Bolt-On Weight Measurement Installation Manual L-Cell® and Microcell® CAUTION It is essential that all instructions in this manual be followed precisely to ensure proper operation of the equipment.
NOTICE The content of this document is the intellectual property of Kistler-Morse. Any reproduction or translation of this document without the written authorization of a Kistler-Morse officer is prohibited. CAUTION Equipment should be inspected for damages after packing is removed to insure operating safety.
Table of Contents Table of Contents Introduction................................................................................................ I-1 Welcome ........................................................................................................................................................ I-1 About This Manual ....................................................................................................................................... I-1 Contact Information ...................
Table of Contents Chapter 5: Installation of the L-Cell on Skirt Supported Vessels ............... 5-1 Mounting Information .................................................................................................................................. 5-1 L-Cell Sets ....................................................................................................................................... 5-1 Distribution of L-Cells and Junction Boxes Around Vessel (Carbon Steel) ............................
Introduction Introduction This chapter will describe the organization, manual conventions, and provide contact and technical service information . Welcome This manual describes the installation of the Bolt-On Sensors, L-Cell and Microcell. The L-Cell is installed on Vertical Legs, Horizontal Beams, and Skirted Silo applications. The Microcell is installed on Vertical Pipe Leg applications.
Introduction Contact Information Technical Service You may reach Kistler-Morse at the following: Mail: Kistler-Morse 150 Venture Boulevard Spartanburg, South Carolina USA 29306 Telephone: 1-800-426-9010 (864) 574-2763 Fax: (864) 574-8063 Email: sales@kistlermorse.com Website: http://www.kistlermorse.com A complete, unabridged copy of our product warranty is available upon request from Kistler-Morse.
Introduction On-Site Consultation KM’s 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.
1: Bolt-On Description Chapter 1: Description of the Bolt-On Weight Measurement Sensors This chapter will describe the L-cell and the Microcell sensors, including their application details. Introduction Bolt-On Technology creates weighing systems by: * mounting L-Cells on structural support members of the vessels legs, shear beam supports, or structural skirts * mounting Microcells to the vessels pipe leg supports.
1: Bolt-On Description L-Cell Application Details Currently, L-Cells are available for installation on the following types of vessels: • • • • Carbon steel, skirt-supported vessels with maximum live load stresses between 1,500 and 8,500 psi (1.0 and 6.0 kg/mm2) Aluminum, skirt-supported vessels with maximum live load stresses between 1,500 and 4,500 psi (1.0 and 3.2 kg/mm2) Leg Supported Vessels (non-pipe) with maximum live load stresses between 1,500 and 8,500 psi (1.0 and 6.
2: Prepare for Installation Chapter 2: Pr epare Bolt-On W eight Measur ement Sensors for Installation This chapter will describe the pre-installation procedures for L-Cells and Microcells. By verifying the application and checking the cells before installation, it will ensure proper installation of working cells that will provide accurate monitoring of the vessel contents. Application V erification Prior to ordering the Bolt-On Sensors, you should have completed the Application Data Form #97-5092.
2: Prepare for Installation Junction Boxes, each complete with: • • • Assy 63-1170-01 terminal board Watertight fittings (4) Watertight plugs (for any cable openings that will not be used) Microcell Order The following items may be included with your order for each vessel (quantities are dependent on application): Microcells, each complete with: • Sensor • Environmental Cover • #8-32 socket head cap screws (2) • #8 hardened flat washers (2) Junction Boxes, each complete with: • • • Assy #63-1170-01 ter
2: Prepare for Installation Microcell Installation Equipment The following additional equipment is used to install Microcells: Optional Installation Kit* #39-2012-0X, each complete with: Microcell drill template with #8-32 socket head cap screw 9/64” Hex T-handle driver #29 drill bits #8-32, 2-flute, spiral-point taps Sikaflex 1A polyurethane sealant and Material Safety Data Sheet (MSDS) * Kit items are also Rust-inhibiting silicone grease available individually.
