LD3xi LD3xiC This section describes the installation procedures for the following General Installation hardware options Universal Top Plate Adapter Leveling Top Plate Adapter Anyadapter Plate Leveling Base Adapter Plate as well as the LD3xiC Prior to installing the load cell verify that they are the correct capacity for your application by reviewing the information on the label Measure the load cell voltage output With no load the meter should read OmV This measurement range is used only to verify the condition of the Load Disc If the reading is significantly outside of this range consult the factory before continuing the installation If you have the LD3xiC go to Step 5 Place bolt through center hole of adapter plate and install hardware for your application See Appendix D TI Drawings a For Universal Top Plate Adapter install bolt and plate to LD3xi tightening bolt to 5 10 ft Ibs b For Leveling and Anyadapter install washers and nuts to the bolt and plate making sure the washers nuts are loosely tightened against plate Install the plate assembly to the LD3xi tightening bolt to 5 10 ft lbs For Leveling and Anyadapter
26. it junction boxes and PCBs for Changes or Erratic by moisture in cable conduit water contamination Find water entry source Fluctuations in display junction boxes or PCBs and correct problem Dry with a hair drier readings Remove replace corroded parts and materials CAUTION If using sealant to eliminate water entry use Sikaflex 1A polyurethane sealant or Dow Corning RTV 739 or RTV 738 Other sealants may contain acetic acid which is harmful to electronics Fluctuations can be caused Using Digital Multimeter DMM check by damaged Load Disc resistance for individual Load Discs 1 Measure between the disconnected excitation wires and verify the resis tance to be 700 ohms 15 ohms with a stable reading Measure between the disconnected output wires and verify the resistance to be 700 ohms 15 ohms with a stable reading Place one DMM lead on the LD s shield wire and take four measurements to each of the other wires The reading should be greater than 5 giga ohms Repeat Steps 1 through 3 for each suspect Load Disc until damaged Load Disc is located C2 Appendix C Troubleshootin Small Amplitude Fluctuations can be caused Check signal processor excitation voltage by problems with signal and incoming AC voltage for accuracy and processor stability refer to signal processor manual Changes or Erratic Fluctuations in display readings Sudden Change in One broken Load Disc can Using Digit
27. l legs This section will briefly describe the following hardware options Universal Top Plate Adapter Leveling Top Plate Adapter Anyadapter Plate and Leveling Base Adapter Plate As well as the LD3xiC Load Cell configuration See Chapter 2 and 3 for more specific installation instructions and refer to the TI drawings located in Appendix D Universal Top Adapter Plate This option consists of the Universal Top Adapter Plate spring washer anda hex head bolt The adapter plate attaches to the load disc with the bolt and washer The adapter plate then bolts to a vessel gusset or a flat plate welded to the vessel leg using customer supplied hardware LAD N NI AZ Sy MOUNTING BOLT D3xi ASSEMBLY Chapter 1 Description Leveling Top Plate Adapter This option consists of the Universal Top Adapter Plate a hex head bolt spherical washer set and jam nuts The adapter plate attaches to the load disc with the hex bolt and hardware The adapter plate then bolts to a vessel gusset or a flat plate welded to the vessel leg using customer supplied hardware This hardware arrangement allows 360 degree movement of the top plate and angular misalignment of up to 3 degrees Additionally there is a leveling feature that allows vertical height adjustments This arrangement also incorporates a locking jam nut to insure the height remains unchanged MOUNTING BOLT SPRING WASHER SAL ADAPTER PLATE ERICA
