Trident Precast Concrete Deck Truck Scale
Contents
1. bi LAA INSTALLATION MANUAL Manufactured by Fairbanks Scales Inc DOCUMENT 51255 821 Locust St Kansas City MO 64106 www fairbanks com2. Em Pit Power Supply Smart Section Controller Part 26172 Part 26168 w o float Part 26172 w float Undermount model 51255 10 04 11 22 51255 Rev 2 a A Section 3 Scale Installation Smart Section Contro On pit friendly models with cover plates the Pit Power Supply and Smart Section controller mount to ihe end weldrnents Pit Power Supply Smart Section Controller Part 26172 Part 26168 w o float Part 26172 w float Cover plated model 51255 11 NOTE All Tridents come standard with Intalogix If the analog model is ordered Box 21912 mount as follows Balance box 21912 Installation for analog instruments 1 2 04 11 Introduction Balance box 21912 is to be installed at the platform one box per section Description Each stainless steel balance box has four 4 terminal blocks to connect two 2 load cells and two 2 cables for connection to the analog instrument Load cells and sections are adjusted using adjusting potentiometers Installation a Boxes The box has tabs for bolting to mounting brackets on the side of the modules See figure 51255 10 or if cover plated under each sectional cover plate See figure 51255 11 Attach the ground wire lug to one of the mounting bolt studs and tighten securely
3. FAIRBANKS installation Manual Trident Precast Concrete Deck Truck Scale TRIDENT Y Precast Concrete Truck Scale 1 M Lo m a b S ty 2 A 1 la n Br EZ 91299 2011 by Fairbanks Scales Inc Revision2 04 11 All rights reserved Amendment Record TRIDENT PRECAST CONCRETE DECK TRUCK SCALE Document 51255 Manufactured by Fairbanks Scales Inc 821 Locust St Kansas City Missouri 64106 Created Created document Revision 1 Document release Revision 2 Revised section 3 51255 Rev 2 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 Fairbanks Scales shall not be liable for any loss damage cost of repairs incidental or consequential damages of any kind whether or not based on express or implied warranty contract negligence or strict liability arising in connection with the design development installation or use of the scale Copyright 2011 This document contains proprietary information protected by copyright All rights are reserved no part of this manual may be reproduced copied translated or trans
4. Te 1 8 x 6 1 2 FULL THREAD BOLT PART NUMBER 60312 1 i 1 8 HEX NUT PART NUMBER 54277 3 4 10 X 3 CAP SCREW SIDE CHECKING ANGLE PART NUMBER 54599 PART NUMBER 75398 Undermount side checking detail 51255 8 04 11 19 51255 Rev 2 25 Section 3 Scale Installation FAIRBANKS For cover plate model e Install the side checking brackets e Bolt the brackets into the end copings per the certified drawings e Set the side checking bolts so they touch the channels they bump against Approach coping with embeds WA 3 4 10 x 3 Bolt Part 54559 e Coupling nuts tome pre welded to approach coping Bumper Block Part 64213 Urethane Pad Part 70043 1 4 Shims Part 64208 1 16 Shim Part 64209 1 8 x 5 Full Thread Bolt 1 8 Hex Part 60237 Part 54 Li Side Check Angle Part 61380 3 4 10 x 3 Bolt Part 54559 Cover plated side and end checking 51255 9 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 using a hammer drill and the 5 drill bit Tap the anchors into clean holes and tighten the nuts securely 04 11 20 51255 Rev 2 PAN Section 3 Scale Installation
5. 148120 Trident Precast 120 x 10 125 ton capacity 6 modules 7 sections 148121 Trident Precast 120 x 11 125 ton capacity 6 modules 7 sections 04 11 37 51255 Rev 2 Appendix TII Trident Precast Concrete Deck Typical Installation Analog D iring peo Bojeuy SSZTS 8 T130 avol 7 t u m o zu z vid 208 ama 8 aus Gau N3IA TH LSNI 9 T139 avol N3335 Ovid amma LNAWNYLSNI 4 NI QvOT aaa 5IS NOHDSS gna IHM sre qus us T a39Nvuo 8 NIS ama 4 5 da NOISNVdX3 S 1190 NOISNVd4X3 1NAWNYLSNI OL uo pesn eq LSNW Spee esueg e papjalys 9 e eq ISNW QLI e 10 uon euuo T2 ox 2a Nas ama Nas aqus aus Sis 5IS INIWNYLSNI z 7 228 zum 8 ams t aus 915 915 LNAWMALSNI NOISNVdX3 NOISNVdX3 T139 915 aun 515 qus aus T 9 Nas ama 4 nas oxa da T T139 5125
6. ELECTRICAL INSTALLATION 25 SECTION 5 MAINTENANCE 29 Scale Maintenance 2 29 Mechanical Faults eest su summatim 50084 bee erg eR 29 SECTION 6 PARTS amp PARTS REPLACEMENT 30 Prou RC IIIS 30 Load cells and load cell hardware oo ee 31 O RIBUS 23 Sit bei sae veda dace ee da de Pee 32 Replacing RC load cell oo ee 33 General load cell information ssec hr 33 SECTION 7 ACCESSORIES 34 Rub Rails These accessories are available in factory installed and field installed types 34 APPENDIX I FOUNDATION CHECKLIST 35 APPENDIX II SPECIFICATIONS 37 Trident Precast Concrete Deck ee 37 APPENDIX III WIRING DIAGRAMS 38 Trident Precast Concrete Deck Typical Installation Wiring Diagram Analog 38 Trident Precast Concrete Deck Typical Installation Wiring Diagram Intalogix 39 04 11 5 51255 Rev 2 Section 1 General Information INTRODUCTION This manual provides installation instructions for the Fairbanks Trident Precast Concrete Deck Truck Scale For complete Trident scale installation use e Methods and Procedures FF 2267 101732 Appendix I e The certified prints setting plans supplied with the