2: Prepare for Installation Junction Box and Field Wiring Equipment CAUTION Only use Sikaflex 1A polyurethane sealant or Dow Corning RTV 739 or RTV 738. Other sealants may contain acetic acid, which is harmful to sensors and electronics.
2: Prepare for Installation Testing Sensors with K-M Test Meter The KM Test Meter (Figure 2-1) is designed specifically to test KM sensors. If you do not own a Test Meter, disregard this section and proceed to Testing Sensors with Digital Multimeter. Note: The Test Meter display indicates Low Battery or behaves erratically when the batteries are weak. When this occurs, replace the batteries before testing. 1.
Chapter 3. L-Cell Installation on Vertical Legs Chapter 3: Installation of the L-Cell on Vertical Legs Follow the instructions in this chapter only if installing L-Cells on vertical column legs. Skip this chapter if installing other options. This chapter describes the mounting locations, and wiring installation details for L-Cells and their junction boxes on vertical leg applications. Follow the procedures below to determine L-Cell mounting locations prior to beginning installation.
Chapter 3. L-Cell Installation on Vertical Legs (Cont. Vertical Location of L-Cell Sets) Support Legs without X-Braces See Figure 3-3. Note minH is defined as the minimum free height to install sensors. The height should be three times the beam width or 12” (305 mm) , whichever is highest of the two. • • • If the free leg distance (length between foundation and the vessel) is between minH (see Note) and 11’ (3.4m), mount the L-Cell sets at midheight of the free leg.
Chapter 3. L-Cell Installation on Vertical Legs Installing L-Cells 0.5” Figure 3-6: Drill Mounting Hole Notes 1. Use lubricating fluid (Relton RapidTap® Heavy Duty Cutting Fluid or equivalent) when drilling and tapping. 2. Drilling and tapping instructions assume metal thickness greater than 3/4” (19mm). If the thickness is less, drill all the way through the metal and tap until cutting complete threads through the other side. Minimum metal thickness is 0.
Chapter 3. L-Cell Installation on Vertical Legs Template Mounting Hole (mount here with #6-32 x 1 5/8” screw) 4. Drill the L-Cell mounting holes with the #36 drill bit, using the template guides (Fig. 3-9) as follows: A. Drill hole #2. B. Insert a spare drill bit through hole #2 in the template to hold the template securely in place. C. Drill hole #1 and #3. Remove the spare drill bit from hole #2. 5. Tap the mounting holes: A.
Chapter 3. L-Cell Installation on Vertical Legs CAUTION For proper installation, tighten each screw until the T-handle driver flexes in torsion 1/4 turn past the point where the screw stops turning. Repeat this flexing procedure several times to ensure the screw is tight. When all three screws are tight, the voltage must be in the range -200 to +200 mV. Follow the procedure in Steps 5 through 7 to achieve this goal. CAUTION Only use Sikaflex 1A polyurethane sealant or Dow Corning RTV 739 or RTV 738.
Chapter 3. L-Cell Installation on Vertical Legs 8. Prior to installing the environmental cover(s), ensure the mating surface(s) on the leg is free of dirt and grease. Reclean if necessary, being careful not to remove the rust inhibitor on the bare metal. 9. Fig 3-13. Peel the protective backing from the double-sided tape on the environmental cover’s inside flange. A. Align the environmental cover over the installed L-Cell, with the cable through the cover’s exit channel.
Chapter 3. L-Cell Installation on Vertical Legs Mounting the Junction Box CAUTION Do not install junction boxes in the rain. Moisture in the junction box will cause corrosion and system errors. Note Junction box mounting hardware is not supplied by KM. KM recommends #8-32 socket head cap screws and flat washers. The instructions below reflect this recommendation.
