Survivor Pitless Modular Railroad Track Scale. Installation Manual

Transcription

1 Survivor PL Pitless Modular Railroad Track Scale Installation Manual 98740

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3 About This Manual....0 Introduction Installation Foundation Installation Weighbridge Installation Approach and Dead Space Hardware Installation Rail Installation Grouting Junction Box and Grounding Load Cells to Junction Box Junction Box to Indicator Indicator to Peripherals Single-Point Ground Conductor Junction Box Connections Electrical Ground Connections Survivor PL Limited Warranty... 8 Technical training seminars are available through Rice Lake Weighing Systems. Course descriptions and dates can be viewed at or obtained by calling and asking for the training department. 200 Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America. Specifications subject to change without notice. Rice Lake Weighing Systems is an ISO 900 registered company. Version.0, May 200

4 2 Survivor PL Installation Manual Rice Lake continually offers web-based video training on a growing selection of product-related topics at no cost. Visit

5 About This Manual This manual is intended for use by service technicians responsible for installing and servicing Survivor PL pitless modular railroad track scales. W arning Some procedures described in this manual are potentially dangerous. These procedures are to be performed by qualified service personnel only. Authorized distributors and their employees can view or download this manual from the Rice Lake Weighing Systems distributor site at Introduction The Survivor PL is a low-profile, pitless modular railroad track scale. This heavy-duty workhorse should provide decades of accurate rail car weighing. Onboard Features Features of the basic Survivor PL include: Gross capacity - 85 tons to 75 tons. Sectional capacity - 85 tons. Module sizes available in 2 6, 5, 8, and 25. Platform width - 7 8, 8.5 low-profile design. Bolted checkered steel top plate; side accessible. Designed for 5 lb. and 32 lb. rail. Longitudinal and lateral checking assemblies. 00K CSP 00K load cells. Lightning and SS suppression kit. Rail clips for deck. Anti-creep angles. Low-profile above-grade installation. Outside access covers for load cells. Copper transient bypass cables. NTEP-certified, CC#02-087, A. Meets AREMA and Cooper E-80 design specs. Optional features and accessories include: Approach rail base plates, rail clips, nuts, washers, and anti-creep angles. Anchor bolts for approach rail plates. Custom sizes available. Hardware for intermediate section. Anchor bolts for load cell and check stands. The Survivor PL is manufactured on-site at Rice Lake Weighing Systems. All railroad track scale production is conducted in-house under exacting quality control standards. Each railroad track scale is manufactured under the precise guidelines outlined by ISO 900 standards. All weighbridge components are sandblasted to SSPC-A-SP6 standards and cleaned with a hot phosphate cleaning process to remove grease and oil contaminants. After assembly, all Survivor track scales are painted with a two-component high solids urethane primer, as well as a finish coat of a two-component high solids urethane paint that protects the weighbridge s structural integrity and ensures a long life. Model Configuration Platform Size Capacity PL-2-85 Single tons PL-5-85 Single 5 85 tons PL-8-85 Single 8 85 tons PL Single/Single tons PL Single/Single tons PL-2-5 Single/Single tons PL-5-8 Single/Single tons PL Single/Single tons PL-5-5 Single/Single tons PL Single/Double tons PL-5-25 Single/Double tons PL-25 Double tons PL Double/Double tons Table -. Survivor PL Series Platform Sizes Introduction

6 2.0 Installation This section describes procedures for installing the foundation and weighbridge for of the Survivor PL railroad track scale. 2. Foundation Installation Please reference foundation drawings supplied by Rice Lake Weighing Systems for the scale you have purchased. Do not start construction of the foundation if you do not have certified prints.. Pour the scale slab(s). 2. Pour the approach slab and, if applicable, dead slab over rebar or optional anchor bolts. NOTE: Anchor bolts should protrude from the concrete enough for the lower base plates to be secured onto them. 2.2 Weighbridge Installation The following steps describe the procedure for installing the Survivor PL weighbridge.. Set load cell lower base plates over the pre-cast anchor bolts. 2. Install leveling bolts into base plates as shown in Figure 2-. Figure 2-. Leveling bolts installed into lower base plate 3. Install load cell, spacer block, and base plate onto lower base plates. Figure 2-2. Load cell, spacer block, and base plate 2 Survivor PL Installation Manual