28. low alarms transmission Figure 1 2 General installation layout for LD3xi LD3xiC using a junction box Introduction The Load Disc 3xi 3x1C 3xiMJ is a low profile load cell that is bolted to both the support surface and the vessel supports and is used to measure the weight of materials in vessels and tanks The sealed stainless steel construc tion IP68 rated unit with an optional NEMA 6P watertight cable system and cable entry makes the LD3xi 3x1C 3x1MJ ideal for use in high pressure wash down and occasionally submerged environments The LD3xi LD3xiC 3xiMJ offers system performance accuracy of 0 03 The low profile design for low clearance installations also keeps the vessels center of gravity low and stable Vessel tipping walking or overturning while agitating is eliminated Installation and setup is simplified with less hardware No external vessel hold downs are necessary even in areas of high wind or seismic activity There are no moving parts that can wear out or require replacement In bakery pasta confectionary and spice processing to resins concrete aggregate sand pulp minerals and other dry to wet operating conditions the LD3xiC offers very specific advantages not available in most higher priced load cells Standards include a tough cage mounting fixture into which the 17 4 stainless steel LD3xiC cell securely locks in place Since the LD3xiC cell can be loaded before or after the tank is install
29. or feature critical to the installation or operation of the Load Disc Introduction Specifications LD3xi Mechanical Compression 3 x rated load Tension 1 x rated load Shear capacity 220 Ibs 2200 Ibs 0 5 x rated load capacity 5500 Ibs 0 25 x rated load Functional Integrity 1 5x rated load compression Electrical Excitation Voltage Operating Range 5 15 VDC Recommended Supply Voltage 10 VDC Maximum Current 16mA 10 VDC excitation 0 F Output Resistance 700 ohms 2 Output Non linearity Hysteresis combined 0 03 standardized output Return to Zero over 30 min 0 026 standardized output Creep over 30 min 0 028 standardized output Creep over 20 and 30 min 0 008 standardized output Zero Balance 1 standardized output Rated Output 2 mV V 0 1 Environmental Temperature Range Standard 14 to 104 F 10 to 40 C Temperature Zero Shift 0 0013 F 0 0024 C Temperature Sensitivity Change 0 00094 F 0 0017 Storage Temp Range 4 to 176 F 20 C to 80 C Humidity 100 Physical Construction 17 4 PH 900 stainless steel Connector optional 6P rated sealed 5 conductor 12mm male receptacle Cable Length 16ft 5 m with tinned pigtail termination Rating IP68 100h at 1m water column Shipping Weight 5 Ibs 2 3 kg LD3xiC LD3xiMJ Mechanical Compression 3 x rated load Tension x rated load Shear 0 5 x rated load Functional Integrity 1
30. osite side Keep this in mind while shimming CAUTION If you need to raise the vessel or one vessel leg after installation loosen the bolts on all Load Discs to prevent overloading Leveling Shimming for the Leveling Top plate Adapter Leveling Base Adapter Plate and the Anyadapter Plate 1 Based on the Weight Distribution Chart and visual inspection raise the leveling nut to adjust the top plate until the weight distribution falls within the weight distribution guidelines See page 3 4 Check for gaps and use shims as required Objects and support members may cause the weight to be distributed unevenly Shimming will involve some judge ment 2 Gently lower the vessel and measure the dead weight output and the output change of all of the Load Discs to see how they are affected See Weight Distribution Chart page 3 3 3 Repeat Steps land 2 until you have achieved the desired output change of all of the Load Discs Since the output of each load cell may vary the change from no load to dead weight being equal is more important than the absolute value 3 6 Chapter 3 LD3xi LD3xiC_ Mounting Junction Box Mounting and Wiring Mounting Junction Box 1 See Figure 3 6 Hold the junction box at the J 79 250 635mm Mounting Holes 9 3107 88mm Mounting desired mounting location Mark the four 4 Places eie Holes 4 Places mounting holes 2 Mount the junction box with
31. ounting dimensions 10 LD3xi mounting to floor and I beam 11 LD3xi cabling using molded junction conn J Box 12 LD3xi conduit non conduit cable layout 13 TI LD3xi 01 LD3xi Typical Cabling Diagram 1 page 1 TI LC LD3xiC 01 Installation Arrangments 220 22 000 Ibs Load Disc 3xiC 7 pages LD3xiC Installation Instructions 1 3 LD3xiC Mounting Dimensions 4 LD3xiC Mounting to Floor and I beam 5 LD3xiC Conduit Non conduit Cable Layout 6 LD3xiC Orientation 7 D 1 Appendix D Technical Drawings D 2