Chapter 3. L-Cell Installation on Vertical Legs Wiring L-Cells to Junction Boxes Note 1. The four small holes in the bottom of the junction box are for wiring the L-Cells to the junction box. 1. Remove the junction box cover. 2. See Figure 3-16. Place a plastic washer on a watertight fitting. Thread the L-Cell cable through a cap and watertight fitting. Leave an adequate length of cable between the L-Cell and fitting to provide a drip loop (see Figure 3-15). 3.
Chapter 3. L-Cell Installation on Vertical Legs Wiring Junction Boxes Together and to Signal Processor There are two versions of the junction box enclosure. Both versions have four small holes for wiring L-Cells to the junction box, as described above. In addition, the junction box has one or two large holes: • • One large hole for conduited installation — The large hole, which accommodates a 3/4” conduit fitting, is for wiring the junction box to the other junction boxes and to the signal processor.
Chapter 3. L-Cell Installation on Vertical Legs 2. See Figure 3-19 (conduited installation) or Figure 3-20 (non-conduited installation). Route the 3-conductor cable through the fitting into the junction box farthest from the signal processor. Connect wires from the cable to the TB2 terminal in the junction box: black wire to B terminal, white wire to W terminal, and red wire to R terminal. Connect the cable shield wire to the Shield terminal between TB1 and TB2. 3.
Chapter 3. L-Cell Installation on Vertical Legs Connect Shield Wire to Shield Terminal Connect 3-Conductor Cable to TB2 Connect 3-Conductor Cable from First Junction Box to TB1 Connect Shield Wire from Both Cables to Shield Terminal Connect another 3-Conductor Cable to TB2 First Junction Box To L-Cells (typical) To Next Junction Box or Signal Processor Figure 3-19.
Chapter 4. L-Cell Installation on Horizontal Beams Chapter 4: Installation of the L-Cell on Horizontal Beams Follow the instructions in this chapter only if installing L-Cells on horizontal beams. This chapter describes the mounting locations, installation details, and wiring details for L-Cells and junction boxes. Follow all instructions carefully to ensure proper system operation. Follow the procedures below to determine L-Cell mounting locations prior to beginning installation.
Chapter 4.
Chapter 4. L-Cell Installation on Horizontal Beams L-Cell Mounting Methods The sensors are mounted at the neutral axis on the web of the beam, at a 45-degree angle, halfway between the loading point and the support point. The following methods provide varied degrees of accuracy. I. Same Side: One L-Cell to the left and one L-Cell to the right of the load point equidistant between the load and the support. The L-Cells are mounted on the same side of the web.
Chapter 4. L-Cell Installation on Horizontal Beams IV. Single L-Cell: One L-Cell mounted on the web. It can be located on either side of the web and either side of the load point. It should be mounted equidistant between the load and the support. This arrangement yields the lowest accuracy performance.
Chapter 4. L-Cell Installation on Horizontal Beams Installing L-Cells Notes 1.Use lubricating fluid (Relton RapidTap® Heavy Duty Cutting Fluid or equivalent) when drilling and tapping. 2.Drilling and tapping instructions assume a metal thickness greater than 3/4” (19mm). If the thickness is less, drill all the way through the metal and tap until cutting complete threads through the other side. Minimum metal thickness is 0.1875” (5mm), which provides six thread engagement.
Chapter 4. L-Cell Installation on Horizontal Beams Mounting L-Cell CAUTION Do not install L-Cells in the rain. Do not trap moisture under the environmental cover. #6-32 Cap Screw S2 1. Apply Rust Inhibitor to 2.50” (63.5mm) diameter bare metal surface S1 S3 Degrease 4.50” (114mm) diameter surface Notes: 1. Do not apply rust inhibitor outside the 2.50” (63.5mm) diameter bare metal, or environmental cover will not adhere properly. 2. Place small amount of sealant on each screw before mounting L-Cell.
