Installation Manual TRACKER SERIES TRUCK SCALE MODEL: VS SERIES VSX SERIES © 2008-2012 by Fairbanks Scales, Inc.
DISCLAIMER Every effort has been made to provide complete and accurate information in this manual. However, although this manual may include a specifically identified warranty notice for the product, Fairbanks Scales makes no representations or warranties with respect to the contents of this manual, and reserves the right to make changes to this manual without notice when and as improvements are made.
Amendment Record TRACKER SERIES TRUCK SCALE INSTALLATION MANUAL Document 51173 Manufactured by Fairbanks Scales, Inc. 821 Locust Kansas City, Missouri 64106 Created 02/2008 Revision 1 04/2008 Released document Revision 2 08/2009 Added product improvements Revision 3 10/2009 Revised deck construction instructions Revision 4 03/2010 Updated manual per engineering request for deck construction and parts description correction.
Table of Contents SECTION 1: GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rocker Column Load Cell Systems . . . . . . . . .
Table of Contents SECTION 4: CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Initial Zero and Span Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repeatability and Return-to-Zero Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ™ Section Test and Adjustment, Intalogix Technology Systems . . . . . . . . . . . . . . . . . . . . . . . .
Section 1: General Information INTRODUCTION The Tracker Series is a uniquely designed truck scale, combining the proven reliability of an environmentally sealed load cell system with the added benefit of an above grade, low profile, incorporated side rail, concrete deck design. The Tracker Series is a field assembled style scale featuring compact shipment and ready for module assembly. DESCRIPTION The Tracker Weighbridge consists of one or more field assembled modules with a field poured concrete deck.
Section 1: General Information FAIRBANKS SERVICE POLICIES Prior to installation, always 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 NOT be attempted.
Section 1: General Information Physical Installation Notes, Continued 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. IMPORTANT NOTICE: 1.
Section 1: General Information Electronic Component Care Much of the equipment consists of printed circuit assemblies, which must be installed using ESD handling procedures. These assemblies must be replaced as assemblies or units. Replacement of individual components is not allowed. The assemblies must be properly packaged in ESD protective material. These components must be returned intact for replacement credit per normal procedures.
Section 1: General Information PHASES OF INSTALLATION The complete installation consists of the following phases: A. Pre-Installation Checklist B. Unpacking C. Equipment location D. Safety E. User Responsibility F. Installation G. Calibration Pre-Installation Checklist The following points should be checked and discussed with the Area Sales Manager and/or customer, if necessary, before the technician goes to the site and installs the equipment.
Section 1: General Information Unpacking, Continued 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. Collect all necessary installation manuals for the equipment and accessories.
Section 1: General Information Safety Follow these safety precautions during operation: Do not load the platform if there is any evidence of damage to the platform or supporting structure. Use safety chains or other suitable restraining devices if there is any possibility of the load shifting, falling, or rolling from its position on the platform.
Section 2: Installation OVERALL STEPS A. Foundation check, layout, and base plate setting B. Preparing tools, materials, documentation and renting a crane. C. Setting up the modules D. Setting the modules on load cells. E. Wiring F. Calibrating and Testing Tools, Equipment and Materials Certified Prints A mobile crane of sufficient lifting capacity to safely lift and place the main beams which are approximately 2000 lbs. Four equal length twenty foot (4-20 ft.) lifting chains or cables with hooks.
Section 2: Installation SITE PREPARATION 1. Assist the customer in selecting a site which allows easy access to and from the scale, ensuring enough area for straight and level approaches, and to meet all State and Local Weights and Measures Regulations. Refer to the serial tag located on the scale to determine the capacity of the scale to be installed. Use only certified prints for all concrete work.
Section 2: Installation SITE PREPARATION, CONTINUED 5. Remove forms and backfill for proper drainage. A slope away from the scale is recommended. Allow concrete to cure for 28 days or until a test cylinder indicates the concrete has reached its design strength before allowing traffic on the scale. MODULE ASSEMBLY The Tracker scale is shipped as a bundle of steel beams and hardware that are ready to be assembled on the jobsite. Lay Out the Foundation 1.
Section 2: Installation Place Main Beams 1. Move the beams close to their approximate locations. All girders with j-box mounting bars should be on the same side, nearest the scale house. 2. To identify your beams, see Figure 2-2. If there are several interior beams, consult the certified print for the correct placement order. Figure 2-2 Assemble the Left Hand Base Module 1. Set the left hand base girders first (both J-Box and Plain sides). a. To begin, set girders on shoring timbers.
Section 2: Installation Assemble the Left Hand Base Module, continued 2. Install the cross members. a. There are two (2) different types of cross members. See Table 2-1 to identify them. b. Place the appropriate cross members at the appropriate location. The channel should be toward the bottom. The cross member should sit on top of the bar on the girder flange. c. Loosely bolt each end of the cross member to the main girder including one spring lock washer per bolt. Do not fully tighten. d.