7. Trident Precast 30 x 10 75 ton capacity 2 modules 3 sections 148031 Trident Precast 30 x 11 75 ton capacity 2 modules 3 sections 148040 Trident Precast 40 x 10 75 ton capacity 2 modules 3 sections 148041 Trident Precast 40 x 11 75 ton capacity 2 modules 3 sections 148047 Trident Precast 47 x 10 75 ton capacity 2 modules 3 sections 148048 Trident Precast 47 x 11 75 ton capacity 2 modules 3 sections 148060 Trident Precast 60 x 10 100 ton capacity 3 modules 4 sections 148061 Trident Precast 60 x 11 100 ton capacity 3 modules 4 sections 148070 Trident Precast 70 x 10 100 ton capacity 3 modules 4 sections 148071 Trident Precast 70 x 11 100 ton capacity 3 modules 4 sections 148080 Trident Precast 80 x 10 125 ton capacity 4 modules 5 sections 148081 Trident Precast 80 x 11 125 ton capacity 4 modules 5 sections 148090 Trident Precast 90 x 10 125 ton capacity 4 modules 5 sections 148091 Trident Precast 90 x 11 125 ton capacity 4 modules 5 sections 148100 Trident Precast 100 x 10 125 ton capacity 5 modules 6 sections 148101 Trident Precast 100 x 11 125 ton capacity 5 modules 6 sections 148110 Trident Precast 110 x 10 125 ton capacity 5 modules 6 sections 148111 Trident Precast 110 x 11 125 ton capacity 5 modules 6 sections
8. a result of the equipment s inability to be adjusted to performance specifications may be charged to warranty No physical alterations mounting holes etc are allowed during installation The installing technician is responsible that all personnel are fully trained and familiar with the equipment s capabilities and limitations before the installation is considered complete All electrical assemblies must be replaced as assemblies or units Replacement of individual components is not allowed These components must be returned intact for replacement credit per normal procedures All electronic and mechanical adjustments are considered to be part of the installation and are included in the installation charge s Included is any required computer programming or upgrades Included are any accuracy and or operational specification changes The AC receptacle outlet shall be located near the Instrument and easily accessible Electrical connections other than those specified may not be performed Conferring with our Client The technician must be prepared to recommend the arrangement of components which provide the most efficient layout utilizing the equipment to the best possible advantage The warranty policy must be explained and reviewed with the customer 04 11 8 51255 Rev 2 zac Section 2 Company Service Information Pre Installation Checklist The following points should be checked and discussed with
9. rS ws Pd f bw 04 11 14 51255 Rev 2 a A Section 3 Scale Installation E Setting the Center Module The center module is always set first The center module will have four load cells to install all other modules will have two load cells The modules must be placed in the proper order and aligned in the foundation so that all modules fit correctly 04 11 Undermount scales have a definite orientation because the junction box mounting bars are welded to one 1 side only The j box side of the modules should face the home run conduit Place blocks that will set the modules at a height slightly less than the finished height as safety blocks or for setting the modules on Lift the center module to a location above the four center load cell base plates Install a load cell bearing cup with O rings into the upper receiver of each corner grease will help hold the cup in place Insert the upper end of the locating tool into the upper cup on the module Set the module directly on the locating tools and the blocks will act as safety stands Lower the module while holding the locating tool upright and guiding the bottom of the tool into the lower cup When the center module is set on all four locating tools keep tension on the cables until the module is centered and straight Once square and plumb are verified you can release tension s owly Use hydraulic jacks to lift the unit slightly and shift