7 4. Set longitudinal brackets (2) and side brackets (2) over pre-cast anchor bolts. Figure 2-3. Align bracket with anchor bolts Figure 2-4. Brackets in place 5. Remove steel top plates from weighbridge module. Mark plates to identify location for re-assembly. 6. Install bearing block, upper mount plate, spacer tubes, bearing cushions, and shim plate in each load cell pocket of weighbridge module. Figure 2-5. Upper load cell plate mounting procedure 7. Set the weighbridge module on 5 setting blocks. Center the module between approaches. Figure 2-6. Weighbridge module on setting blocks Installation 3

8 8. Using a jack and shims, level the module and set its elevation between 2 /8 and 2 /4 above concrete approaches. Figure 2-7. Module elevation 9. Using leveling bolts, raise and level the load cell assemblies to contact the upper mount bearing plates. Figure 2-8. Load cell assembly 0. Jack the weighbridge to allow removal of setting blocks and shims.. Install lower base plate washers and nuts. NOTE: Do not torque nuts until after plates are grouted. 2. Install check rods and hardware. Set check rods level with a horizontal plane to within +/- /2 degree. 4 Survivor PL Installation Manual

9 Figure 2-9. Check rod level with horizontal plane 3. Weld spacer plates (P/N 7860) to weighbridge to secure it in place. 4. Repeat steps -4 for the second weighbridge module. 2.3 Approach and Dead Space Hardware Installation The below instructions describe the installation of approach and dead space hardware. NOTE: Reference drawings provided for approach and dead space for important details.. Install approach plates on anchor bolts. Figure 2-0. Approach plate on anchor bolts 2. Install approach plates at the required elevation using shims or jam nuts beneath each plate. 3. Install dead space rail plates on anchor bolts. 4. Install dead space rail plates at the required elevation. 5. The rail can now be installed. 6. Once the rail is installed, the elevation plates are ready to grout. 2.4 Rail Installation The following instructions describe the installation of rail sections on the Survivor PL.. Cut A.R.E.A. 5 lb. rail sections using 45-degree mitered rail head cuts at the weigh rail and approach rail transitions. Installation 5

10 Figure 2-. Mitered rail head cuts location 2. Set rail support plates over the pre-cast anchor bolts on the approach and center section foundations. 3. Set weigh rails and approach rails onto the rail support plates. 4. Shim and align rails to match elevation of scale and set the desired grade. Option: Install jam nuts under approach rail support plates to act as a leveling device. 5. Install rail clips and secure rails in place. 6. Install anti-creep rail anchors. 2.5 Grouting Prior to grouting, re-check all weighbridge and rail alignment, levels, and elevations.. Use an epoxy-type 9000 psi grout under the load cell base plates, and a non-shrink cement-type grout under the approach and center section rail support plates. NOTE: Do not grout under the longitudinal check brackets or side check brackets. 2. After grout has hardened, tighten/torque nuts on all anchor bolts. 3. The checking system can now be tightened. Bring the nuts up to snug, then use jam nuts to jam. 6 Survivor PL Installation Manual