Section 2: Installation Assemble the Remaining Modules One at a Time 1. Set the second beams (both J-Box and Plain sides). a. The end of the beams without an upper receiver plate should rest on the receiver plate protruding from the base girder. Center the girder on the load cell centerline and set on shoring timbers. b. Align the hole in the flange of the interior beam with the hole in the receiver plate on the base girder. Loosely bolt this connection, but do not fully tighten. c.
Section 2: Installation Figure 2-3 Figure 2-4 04/12 19 51173 Rev.
Section 2: Installation Deck Construction 1. Place shoring as shown in the certified prints. If using the optional Fairbanks corrugate and shoring kit: -- Shoring is pre-cut and primed L 2” x 23/16” formed steel angle. -- 11’ and 12’ scales each use 5 pieces of shoring per bay. 14’ scales use 6 pieces of shoring per bay. -- Space shoring evenly in the bay starting 6 to 8” from main beam. -- Maximum spacing for shoring is 3’0”.
Section 2: Installation Figure 2-6 *** DO NOT WELD SHORING *** Figure 2-7 Corrugate MUST be properly seated for proper deck installation. 04/12 21 51173 Rev.
Section 2: Installation Figure 2-8 Figure 2-9 Corrugate MUST be properly seated for proper deck installation. 04/12 22 51173 Rev.
Section 2: Installation Adjusting the Scale after the Pour 1. Once the deck is complete, set the side and end checking to desired gaps. 2. Install load cells under main girders and position the base plates so that each load cell is plumb. See Installing Load Cells section on next page. 3. Drill and insert anchor bolts through the holes in each base plate. Install clamp bars, washers, and finger-tighten bolts on each anchor. 4. Check load cell plumb once more, and then tighten down nuts on anchors.
Section 2: Installation LOAD CELL CABLES 1. Cable protection on truck scales is extremely important to the reliability of the scale. It is imperative for all cables to be installed off of the ground and securely fasten. The Tracker series scale has been designed to accommodate this type of cable protection. This section describes the manufacturer’s recommended installation procedure for installing and protecting cables on the Tracker series truck scale. 2.
Section 2: Installation LOAD CELL CABLES, continued 4. Route the interconnect cables through the angle on the side of the main girder beam and through the top hole in the stiffener plates at the end of each girder beam. Figure 2-11 5. Complete installation is accomplished once all of the cables have been run and the wiring is complete. Tighten all of the cables and hang any excess load cell cable on the cable hangers to orderly dress them and keep the load cell cable off the ground.
Section 3: Wiring for Intalogix™ Systems INTRODUCTION Intalogix™ systems use Smart Sectional Controllers (SSC) and Pit Power Supplies (PPS) for load cell excitation and signal processing. DESCRIPTION One (1) Smart Sectional Controller (SSC) per section. One (1) Pit Power Supply (PPS) per platform unless the number and resistance of the cells require a second Pit Power Supply (PPS).
Section 3: Wiring LOAD CELL WIRING Intalogix™ installations use a different numbering system for load cells because of the digital addressing of the Smart Sectional Controllers (SSC). Cell Numbering With respect to the following starting position, face the platform from where the indicator is located. The cell at the upper left (far side) of the platform is Cell One (1). The cell positions along the far side are odd cell numbers, The near side locations are even cell numbers.
Section 3: Wiring Installing Load Cells The cable used in all wiring (other than load cells) must be a 18 AWG (Cable 17246). minimum of The Smart Sectional Controller (SSC) boxes are daisy-chained to the end where they terminate into the Pit Power Supply (24722). 7. Wire the load cells into each section’s Smart Sectional Controllers (SSC), as illustrated in Appendix 1: Wiring, Drawing 51139-1d.
Section 3: Wiring Installing Load Cells, Continued 9. Wire the Smart Sectional Controllers (SSC) to each other. Terminal Number 1 2 5 6 7 8 Function (-) 8.0 volts (+) 8.0 volts DC Return Shield RS-485 (+) RS-485 (-) 17246 Cable Black Green Blue Shield White Red NOTE: On the 17246 Cable, do not use the Orange wire. 04/12 29 51173 Rev.
Section 3: Wiring Installing Load Cells, Continued 10. Set the Switches. Dip (Address) Switch Setup, Smart Sectional Controllers (SSC) In each of the smart SSC boxes there is a 10-position dip switch labeled S1. This switch is used to identify the section in a binary code. The switches must be set properly for the scale to operate. Note: Switches 1, 2, and 3 are always OFF.
Section 3: Wiring WIRING THE POWER SUPPLY 1. Connect the Pit Power Supply (PPS) to a Smart Sectional Controller (SSC) (#1 or any SSC). Feed a cable from SSC#1 TB3 through the bushing for in the PPS for TB3 and make connections as follows: TB3 SSC#1 TB3 PPS 17246 Cable Description 1 1 Black (-) 8.0 volts 2 2 Green (+) 8.0 volts 5 5 Blue DC Return 6 6 Shield Shield 7 7 White RS-485 (+) 8 8 Red RS-485 (-) 04/12 31 51173 Rev.