10. the base plates to get the locating tools plumb and the top and bottom flanges FLUSH with the sides of the cup 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 Remove threaded eye bolts and install on next module for proper lifting 15 51255 Rev 2 a A 7 Section 3 Scale Installation F Setting end modules For undermount model e Module Placement 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 See Figure 51255 3 a Before releasing tension on the cables check the alignment of the end modules to the center module and to the end wall e Use the provided shims to set height and fill any gaps on the supporting blocks to get the modules aligned b Repeat this process for the other end module or for the interior module Undermount model panel block detail 51255 3 04 11 16 51255 Rev 2 7 Section 3 Scale Installation For cover plated model a Install interlocking pin into hole on top of the load block of the panel already resting on locating tools b Guide the modules into place with the deck seats on the end of the module coming to rest on the center module load block interlocking pins Lower the other end of the module onto the
11. 3 MC AM 4949 04 11 6 51255 Rev 2 Section 2 Company Service Information GENERAL SERVICE POLICY Prior to installation a ways verify that the equipment satisfies the customer s requirements as supplied and as described in this manual If the equipment cannot satisfy the application and the application cannot be modified to meet the design parameters of the equipment the installation should VO7 be attempted It is the customer operator s responsibility to ensure the equipment provided by Fairbanks is operated within the parameters of the equipment s specifications and protected from accidental or malicious damage SS SAS SAS AS SAS SS SSS SS SAG Absolutely NO physical electrical or program modifications other than selection of standard options and accessories may be made to this equipment by customers Repairs must be performed by Fairbanks Scales service technicians and authorized distributor personnel ONLY Failure to comply with this policy voids all implied and or written warranties Me NN NANANANNANANNANANANS LLL LLL LLL SLL LL LLL SSL LS SLL SS SLL 04 11 7 51255 Rev 2 zac Section 2 Company Service Information Physical Installation Notes Check all devices for proper operation If any error messages occur refer to Troubleshooting or the proper manual of that device Only those charges which are incurred as
12. 5 8 51255 Rev 2 38 04 11 JAIM NOLIWLIOX ueaug NN SSCTS 30718 1fnd1no C 555 ped JAIM 33ddOO JUVE amam ANALNO DIS SHY NOLLWLIDxa peg pays penunuo 366 03 P9 peo1 ISS 195 peo1 a v jeuon es jeuon es 2 IPD peo P 0 1 Z 95 peo peo1 T moD Uu E z dnog AS Q v Jeuonoes 8 E Ey gt E an E i Tal EM xa vaL 8 8 8 8 F noL HE I D qndino 9 9 9 9 O s 6 s S o gt v vi R e aS 1 1 1 1 C 1 uone 1 pal ggl pal Q S 8 8 8 8 s 8 8 amcuma dee L L L IN AR 3 peta 9 09 m S G S 6 s 6 S T b usy b b v YQ V e le el le e z e z c S T T T T T T T V I T z 1 2 T 2 Ajddng j9Mod E 51255 9 51255 Rev 2 39 04 11 zzi Trident Precast Concrete Deck Truck Scale FAIRBANKS
13. B1 1 BLACK EXC EXC 2 GREEN EXC EXC 3 BLUE SENSE ener oe BE 4 ORANGE SENSE SENSE USED 5 N C N C N C 6 SHIELD SHIELD SHIELD 7 WHITE SIG SIG 5 M gt sic SIG Instrument to J Box Position TB1 or TB2 1 EXC 2 3 SENSE 4 SENSE 6 SHIELD 7 SIG 8 SIG 04 11 25 51255 Rev 2 PN Section 4 Installing Accessories Note This truck scale 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 balance box or SSC through a sealed bushing 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 particularly stainless steel the black plastic fittings have O rings that can be forced out of position if the bushing itself is not tight To prevent this first tighten the inner nut securing the bushing in the hole then insert cable and carefully tighten the gland until it is very snug Do not over tighten where bushing turns Secure the cover Note Balance boxes must have one 1 ground rod in the pit for proper grounding CAUTION Inadequate grounding will prevent the surge voltage protection from functioning properly 1 Instrument cable connection balance b
14. H Installing load cells a Unpack the load cells and mark each calibration certificate with the load cell location position WARNING Place hydraulic jacks ONLY at the CORNERS of the modules Hydraulic jacks must be placed on opposite sides to lift the module in a level position Lifting mid span or between load cells will cause cracks in the concrete 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 Lift the platform so the load cell locating tool can be removed from the upper and lower bearing cups Once removed fill both cups with grease d The bottom of the load cell has two flat sides which must be aligned with the flats in the lower cup Carefully lower the scale hydraulic jacks 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 an equal amount of the load Center section cells will have up to twice the dead load of end section cells Caution Use eye protection e Once satisfied with height and level tighten the module to module bolts e The nuts should be torque to 500 ft Ibs f Load cell cables e Introduction Cable protection on truck scales is extremely important to the reliability of th