11 3.0 Junction Box and Grounding Cable installation instructions for the weigh module(s) are included in the following paragraphs. 3. Load Cells to Junction Box Each load cell is equipped with 30' of load cell cable, sufficient to reach a centrally-located junction box on standard scales. A conduit adapter and a 4" section of 3/4" flexible conduit is supplied for both ends of each load cell cable located at the load cell and at the junction box. Main conduit runs between these 4" flexible end sections are 3/4" galvanized metal conduit already installed on the deck as shown above. NOTE: Flexible conduit can not come in contact with the ground. Plastic tie wraps are included in the hardware shipping box and should be used to tie up the flexible conduit. 3.2 Junction Box to Indicator Sixty feet of six-wire homerun cable is supplied for wiring the junction box to the indicator. It is run in 3/4" galvanized metal conduit from the junction box to the indicator. Conduit for this purpose is to be obtained locally. A 30" flexible conduit section and conduit connector is provided where this cable exits the junction box. Do not run any other electrical cables in or near the conduit to the indicator. 3.3 Indicator to Peripherals All 3/4" conduit for cabling from the indicator to remote displays and other peripheral devices is to be obtained locally. Conduit runs may be buried in a trench or secured above ground. Use separate conduit runs for AC power and DC data lines to avoid interference. As a general guideline, run AC and DC cables in separate trenches if possible. When DC data cables must run in the same trench as AC power lines, separate cables as much as possible (preferably more than 34" apart). 3.4 Single-Point Ground Conductor A bare 0 gauge solid wire is to be run from the scale frame to the grounding lug on the junction box then underground to the main AC power earth ground. If the DC transient protection board is installed, the ground conductor should also be connected to the transient protection board s ground lug. 3.5 Junction Box Connections Each junction box is large enough to hold the summing board, transient protection devices, packaged desiccant, and extra load cell cable coiled inside the enclosure. An industrial corrosion inhibitor and desiccant such as the RLWS Industrial Corrosion Inhibitor (PN 6037) should be added to the junction box enclosure before final closure. A summing card mounted within the junction box is used to make all cable terminal connections. All terminal pins are clearly marked as to function. 3.6 Electrical Ground Connections Improper grounding systems are often a cause of corrupted data from ground-loop current flows and costly lightning damage to electronics. Always strive for a single-point grounding system. Do not drive ground rods at the scale location which establishes separate earth grounds for the scale. These separate earth grounds will not share the same zero reference as the existing earth ground for the AC power system. This difference in electrical potential invites ground-loop current flow between the separate grounds, often corrupting serial data like RS-232 which depends on a stable zero reference. In addition, a separate earth ground system at the scale can actually invite lightning or power surge damage: A minor power line surge should immediately be shunted to ground. If a separate ground system exists at the scale with a lower potential than the main ground, the surge may travel out to the scale ground rod, damaging load cells on its way. A nearby lightning ground strike may instantly raise the zero potential of a ground rod at the scale location, while leaving the scale house ground rod unaffected. That lightning surge will now take the easiest path to the lower-potential ground through the scale wiring and back to the scale house ground, possibly damaging the indicator on its way. Junction Box and Grounding 7

12 J3 R4 J R 7 2 R7 R4 R8 8 R5 3 R9 R6 R20 R2 R8 R22 9 R9 4 R23 R0 0 5 J4 R26 R3 J2 J7 R40 J5 R R43 R30 R44 8 R3 3 R45 R32 R46 R47 R34 R48 9 R35 4 R49 R J8 R52 J6 R39 CONNECT BOTH SHUNTS DISCONNECT BOTH SHUNTS TO APPLY TO REMOVE VR3 VR9 VR2 6 VR VR7 6 VR8 TO CUT R5 R24 R4 R42 R50 R5 VR6 VR0 VR5 VR4 VR VR2 TO R2 R3 R R2 R28 R29 R37 R38 R7 L R33 L2 L4 L3 Assembly PN Rev. ARGND ARC EXPANSION/J9 INDICATOR/J0 +SEN -SEN CUT TRACE TO ISOLATE SENSE LINE JMP/POS JMP/NEG +SEN -SEN D DL 2005 Therefore, the best grounding system for the scale is the same grounding system used for the incoming AC power system. The 20 VAC power source used to power the indicator will be connected to an existing earth grounded rod system at the scale house or other building where the indicator is located. This should consist of a double ground rod system of two 5/8" x 8' copper rods driven 8' deep at the service entrance where the local utility company brings their lines into the building. The local utility company can test the resistance of the existing ground rods with a clamp-on megohmeter that measures zero resistance. A reading of 3¾ or less is acceptable as a ground. If the test determines that the grounding system is inadequate, the utility company can suggest methods to improve the system. It s crucial that the scale owner authorize and make the recommended improvements to assure an adequate electrical ground. Do not connect the scale to the AC power supply until the grounding system is adequate. These, and all, ground connections must be torqued to a specified value and retorqued at regular service intervals. A thick coating of anti-oxidant grease should be maintained on all ground connections to prevent corrosion. A separate grounding system conductor must extend uninterrupted from the main service panel ground to the scale to protect load cells and scale wiring from lightning and other transient damage. This ground wire conductor must be an unsheathed #0 copper wire or larger. Run the bare ground wire conductor intact from the AC power ground rod to the scale in a separate trench. Bring the wire up from the trench near the junction box and attach it to the ground lug of the junction box. A #0 bare ground wire is run from the ground lug of the junction box to one of the junction box mounting studs on the scale frame, thus grounding the scale frame to the same single-point ground as the AC power for the indicator. Be certain each load cell grounding strap is securely connected to the top plate and bottom plate of each load cell mount. There should be metal-to-metal contact with no presence of paint or grout. This strap is designed to channel power surges on the deck around rather than through the load cell to ground. RICE LAKE WEIGHING SYSTEMS CUT TO R25 R6 CUT TO CUT Transient Board Connectors Grounding Lug Ground Lug Grounding Strap 0 ga. Bare Ground Wire To DC Protection Ground Connection before Indicator Figure 3-2. Junction box ground wire connections. Figure 3-. Grounding strap on load cell mount. NOTES: The scale frame must be connected with 0 ga. wire to the ground lug of the transient protection board inside the junction box. Scales with more than one junction box require ground straps to be installed between modules. In addition, all junction boxes need to be connected to the scale frame. The final ground wire connection must be at the AC power supply ground terminal or ground rod. 8 Survivor PL Installation Manual