32. ssel and the Load Disc mounting holes The bolts must be able to pass freely through the holes without interference Tighten the bolts leaving a 1 4 inch gap for positioning See Figure 3 2 11 Check dead weight output a 34 Record the dead weight output on your Weight Distribution Chart that was started on page 3 3 Calculate the Output Change Change should be positive Chapter 3 LD3xi LD3xiC Mounting Leveling and Shimming Note For installations where leveling nuts are not used load balancing on the Load Discs must be achieved by adding or removing shims Adjusting the Load Discs to distribute the vessel weight evenly may require adding shims supplied by customer systematically to all disc locations Note The Universal Top Plate will accomodate angular misalignment up to three degrees maximum Figure 3 5 Ideally the load is distributed evenly across the top plate Note Shimming the plates of one Load Disc will probably affect the weight distribution on the Load Disc located on the opposite side Keep this in mind while shimming Note Shims are typically applied between the LD3xi s Top Plate and mating vessel plate but the gap condition may exist at either the top or bottom plates CAUTION If you need to raise the vessel or one vessel leg after installation loosen the bolts on all Load Discs to prevent overloading The main objective of leveling shimming the ve
33. ssel is to distribute the weight evenly on all of the Load Discs Uneven weight distribu tion will reduce the accuracy of the weight measurement system as a whole and in extreme cases may cause Load Disc damage Once the general instructions have been completed page 3 2 through 3 4 begin the leveling and shimming instructions in this section Leveling Shimming for the Universal Top Adapter Plate Based on the Weight Distribution Chart Figure 3 3 and visual inspection raise the vessel and cut place shims as required to adjust the distribution of weight on the Load Discs Begin with the lowest output support first Objects and support members may cause the weight to be distributed unevenly Shimming will involve some judgement 2 Gently lower the vessel and measure the dead weight output and the output change of all of the Load Discs to see how they are affected Record again into the Weight Distribution Chart on page 3 3 3 Repeat Steps 1 and 2 until you have achieved the desired output change of all of the Load Discs Since the output of each load cell may vary the change from no load to dead weight being equal is more important than the absolute value Figure 3 5 Angular misalignment up to 3 degrees 3 5 Chapter 3 LD3xi LD3xiC Mounting Note Shimming the plates of one Load Disc will probably affect the weight distribution on the Load Disc located on the opp
34. t weights should be directly above each load cell and not overhanging 10 The cell that has the owest weight displayed will not be adjusted it will be the reference load cell Place the weights above a load cell and adjust the potentiometer to match the displayed weight from the reference load cell After each potentiometer adjustment the zero no test weights applied should be checked 12 Repeat for each load cell Do not adjust the reference load cell potentiometer 13 When all ofthe cells are trimmed a final calibration is required CELL 1 2 100K 100K EX E lt ry EXLP INDICATOR 202 SLI Ex SI S SI SHD lt 5 Me SHD S SHD SHD 5 gt SHD S lt d i Sl 5 4 lt S 4 S j EX j LS s cr gt 404 LS y JUS EX j E ry E POTS X 160KPOTI TOOK CELL 4 CELL 3 Figure 3 10 Wiring Load Discs to Junction Box 3 11 Chapter 3 LD3xi LD3xiC Mounting 3 12 Appendix A Contact Information Appendix A Contact Information Contact Information Technical Service You
35. tems are needed contact KM before proceeding Substituting parts without KM approval may cause system problems and will void the warranty Visual Check Visually inspect all equipment in the order including Load Discs junction boxes and signal processors to verify they have not been damaged during shipment If any item has been damaged contact KM for a replacement Chapter 2 Pre Installation Measuring Sensor Output To measure the output of the LD3xi LD3xiC the sensor needs to have an excitation voltage applied to it from a signal processor a DC voltage generator or a KM test meter To use the excitation from the KM Test Meter put the switch in the simulate position and wire the positive to the red position and the negative to the black position Turck Option The excitation would be applied to the excitation wires or the quick disconnect cable brown positive and black negative The millivolt signal would be measured with a multimeter on the output wires white positive and blue negative TURCK CONNECTOR OPTION MULTIMETER BLUE SUPPLY METEDS RED 4 BROWN OAD DISC KM METER BARIS Standard Fixed Cable The excitation would be applied to the excitation wires of the standard fixed cable red positive and black negative The millivolt signal can be measured on the output wires white positive and Yellow negative STANDARD FIXED CABLI
Download Pdf Manuals
Related Search