15. The box has tabs for bolting to adapters as shown in Installing load cells 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 instrument being installed or use Appendix III to connect PPSes and SSCs D Smart Sectional Controller Wire cells into each section s SSC per the appropriate manual Remember that odd numbered cells go to TB1 location and even numbered cells go to TB2 location Load cell drain wires connect to the ground lug on the sectional controller box exterior Note Intalogix installations utilize a different 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 instrument is located The cell at the upper left far side of the platform is Cell 1 The cell positions along the far side will be odd cell number and the near side locations will be even cell numbers Note SSCs have connections for two 2 load cells TB1 and TB2 The odd numbered cell should go to the TB1 connection and the even numbered cell to the TB2 connection 04 11 27 51255 Rev 2 za Section 4 Installing Accessories E Grounding SSCs IntalogixTM systems must have two 2 ground rods in the pit for proper connection Pit power supplies use a ground separate from the steel and SSC ground rod F Instrument to PPS
16. cable connection Prepare the cable ends in the standard manner Use the appropriate manual for wiring instructions of all pit SSCs and power supplies Connect the instrument interface cable to the instrument in the in the scale house per the instructions in the appropriate indicator service manual G Wiring Intalogix Junction Box 3 Cells to Smart Sectional Controller SSC Position TB1 TB2 SHIELD SIG SIG 4 From TB4 Position 8 VDC 8 VDC DC RETURN DC RETURN 2 5 6 SHIELD SHIELD SHIELD 7 WHITE RS485 RS485 8 RS485 RS485 5 Pit Power Supply to instrument Position To TB1 instrument BLACK 28 VAC GREEN ACR BLUE 20 VDC 20 VDC ORANGE ENABLE 5 VDC ENABLE 5 VDC SHIELD DC RETURN DC RETURN B GU Nh WHITE RS485 RS485 RS485 RS485 04 11 28 51255 Rev 2 Section 9 Maintenance Scale Maintenance Als Check for accumulations of solid material under the scale which may affect the accuracy ice frozen mud debris Check to see that the customer has cleaned 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 an
17. ction on Layout See other side for foundation amp Layout charts 101732 12 10 Issue 2 04 11 35 51255 Rev 2 zac Appendix 1 Foundation Checklist Length amp Width Check r 1 Measurement A to A Diagonial Measurements Check Measurement B to B Strings Pier Height Check Side View Pier i i i i i i H Y Lead Cell Date Line corereta Longitudinal Layout Coping Length Concrete Mails f the coping length OR Centerline Centerline of of Scale nce from Centerline to Load Cell Data Lines TOP VIEW Lateral Layout 12 10 155 2 04 11 36 51255 2 Appendix II Specifications Trident Precast Concrete Deck 148010 Trident Precast 10 x 10 50 ton capacity 1 module 2 sections 148011 Trident Precast 10 x 11 50 ton capacity 1 module 2 sections 148015 Trident Precast 15 x 10 50 ton capacity 1 module 2 sections 148016 Trident Precast 15 x 11 50 ton capacity 1 module 2 sections 148020 Trident Precast 20 x 10 50 ton capacity 1 module 2 sections 148021 Trident Precast 20 x 11 50 ton capacity 1 module 2 sections 148023 Trident Precast 23 x 10 50 ton capacity 1 module 2 sections 148024 Trident Precast 23 x 11 50 ton capacity 1 module 2 sections 148030
18. d greased periodically Inspect and adjust all check bolts using anti seize on the threads Mechanical Faults 1 Check for all clearances around the scale for obstructions or interference with the free movement of the platform Check all check bolt clearances both with and without a concentrated load over each section one at a time 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 and dry it thoroughly Check all connections at the terminal blocks to ensure they are tight 04 11 29 51255 Rev 2 Section 6 Parts amp Parts Replacement Parts List PART NO DESCRIPTION 54511 34 10 x 172 hex bolt for cover plate model only 63310 Interlocking pin cover plate model only 64213 Bumper block cover plate model only 64327 Load cell base plate cover plate model only 61380 Side checking cover plate model only 54304 Hex nut 1 7 undermount model only 54891 Jam nut 1 7 undermount model only 76708 178 7 x 8 threaded rod zinc module module undermount model only 54788 178 lock washer module module undermount model only 54255 178 flat washer module module undermount model only 85593 Load cell base plate undermount model only 75398 Side check bracket undermount model only 61743 Clamp bar washer base p