Chapter 4. L-Cell Installation on Horizontal Beams Note If the following occurs while tightening screws, check L-Cell resistance using a DMM (described in Problem 1 in Chapter 6, Troubleshooting): • Voltage does not change or changes less than 25 mV as you turn a screw, or • Voltage changes randomly as you turn a screw (i.e., not in a consistent direction). 8.
Chapter 4. L-Cell Installation on Horizontal Beams Mounting Junction Box Mounting Location Each junction box can be wired to a maximum of two L-Cell sets (four L-Cells total): • One set of L-Cells on a beam — both L-Cells are wired to one junction box. • Two sets of L-Cells on a beam — all four L-Cells are wired to one junction box if the sets are sufficiently close to each other to allow the L-Cell cables to reach the junction box. CAUTION Do not install junction boxes in the rain.
Chapter 4. L-Cell Installation on Horizontal Beams Wiring L-Cells to Junction Box Notes 1. Junction box PCB 63-1170-01 is used for L-Cell sets on beams. Ensure you have this PCB in the junction box (see Figure 4-16). 2. The four small holes in the bottom of the junction box are for wiring the L-Cells to the junction box. Small Hole Sealant Watertight Fitting and Cap L-Cell Cable 1234567 1234567 Plastic Washer 12 12 12 12 12 Figure 4-15. Inserting L-Cell Cable through Watertight Fitting and Cap 1.
Chapter 4. L-Cell Installation on Horizontal Beams Junction Box PCB 63-1170-01 Drip Loop (typical) Note: • Verify that junction box PCB is 63-1170-01 (bottom center) Figure 4-16. Wiring L-Cells to Junction Box Wiring Junction Boxes Together and to Signal Processors There are two versions of the junction box enclosure. Both junction boxes have four small holes for wiring L-Cells to the junction box, as described above.
Chapter 4. L-Cell Installation on Horizontal Beams 1. Remove the junction box cover. • Conduited installation — Install a conduit fitting in the large hole in the bottom of the junction box. • Non-conduited installation — See Figure 4-17. Spread a generous bead of sealant around the sides of the PG13.5 cable fittings. Install the fittings in the two large holes in the bottom of the junction box. CAUTION Only use Sikaflex 1A polyurethane sealant or Dow Corning RTV 739 or RTV 738.
Chapter 4. L-Cell Installation on Horizontal Beams Connect Shield Wire (typical) Connect 3-Conductor Cable to TB2 Connect 3-Conductor Cable from First Junction Box to TB1 Connect Shield Wire from Both Cables to Shield Terminal Connect another 3-Conductor Cable to TB2 First Junction Box To L-Cells A and B To L-Cells A and B To L-Cells C and D (if applicable) To L-Cells C and D (if applicable) To Next Junction Box or Signal Processor Figure 4-18.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels Chapter 5: Installation of the L-Cell on Skirt Supported Vessels Follow the instructions in this chapter only if you are installing L-Cells on skirt-supported vessels (carbon steel or aluminum). This chapter describes the mounting locations, installation details, and wiring details for L-Cells and junction boxes. Follow all instructions carefully to ensure proper system operation.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels Note If the vessel panels differ significantly from this industry standard or the panel height is less than 6’ (1.8m), consult K-M for assistance in determining optimal mounting locations. Example: The Application Data Form indicates a 12’ diameter bolted vessel. From Figure 5-3, a 12’ bolted vessel has 8 panels around its circumference. 1. 2.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels Legend: = L-Cell Set X = Junction Box = Door X3 2 4 5 5X 1 X3 6 2 9’ (2.7m) Diameter 9’-5” (2.9m) L-Cell Spacing X 7 6 5 8 4 X 3 2 1 X 10 8 11 7 10 11 4 12 3 X X7 13 4 X 15 3 2 1 17 16 2 1 9 14 15 17 4 18 3 X 26’ (7.9m) Diameter 9’-7” (2.9m) L-Cell Spacing (except around door) X 2 19 1 20 X 28’ (8.5m) Diameter 8’-10” (2.