13 J8 J3 J4 J7 VR3 VR9 R7 R8 R9 R2 R22 R23 R43 R44 R45 R47 R48 R49 VR2 R4 R26 R40 R5 6 CUT VR VR7 R24 R4 R42 6 VR8 TO R50 R5 R52 CONNECT BOTH SHUNTS TO APPLY J6 R20 R46 J J2 J5 VR6 VR0 R4 R5 R6 R8 R9 R0 R30 R3 R32 R34 R35 R36 VR5 VR4 VR VR2 R TO R3 R27 R2 R3 R R2 R28 R29 R37 R R39 DISCONNECT BOTH SHUNTS TO REMOVE R7 L2 L L4 L3 Assembly PN Rev. CUT TRACE TO ISOLATE SENSE LINE R33 Transient Board Connectors JMP/POS JMP/NEG ARGND ARC EXPANSION/J9 +SEN -SEN INDICATOR/J0 +SEN -SEN D DL 2005 Grounding Lug J8 J3 J4 J7 VR3 R25 R6 VR9 R7 R8 R9 R2 R22 R23 R43 R44 R45 R47 R48 R49 VR2 R4 R26 R40 R5 6 CUT VR VR7 R24 R4 R42 6 VR8 TO R50 R5 R52 CONNECT BOTH SHUNTS TO APPLY J6 R20 R46 J J2 J5 VR6 VR0 R4 R5 R6 R8 R9 R0 R30 R3 R32 CUT TO RICE LAKE WEIGHING SYSTEMS CUT TO CUT R34 R35 R36 VR5 VR4 R2 R28 R CUT TRACE TO ISOLATE SENSE LINE R33 Transient Board Connectors JMP/POS JMP/NEG 8620 R25 R6 VR VR2 R TO R3 R27 R3 R R2 R29 R R39 DISCONNECT BOTH SHUNTS TO REMOVE R7 L2 L L4 L3 ARGND ARC EXPANSION/J9 +SEN -SEN INDICATOR/J0 +SEN -SEN D DL 2005 CUT TO CUT TO CUT RICE LAKE WEIGHING SYSTEMS Assembly PN Rev. Grounding Lug JB8SPT Junction Box With Transient Protection RLWS PN 9783 JB8SPT Junction Box With Transient Protection RLWS PN 9783 TP-232 DC Transient Protection RLWS PN 3385 UJB-3T6 DC Transient Protection RLWS PN 234 TP-232 DC Transient Protection RLWS PN 3385 AC Power Supply SOLA SK520 AC Transient Protection RLWS PN 082 AC Outlet #0 Copper Ground Wire Serial Communication AC Outlet SOLA SK 520 AC Transient Protection RLWS PN 082 Homerun Cable Load Cell Cable Power Company Ground Rod *Always verify that installed wiring is properly grounded Figure 3-3. Single-point grounding diagram. Junction Box and Grounding 9