19. e scale It is imperative for all cables to be installed off the ground and out of sight The Trident truck scale has been designed to accommodate this type of cable protection Described in this section is the manufacturer s recommended installation procedure for installing and protecting cables on the Trident truck scale e Cable hangers Behind every SSC or PPS mounting block is a cable hanger These cable hangers are used to hang excess load cell and interconnecting cables 04 11 21 51255 Rev 2 PA Section 3 Scale Installation e Complete installation Once all cables have been run and wiring is complete See section 4 tighten all the cables and hang them on the cable hangers to get them out of sight and off the ground In a correct installation the only cables visible are those coming out of the holes in the side beam to the SSC or PPS See photo below Undermount model Pit Power Supply 5 Section Controller HD On EZ Undermount type scale the Power Supply and Smart Section controller mount to the side beams ol de aS pege Tet E 3 2708708102115 5 ii e a IGM lee Y el prm rr rr
20. em yet See Figure 51255 6 1 x3 A325 a Bolt with Nut Interlocking Part 54269 Pin 7 Load Block Va Cover plate F tie down 7 B H Hi gt Deck Seat lt 172 Spacer Part 63959 lt Flat Washer v ES 1 7 Part 54249 Bar y Cover plate model panel connection detail 51255 6 04 11 18 51255 Rev 2 7 Section 3 Scale Installation Warning Module to module bolts MUST be installed correctly and with proper torque after all lifting etc is completed Do NOT substitute or omit bolts B Checking Adjustment see Figures 51255 7 through 51255 10 For undermount model a Adjust end checking Adjust the end checking bolts so that they touch and prevent movement See figure 51255 7 b Install the side checking brackets Bolt the brackets to the end checking plates embedded in the end walls per certified prints Set the bolts so that they touch the block they bump against See figure 51255 8 1 1 8 7 x 8 HEX HEAD BOLT PART NUMBER 75698 1 1 8 7 HEX NUT PART NUMBER 54304 ri NOTE END CHECKING HARDWARE m ARRIVES ASSEMBLED IN PANELS Undermount end checking detail 51255 7 EDGE OF APPROACH OF LOAD CELL UNDERNEATH EMBEDDED BUMPER PLATE PART NUMBER 76170 TE TE 1 4
21. er from the instrument 2 Lift the scale using a proper sized and rated hydraulic jack or jacks at the corners closest to the defective load cell location WARNING Place hydraulic jacks ONLY at the CORNERS of the modules Hydraulic jacks must be placed on opposite sides to lift the module in a level position Lifting mid span or between load cells will cause cracks in the concrete Do NOT lift panels with a fork lift 3 Check upper and lower receiving cups and O rings for damage Replace as necessary and reapply grease 4 Insert the new cell into the upper receiving cup and position the anti rotation pin 5 Carefully lower the hydraulic jack s until the cell is set into the lower cup 6 Remove the cover of the SSC J box then loosen the gland bushing to free the cable Remove the old cell wires and connect new cell wires in the balance box SSC Secure the cover 7 Test and adjust the scale as necessary General load cell information Load cell part number 70510 Description 512 2mV V 66k or 30t 1000 Q 04 11 33 51255 Rev 2 Section 7 Accessories Rub Rails These accessories are available in factory installed and field installed types Field installed rub rail installation e Use the print with the accessory for actual measurements e Bolt the gussets to the stiffeners and end weldments WARNING Fairbanks does NOT recommend using foundation mounted guide rails along the sides of th
22. is truck scale platform Damage may occur to the scale if a truck hits the guide rail transferring damaging force to the platform and checking system Use of this type guide rail will VOID PRODUCT WARRANTY 04 11 34 51255 Rev 2 Appendix I Foundation checklist 100732 Page 1 of 2 Foundation Inspection FOUNDATION FIELD CHECK LIST Field Form Se E A Foundation Inspection should ALWAYS be performed prior to scale installation and to confirm correct foundation construction If possible this should be done prior to scale shipment Tools required 0 Certified drawings and site plan 0 2 to 4 level 0 100 and 25 steel tapes Hammer and concrete nails 0 Laser or builders level if possible O String line construction string L Straight edge for pit foundations 2 x 4 very straight and 4 wider than pit walls 0 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 0 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 0 2 Check for