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels Distribution of L-Cells and Junction Boxes Around Vessel (Aluminum Vessels) See Figures 5-5 and 5-6. Typical aluminum skirt-supported vessel sizes are shown in Figure 5-5. L-Cells are placed symmetrically around the vessel, with a maximum spacing of 4’ (1.2m) between L-Cells. Typically, the tiers are 6.6’ to 8.2’ (2.0 to 2.5m) high, and the L-Cells are placed at the vertical centerline of the tier.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels Location Centerline Mount Junction Box 6’ (1.8m) above Foundation 1’ (0.3m) Alternate Conduit Locations L-Cell A L-Cell B L-Cell C L-Cell D Center L-Cells Vertically on Panel Notes: • L-Cells A and C are on inside of skirt. • L-Cells B and D are on outside of skirt. • Distribute L-Cells symmetrically around vessel. • Minimum panel height for L-Cell installation is 6’ (1.8m). • Junction box is on inside of skirt, 6’ (1.8m) above foundation.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels Obstructions Obstructions typically encountered on a skirt-supported vessel include: • pipe, conduit, auger, or other material conveyor passing through a panel • open hole in a panel • welded or bolted seams between panels • bracket or electrical box welded or bolted to a panel • welds around a patch, plugged opening Carbon Steel Obstructions can be classified as major or minor: • Figure 5-8 shows an example of a major obstruction.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels Mark Locations (Bolted, Skirt-Supported Vessels) Note The procedure for marking mounting locations is based on the nominal locations shown. Refer to the Application Data Form for the approximate mounting locations selected by KM. 1. 2. Beginning on the outside of the skirt at the door panel (panel 1), walk clockwise to panel 2. Mark the preliminary L-Cell location: • Locate the L-Cell on the panel horizontal centerline.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels 3. Proceed to the inside of the skirt and walk clockwise to panel 2. Mark the preliminary L-Cell location to match the marked location on the outside of the skirt: • If you adjusted the outside location because of an obstruction, maintain offset configuration of the set (i.e., if you move the outside L-Cell in the set from its ideal location, move the inside LCell as well).
Chapter 5. L-Cell Installation on Skirt-Supported Vessels 2. Continuing to move clockwise around the outside of the skirt and now measuring the full spacing distance, repeat Step 1, marking preliminary mounting locations all the way around the outside of the skirt. • Measure the spacing distance from the ideal location for the previous L-Cell. Do not measure from the modified location if you relocated the previous L-Cell because of an obstruction. 3.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels Obstructions Obstructions can be classified as major or minor: • Figure 5-12 shows an example of a major obstruction. Do not place an L-Cell set within 1.3’ (0.4m) of a major obstruction. • Figure 5-13 shows an example of a minor obstruction. Do not place an L-Cell set within 0.7’ (0.2m) of a minor obstruction — less than 4” (102mm) in size. (Aluminum) r u c t See Figure 5-14. Minor obstructions may occur near the top or bottom of a tier.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels IInstalling L-Cells Note: Use industrial-grade, heavy-duty tapping fluid when drilling and tapping. Surface Preparation Figure 5-16. Drill Mounting Hole Figure 5-17. Prepare area with Disc Sander Figure 5-18. Use finer grit sander disc. 1. See Figure 5-16. At the center of the previously marked mounting location for the outside L-Cell, drill all the way through the skirt with the #36 drill bit. This produces the template mounting hole. 2.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels Drill and Tap 1. Using the #6-32 tap, thread the template mounting hole for the outside L-Cell (drilled during Surface Preparation) until the tap is cutting complete threads through to the other side. Remove any burrs from the hole. See Fig. 19. 2. See Figure 5-20. Fasten the drill template to the template mounting hole through hole #5A, using the #6-32 x 1 5/8” socket head cap screw.