14 Survivor PL Limited Warranty Statement of Limited Warranty Subject to the terms and conditions as stated herein: Rice Lake Weighing Systems (hereafter referred to as RLWS ) warrants its equipment to be free from defects in material and factory workmanship for a period of time from the date of shipment as stated in this document. Electronic Components Two (2) years - load cells, junction boxes, suspension system. This covers SURVIVOR PL and RT Rail Scales. Load cells, junction boxes, and internal cabling are warranted against manufacturing defects provided the scale and all electronic devices have been properly installed, grounded and sealed by RLWS dealer. Weighbridge Components Applies to RICE LAKE SURVIVOR models Five (5) years - SURVIVOR PL and RT weighbridge structure Exclusions to the warranty include but are not limited to: corrosion, lightning, surges concrete & rebar or any other items supplied by others, excessive wear, cosmetic defects that do not affect performance, use and damage caused by electrical surges resulting from welding on or near scale. Terms and Conditions of Limited Warranty This obligation is limited exclusively to original equipment manufactured or supplied by RLWS and is subject to the inspection, analysis and determination by RLWS regarding the nature and cause of any failure. Defective components mechanical or electrical will be repaired or replaced free of any obligation to the owner within ninety (90) days after date of installation. For the remainder of the product warranty period, defective components (mechanical or electrical), will be repaired or replaced provided such services are preformed by an authorized RLWS Dealer and equipment owner agrees to pay Dealer for these services. Service technician labor and travel expenses are not covered by this warranty. RLWS may require the faulty components be returned to the factory, freight prepaid, at the discretion and authorization of RLWS. This warranty does not extend to any labor, material, or service charges involved in removal or replacement of equipment. RLWS is not responsible and will not be held liable for losses, injury or damage caused to persons or property resulting during installation or failure during use of RLWS products or any consequential damages that may arise from their use. RLWS reserves the right to incorporate improvements in material and design of the products without notice and is not obligated to incorporate the same improvements in equipment previously manufactured. In certain cases, such as used equipment or peripheral equipment not manufactured by RLWS, a reduced warranty may apply. Specific details to these exceptions are provided separately or at the time of purchase. RLWS shall not be obligated under any warranty different than as set forth herein. The RLWS warranty is limited to the initial customer and installation and is not transferable in the event of resale. Conditions Which Void Limited Warranty This warranty shall not apply to equipment which: Has had repairs and modifications not authorized by RLWS which in RLWS judgment has affected the performance Has been subject to misuse overloading, negligent handling, improper installation, accident, damage by fire, water, submersion or act of God Has had serial number altered, defaced or removed Had not followed RLWS recommendations for epoxy, galvanizing, or stainless steel construction for installation in harsh environments Has not been grounded according to RLWS recommended procedure Freight Carrier Damage Claims for equipment damaged in transit must be referred to the freight carrier. Visible damage should be reported immediately. Concealed damage as soon as possible in any case, within fifteen (5) days of receipt of shipment, in accordance with freight carrier regulations. THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY EXTENDED BEYOND THE DESCRIPTION OF THE PRODUCT. This warranty statement sets forth the extent of our liability for breach of any warranty or deficiency in connection with the sale or use of the product. It is understood that RLWS will not be liable for consequential damages or any nature, including but not limited to, loss of profit, delays or expenses, whether based on tort or contract. 200 Rice Lake Weighing Systems, Inc. Rice Lake, WI USA. All Rights Reserved. RICE LAKE WEIGHING SYSTEMS 230 WEST COLEMAN STREET RICE LAKE, WISCONSIN USA 8 Survivor PL Installation Manual

15 230 W. Coleman St. Rice Lake, WI USA U.S Canada/Mexico International Rice Lake Weighing Systems PN /0