23. ive material and returned intact for replacement credit per normal procedures 04 11 10 51255 Rev 2 A Introduction 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 B Tools equipment and materials required 04 11 1 Certified prints 2 A mobile crane of sufficient capacity to safely lift and place the weigh bridge modules Approximate maximum weights Factory poured modules 14 500 Ibs 7 2 tons 5 for 23 x 10 module without rub rails 3 Four 4 equal length 20 ft lifting chains or cables with hooks to safely attach to the modules at the lifting points Note The lifting chains or cables MUST be requested in advance from the crane vendor 4 Machinist s levels Starrett 134 and 132 6 5 Hand tools 6 Hammer drill with 2 bit 24 7 Hydraulic jacks Use hydraulic jacks that have sufficient capacity plus a safety factor for the model of scale you are installing 96496 30 ton jacks 96497 Hand pump 96498 Hose 6 8 100 steel tape measure 9 String line and or chalk line 10 Pry bars 11 Grease and anti seize 12 Load cell locating tools one for each load cell Part no 71717 for 512 11 51255 Rev 2 Section 3 Scale Installation C Determine if product is cover plated model or undermount model The profile of the cove
24. ix I a 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 b Re check the locations of each base plate against the certified prints e Insert two 1 2 roll pins into each lower cup for anti rotation C Grease and install the inner O ring in each load cell cup if they are not already installed On all cups grease the large outer O rings then install one in the groove on the outside of each cup Put a 3 16 shim on the lower cups grease the outsides and insert them into the base plates Lower cups for 572 load cells have a pin which must be aligned between the two roll pins in the base plate d Place the upper cup with greased O ring on the edge of the upper foundation next to each base plate e Place the load cell locating tool next to each base plate A Setting the modules Preparing the modules for lifting e The modules do not have integrated lifting channels One 1 set of lifting eye bolts threaded eye bolts is provided by Fairbanks e Thread and bolt lifting eye bolts at each corner of the module for proper lifting WARNING Lift only as shown in drawing below on left side NEVER with a fork lift beneath the panel Lift ONLY as shown below Do NOT lift panels with a fork lift A gs
25. lates 62857 5 x 6 anchor bolts wedge type 55010 Dual ground rod kit 147922 Lifting eye bolt 54310 114 7 hex nut for eye bolt 04 11 30 51255 Rev 2 Section 6 Parts CAL Load cells and load cell hardware LCF HR4020 2A FLINTEC PART NO DESCRIPTION 70510 Load cell 51 2 RC 66k 1000 0 2 mV V 72274 O ring 572 INSIDE of cup ANSI 222 64340 O ring 572 OUTSIDE of cup ANSI 228 70511 Receiver cup 572 LOWER with anti rotation pin 70512 Receiver cup 51 2 UPPER 64382 Roll pin 1 2 x 272 anti rotation base plate 71717 Locating tool 52 OPTIONAL 64438 Shim receiver cup Vs 64334 Shim receiver cup 3 16 ANSI WWW defines a standard O ring size O rings may be obtained at any hardware hydraulic or plumbing supply house by using the number 04 11 31 51255 Rev 2 a A FADD FAIRBANKS O Rings 2 I D 22 O D Part No 64340 Thickness ANSI 228 OUSIDE of all load cell cups 1 134 O D Part No 72274 Thickness ANSI 222 INSIDE of cup 572 load cells WARNING Lift scales ONLY at the CORNERS Section 6 Parts On factory pour scales use two 2 properly rated hydraulic jacks at opposite sides and at the corners and lift the section in a level manner 04 11 32 51255 Rev 2 aane Section 6 Parts BALLA Replacing an RC load cell 1 Remove pow
26. load cell locating tools or blocks b Before releasing tension on the cables check the alignment of the end modules to the center module and to the end wall 3 4 10 x 1 1 2 Hex Bolt Part 54511 Cover plate Panel with deck seat Interlokcing Pin Part 63310 Fully Installed load blocks Bearing Cups Locating Tool Base plate installed on anchors Cover plate model panel block detail 51255 4 04 11 17 51255 Rev 2 PA ORE Section 3 Scale Installation G Connecting the Modules For undermount model Bolt the modules together using the 1 1 x 7 full thread rod lock washer flat washers and nut provided Remember to shim the supporting blocks if necessary to align modules Snug nuts but do not fully tighten them yet See Figure 51255 5 1 1 8 SPRING LOCK WASHER 1 1 8 7 x 7 THREADED ROQ PART NUMBER TX PART NUMBER 76708 1 1 8 7 JAM E S 1 1 8 7 HEX NUT PART NUMBER 54891 PART NUMBER 54304 1 1 8 FLAT WASHER PART NUMBER 54255 Undermount model panel connection detail 51255 5 For cover plate model c Bolt the modules channels together using the 72 x 4 x 6 spacers and 1 x 3 bolts Insert the 72 x 4 x 6 spacer plates between the channels The bolts go through the back to back channels and the spacer Snug the bolts but do not tighten th