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels Mounting L-Cell CAUTION Do not install L-Cells in the rain. Do not trap moisture under the environmental cover. Figure 5-24. Wipe down surface 1. See Figure 5-24. Wipe down a 4.5” (114mm) diameter surface for the outside L-Cell, centered on the template mounting hole, with degreaser. This cleans the bare metal surface and adjacent area. 2. Apply a thin coat of KM rust inhibitor to the exposed 2.50” (63.5mm) diameter bare metal surface. Fig.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels 5. S2 Apply Rust Inhibitor to 2.50” (63.5mm) diameter bare metal surface Holding the L-Cell flat against the surface, loosely fasten the L-Cell with the three screws. Do not tighten the screws. • If the voltage goes outside -200 to +200 mV, immediately loosen the screw(s), as this may indicate a burr or rough surface. Remove the screws and L-Cell.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels 10. See Figure 5-31, 5-32, and 5-33. Peel the protective backing from the double-sided tape on the environmental cover’s inside flange. A. Align the cover over the L-Cell, with the cable through the cover’s exit channel. Press the cover onto the mounting surface. B. Spread a 1/8” (3.2mm) bead of sealant around the joint between the cover and mounting surface. Add extra sealant to the cable exit channel and between cable and skirt. C.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels Wiring L-Cells to Junction Box Note The four small holes in the bottom of the junction box are for wiring L-Cells to the junction box. Figure 5-35. Junction Box 1. 2. 3. Small Hole Sealant Watertight Fitting & Cap L-Cell Cable 123456 Plastic Washer 12 12 12 12 Figure 5-36. Inserting L-Cell Cable through Watertight Fitting and Cap Figure 5-37. Estimate length Remove the junction box cover Fig 5-35. See Figure 5-36.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels Wiring Junction Boxes Together and to Signal Processor There are two versions of the junction box enclosure. Both versions have four small holes for wiring L-Cells to the junction box, as described above. In addition, the junction box has one or two large holes for wiring the junction box to the other junction boxes and to the signal processor: • • One large hole for conduited installation — The large hole accommodates a 3/4” conduit fitting.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels (inside) A (outside) (inside) C B PCB (outside) D # L-Cells A & C are on the inside of the silo. L-Cells B & D are on the outside of the silo. Drip Loop Figure 5-39. Wiring L-Cells to Junction Box (inside view of skirt) 4. Route another 3-conductor cable through the fitting into this junction box, and attach wires to the TB2 terminal: black wire to B, white wire to W, and red wire to R.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels Enlarged view of connections to TB1 and TB2 Connect Shield Wire to Shield Terminal Connect 3-Conductor Cable to TB2 Connect 3-Conductor Cable from Junction Box on Panel 3 to TB1 Connect Shield Wire from Both Cables to Shield Terminal Connect another 3-Conductor Cable to TB2 Figure 5-40.
Chapter 5. L-Cell Installation on Skirt-Supported Vessels Enlarged view of connections to TB1 and TB2 Connect Shield Wire to Shield Terminal PANEL 1 (DOOR) PANEL 2 Connect 3-Conductor Cable from Junction Box on Panel 3 to TB1 Connect 3-Conductor Cable to TB2 PANEL 3 PANEL 4 PANEL 5 PANEL 6 Connect Shield Wire from Both Cables to Shield Terminal PANEL 7 Connect another 3-Conductor Cable to TB2 PANEL 8 To Next Junction Box or Signal Processor Cable Tray Figure 5-41.
Chapter 6. Microcell Installation on Vertical Pipe Legs Chapter 6: Installation of the Microcell on Vertical Pipe Legs Follow the instructions in this chapter only if installing Microcells on vertical pipe legs. Skip this chapter if installing other options. This chapter describes the mounting locations, and wiring installation details for Microcells and junction boxes on vertical pipe leg applications. Follow the procedures below to determine Microcell mounting locations prior to beginning installation.