Section 3: Wiring WIRING THE POWER SUPPLY, CONTINUED 2. Wire the Pit Power Supply (PPS) to the Instrument. Run the ‘Home-Run’ cable from the PPS, TB1 to the Instrument’s TB1, wire as follows: TB1 PPS 1 2 3 4 6 7 8 TB1 Inst 1 2 3 4 6 7 8 17246 Cable Black Green Blue Orange Shield White Red Description 28 volts, AC AC Return 20 Volts, DC Enable Shield/DC Return Transmit Receive Note: Shields are used for DC Return and MUST be connected.
Section 3: Wiring GROUNDING THE SCALE, CONTINUED The 117 VAC SVP Unit (65056) must be connected to a known good ground at the instrument location. Use a voltmeter to test the electrical power source available for the Neutral-toGround voltage level ▪ It must be 0.2VAC or LESS. If unsure about the voltage, or the testing reveals a higher than acceptable level (0.2VAC MAXIMUM), install a separate ground rod at the SVP 65056 location.
Section 4: Calibration INITIAL ZERO AND SPAN ADJUSTMENTS 1. Seat the suspension components. 2. Drive the test truck across the scale stopping and starting several times. 3. Repeat this procedure at least three times to assure that all parts are properly seated. 4. The zero and span of the scale need not be set perfectly, but it should be roughly adjusted to check for repeatability. 5. Return to zero to properly adjust the section readings. 6.
Section 4: Calibration Section Test and Adjustment, Intalogix™ Technology Systems Follow setup and programming instructions in the appropriate Intalogix™ Technology manual. Use a weigh cart or weights placed directly over the section for proper trimming. Digital indicator initial and span calibration Intalogix™ Technology Perform the initial and span adjustments, following the appropriate scale indicator technical manual. 04/12 35 51173 Rev.
Section 5: Parts SCALE COMPONENTS Part # Description 80984 1 1/8" -7 x 8" Threaded Rod, Zinc (module-module) 54255 1 1/8" Flat Washer (module-module) 61743 Clamp Bar Washer (base plates) 62857 5/8" 55010 Ground Rod Kit 73682 Shim, receiver cup, 1/16" 64338 64334 Shim, receiver cup, 1/8" Shim, receiver cup, 3/16" 63319 Side check bracket w/bumper bolts (1” x 5”) 64208 Shim, longitudinal ¼” 64209 Shim, longitudinal 1/16” 70045 Shim kit - 1 dozen mixed longitudinal 54304 1 1/8"-7 Hex n
Section 5: Parts INTALOGIX™ TECHNOLOGY SCALE COMPONENTS 04/12 Part # Description 26168 Sectional Controller Assembly (SSC) 27931 SSC Box 26080 SSC PCB Only 24720 Pit Power Supply Assembly (PPS) 25256 Pit Power Supply Box 23393 Pit Power Supply PCB only 17545 Connector, Liquid Tite (small) 17535 Connector, Liquid Tite (large) 37 51173 Rev.
Appendix I: Wiring Diagram 07/11 38 51173 Rev.
Appendix II: Data Recording Location/Name _____________________________ Phone # __________________ Scale Model _______________________ Serial ____________________________ Date Installed _____________________________________ Date placed in service ______________________________ Installer’s Name ___________________________________ Instrument Model ______________________ Serial __________________ Load Cell #1 Serial ___________________________ Load Cell #2 Serial ___________________________ #1 SSC or J B
Appendix II: Data Recording Location/Name _____________________________ Phone # __________________ Scale Model _______________________ Serial ____________________________ Date Installed _____________________________________ Date placed in service ______________________________ Installer’s Name _______________________________ ____ Instrument Model ______________________ Serial __________________ Load Cell #1 Serial ___________________________ Load Cell #2 Serial ___________________________ #1 SSC or
Appendix III: Parts for Models Prior to 08/2009 SCALE COMPONENTS Part # 76708 54788 54255 61743 62857 55010 73682 64338 64334 63319 64208 64209 70045 21912 21842 Description 1 1/8" -7 x 7" Threaded Rod, Zinc (module-module) 1 1/8" Lock Washer (module-module) 1 1/8" Flat Washer (module-module) Clamp Bar Washer (base plates) 5/8" x 6" Anchor Bolts Ground Rod Kit Shim, receiver cup, 1/16" Shim, receiver cup, 1/8" Shim, receiver cup, 3/16" Side check bracket w/bumper bolts (1” x 5”) Shim, longitudinal ¼” Shim,
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TRACKER SERIES TRUCK SCALE Manufactured by Fairbanks Scales, Inc. 821 Locust Kansas City, Missouri 64106 www.fairbanks.