27. mitted in any form or by any means without prior written permission of the manufacturer 04 11 4 51255 Rev 2 Table of Contents SECTION 1 GENERAL INFORMATION 6 Introduction C O r 6 ES 6 CERTIFICATIONS CRT alee ied 6 SECTION 2 COMPANY SERVICE INFORMATION 7 General Service Policy 7 ae 8 Physical Installation Notes csse 8 Conferring with our Client sss ee 8 Pre Installation Checklist 2 eee 9 Unpacking ERREUR 9 Equipment Checkout sss 10 Users Responsibility sx eurs cles 10 SECTION 3 SCALE INSTALLATION 11 A ANGOGUCHOR gt vse wie ee bn Oe mad EE eee 11 B Tools equipment and materials required 11 C Determine if product is cover plated model or undermount model 12 D Foulldation 3 Esqu ee BG eRe 14 E Setting the Center Module 2 15 F Setting end modules ee di eee e o i 16 G Connecting the Modules 18 H Installing load cells 2 hh 21 L Final checking adjustment 24 SECTION 4
28. ox The two 2 cables from the two 2 center section boxes will enter the 14478 instrument SVP and terminate there The cable from the instrument will connect at 14478 instrument SVP as well Prepare the cable ends in the standard manner Use Appendix II for wiring instructions of all pit balance boxes Connect the instrument interface cable to the instrument in the scale house per the instructions in the appropriate instrument service manual 2 Adjusting cells sections Try to install load cells of matching outputs in sections to reduce side to side errors When calibrating place weights directly over the cell or directly on the section being tested Adjust the potentiometers for the correct cell or section to compensate for differences 04 11 26 51255 Rev 2 PAN Section 4 Installing Accessories C Wiring SSCs and PPSs for Intalogix systems 1 Introduction Intalogix systems utilize smart sectional controllers SSCs and pit power supplies PPSes for load cell excitation and signal processing 2 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 SSC boxes have four 4 terminals two 2 for load cells and two 2 for interconnecting to other SSC boxes or terminating to a pit power supply All cell section and scale adjustments are made via the IntalogixTM system instrument 3 Installation a Boxes
29. r plated model has unique details and looks like this dd Cover plate Upper Bearing Cup Base Plate Part 70512 Overhead View Part 64327 5 1 2 Locating Tool Part 71717 Lower Bearing Cup w Anti Rotation Roll Pin Part 70511 Part 64382 im Part 64334 64338 El fener hardware Clamp Plate Part 61743 LII m Plate Part 64327 Wedge Anchor Part 62857 nut and washer included Top of Pier or Slab COVER PLATE MODEL Locating tool detail 51255 1 04 11 12 51255 Rev 2 04 11 The undermount model looks like this Upper B Section 3 Scale Installation earing Cup Base Plate Part 70512 Overhead View Part 85593 5 1 2 Roll Pin Part 64382 UNDERMOUNT MODEL Locating tool detail 13 Locating Tool Part 71717 Lower Bearing Cup w Anti Rotation Part 70511 Anchor hardware Clamp Plate Part 61743 him Part 64334 64338 Base Plate Part 85593 Wedge Anchor Part 62857 nut and washer included Top of Pier ar Slab 51255 2 51255 Rev 2 7 Section 3 Scale Installation D 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 Append
30. scale e This installation manual 51255 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 prints NOTE It is the owner s responsibility to document notify and follow up regarding shipping damage with the carrier DESCRIPTION The factory poured truck scales are available in various lengths and widths The scale is made up of modules of 10 15 20 or 23 4 in length All modules are assembled and welded at the factory The concrete deck is mixed poured placed finished and cured at the factory The scale should be located so that vehicles can approach and exit the scale as easily as possible The platform should be visible from the instrument location Drainage of surface water must be such that water does not collect under the scale Smooth and level approaches are required at each end of the platform to reduce loading shock and facilitate testing of the scale 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 NOTE Specifications and sizes are shown in Appendix II CERTIFICATIONS NTEP CC 96 089A