Chapter 6. Microcell Installation on Vertical Pipe Legs Horizontal Distribution of Microcell Sets Microcell sets are placed on each support leg. Vertical Location of Microcell Sets Note Microcell locations may be adjusted up to 12” (305mm) vertically to avoid obstacles. If adjusting locations, maintain the configuration of the Microcell set (i.e., if you move one Microcell in the set from its ideal location, move the other(s) as well). Pipe Legs without X-Braces See Figure 6-3. • • Figure 6-2.
Chapter 6. Microcell Installation on Vertical Pipe Legs Alternate location — Microcell sets mounted at mid-height of free leg at top (typical) ‘Free Leg’ H— minH /2 H 1 ‘Free Leg’ H— minH Microcell sets mounted at mid-height of free leg (typical) /2 H 1 Figure 6-4.
Chapter 6. Microcell Installation on Vertical Pipe Legs 2. Mark the surface preparation area for the vertical Microcell. 3. Attach coarse grit sandpaper to the grinder. Remove heavy paint and rust with the grinder until a bare metal surface is achieved for the Microcell(s). Due to the use of coarse grit, the resulting surface is somewhat coarse. Fig 6-7 4. Replace the coarse grit sandpaper with fine grit sandpaper. Grind until the surface(s) is completely down to bare metal and smooth to the touch.
Chapter 6. Microcell Installation on Vertical Pipe Legs CAUTION Do not install Microcells in the rain. Do not trap moisture under the environmental cover. Mounting Microcell 1. Wipe down a 5” by 21/4” (127 by 57mm) surface, centered on the template mounting hole, with degreaser. This cleans the bare metal and adjacent mounting surface for the environmental cover. 2. Apply a thin coat of KM rust inhibitor to the bare metal surface for the vertical Microcell. Fig 6-10.
Chapter 6. Microcell Installation on Vertical Pipe Legs Figure 6-13. CAUTION Only use Sikaflex 1A polyurethane sealant or Dow Corning RTV 739 or RTV 738. Other sealants may contain acetic acid, which is harmful to sensors and electronics. Apply Sealant to Inside Flange of Cover 5. Using the T-handle driver, slowly tighten the top screw. While turning the T-handle driver, monitor the Test Meter carefully.
Chapter 6. Microcell Installation on Vertical Pipe Legs Mounting Junction Box Mounting Location Each junction box can be wired to a maximum of four Microcells: • Vertical Microcells — one junction box can be wired to Microcells from two support legs (two Microcells on each support leg) if the legs are sufficiently close to each other to allow the Microcell cables to reach. See Figure 6-15. Locate the junction box on the support leg or on a brace.
Chapter 6. Microcell Installation on Vertical Pipe Legs 3. Drill and tap the mounting holes with a #29 drill bit and #8-32 tap. 4. Mount the junction box with #8-32 socket head cap screws and flat washers. Tighten the screws until snug. Replace the junction box cover and screws if not ready to begin wiring, to ensure no moisture enters the junction box. Wiring Microcells to Junction Box Note The four small holes in the bottom of the junction box are for wiring the Microcells to the junction box. 1.
Chapter 6. Microcell Installation on Vertical Pipe Legs For Vertical Microcells Junction Box PCB 63-1170-01 A B C D Drip Loop (typical) Notes: • Verify that junction box PCB is 63-1170-01 (bottom center). • Microcells A and B are on one support leg. • Microcells C and D are on another support leg. Microcells C and D can be wired as shown, or can be wired to its own junction box (terminals A and B) if desired. Figure 6-18.Microcell Installation 8.
Chapter 6. Microcell Installation on Vertical Pipe Legs Notes 1. The procedure below assumes the conduit/cable tray has been installed. 2. Seal all conduit fittings against water entry. Install drain holes at conduit’s lowest elevation(s) to allow condensation to drain. 3. Use Belden™ 3-conductor shielded interconnect cable or equivalent to wire junction boxes together and to the signal processor. For lengths up to 1,000’ (305m) use 18-gage Belden 8791 cable.