31. ter the pre installation checkout 04 11 9 51255 Rev 2 7 Section 2 Company Service Information Equipment Checkout Position the equipment with these points in mind Y Intense direct sunlight can harm the display Y Do not locate near magnetic material or equipment Instruments which use magnets in their design Y Avoid areas which have extreme variations in room temperatures Temperatures outside the Instrument specifications will affect the weighing accuracy of this product Y Do not load the platform if there is any evidence of damage to the platform or supporting structure Users Responsibility Y All electronic and mechanical calibrations and or adjustments required for making this equipment perform to accuracy and operational specifications are considered to be part of the installation They are included in the installation charge Only those charges which are incurred as a result of the equipment s inability to be adjusted or calibrated to performance specifications may be charged to warranty Y Absolutely no physical electrical or program modifications other than selection of standard options and accessories are to be made to this equipment Y The equipment consists of printed circuit assemblies which must be handled using ESD handling procedures and must be replaced as units Replacement of individual components is not allowed The assemblies must be properly packaged in ESD protect
32. the Area Sales Manager and or customer if necessary before the technician goes to the site and installs the equipment Y Check the customer s application to make certain it is within the capabilities and design parameters of the equipment Y If the installation process might disrupt normal business operations tell the customer and ask that they make adequate arrangements Y Be sure that the equipment operator s are available for training Y The service technician reviews the recommended setup with the Area Sales Manager or Area Service Manager and together they identify all necessary variations to satisfy the customer s particular application Unpacking Follow these guidelines when unpacking all equipment v Check in all components and accessories according to the customer s order Y Remove all components from their packing material checking against the invoice that they are accounted for and not damaged Advise the shipper immediately if damage has occurred Order any parts necessary to replace those which have been damaged Keep the shipping container and packing material for future use Check the packing list Y Collect all necessary installation manuals for the equipment and accessories Y Open the equipment and perform an inspection making certain that all hardware electrical connections and printed circuit assemblies are secure Y Do not reinstall the cover if the final installation is to be performed af
33. to provide a good electrical ground Wiring Cable used in all wiring must be a minimum of 18 AWG Use cable 17204 or equivalent The balance boxes are interconnected from TB1 to TB2 or TB2 to TB2 beginning at the end section where the interface cable conduit enters the scale An alternate method if the conduit enters the scale in the middle is to use 14478 instrument SVP This will allow separate connections to go in each direction toward the ends of the scale See bulletin 50513 for the wiring diagrams 23 51255 Rev 2 Gime _ Scale Installation I Final checking adjustment a Adjust end checking e Adjust the end checking bolts to 1 6 to Vs clearance b Adjust side checking bolts to allow 1 6 clearance from bumper block 04 11 24 51255 Rev 2 Section 4 Electrical Installation A Load cell wiring color codes 514 RC 30t 66 000 Ibs Load Cell part no 70510 LCF HR4020 2A Black Excitation Green Excitation Red Signal White Signal Yellow Shield B Wiring 21912 Analog Junction Box Cells to J Box 21912 1 box per section Position TB3 TB4 1 BLACK EXC 2 GREEN EXC EXC 3 4 SENSE SENSE 4 SENSE SENSE 5 N C N C 6 SHIELD SHIELD 7 WHITE SIG SIG 5 5 SIG J Box to J Box Position TB1 or TB2 TO 2 second box or T
34. truck and crane access overhead wires fences green concrete etc 0 3 Dimensional length and width check check all 4 sides and record on chart other side 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 0 5 Check ALL pier heights to make sure they are the proper elevation and record on chart other side To high and the scale will not fit correctly to low could result in excessive shimming 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 Trident series O7 Verify conduit locations and pull strings if needed O 8 Verify ground rod locations Oo Verify that drains and sump openings are piped correctly and are clear of debris 40 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 111 Verify location of 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 42 Layout To help in locating pre installed baseplates embeds load cell centerlines etc refer to Methods and Procedures se
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