Chapter 6. Microcell Installation on Vertical Pipe Legs Connect Shield Wire to Shield Terminal Connect 3-Conductor Cable to TB2 Connect 3-Conductor Cable from First Junction Box to TB1 Connect Shield Wire from Both Cables to Shield Terminal Connect another 3-Conductor Cable to TB2 First Junction Box To Microcells (typical) Figure 6-20.
Appendix A. L-Cell Specifications Appendix A: L-Cell Specifications Mechanical Stress Level Carbon Steel — Maximum Recommended* Aluminum — Maximum Recommended* Fatigue Life Carbon Steel — Aluminum — ±15,000 psi (10.5 kg/mm2) 5,000 ± 3,500 psi (3.5 ± 2.5 kg/mm2) ±6,500 psi (4.6 kg/mm2) 3,000 ± 1,500 psi (2.1 ± 1.1 kg/mm2) > 20 million cycles; load and unload at 0 to 7,500 psi (0 to 5.3 kg/mm2) > 20 million cycles; load and unload at 0 to 3,250 psi (0 to 2.
Appendix A.
Appendix B. Microcell Specifications Appendix B: Microcell Specifications Mechanical Stress Level 3-inch Microcell Maximum Recommended* Maximum Recommended* 10,000 psi (7.0 kg/mm2) 5,000 ± 2,500 psi (3.5 ± 1.75 kg/mm2) 2-inch Microcell 15,000 psi (10.5 kg/mm2) 7,500 ± 3,750 psi (5.3 ± 2.6 kg/mm2) Fatigue Life > 20 million cycles; load and unload at 0 to 5,000 psi (0 to 3.5 kg/mm2) *Consult factory for application assistance for stress levels outside the recommended range.
Appendix B. Microcell Specifications A D 0.18” (4.6mm) Diameter B C Reference Dimensions 3-inch Microcell 2-inch Microcell A .375” (9.52mm) .375” (9.52mm) B 0.75” (19.0mm) 0.75” (19.0mm) C 3.00” (76.2mm) 2.00” (50.8mm) D 2.75” (69.8mm) 1.75” (44.4mm) Note: These dimensions are for reference only. Use the Microcell drill template to locate, drill, and tap the mounting holes.
Appendix C. Glossary Appendix C: Glossary Calibration Curve Signal Processor A graph of load versus output. Typically, it is a straight line and relates live load to a voltage or digital count output. The electronic hardware and software box connected to a sensor (such as an L-Cell) or transducer array. If it is augmented with software, the first stage of the signal processor is an A/D converter.
Appendix C.
Appendix D. System Calibration Appendix D: System Calibration This chapter describes general procedures for calibrating the L-Cell system. Before calibrating, you must install a signal processor. Refer to the signal processor manual for the procedures to input calibration parameters. There are two calibration methods: • • Live Load calibration — set lo span and hi span while moving material into or out of the vessel. This is the preferred method.
Appendix D. System Calibration Live Load Calibration Live Load calibration can be performed by adding or removing a known quantity of material from the vessel. The quantity of material moved must be at least 25% of the vessel’s total capacity. The procedures for both Live Load calibration methods follow. Note Refer to the signal processor manual to input Lo Span and Hi Span. Adding Material See Figure D-1: 1. 2. 3. 4. Record the current live load.
Appendix D. System Calibration Manual Calibration Note K-M’s SVS 2000™ signal processor performs a manual calibration automatically, with Quick Config. See Figure D-2: 1. Refer to the signal processor manual to determine how to obtain the A/D converter sensitivity, expressed in Counts/mV. Record this value. 2. Record the L-Cell sensitivity (S): • Carbon steel vessel — 35 mV/1000 psi (35 mV/0.7kg/mm2) • Aluminum vessel — 80 mV/1000 psi (80 mV/0.7kg/mm2) 3.
Appendix E. Troubleshooting Appendix E: Troubleshooting the Bolt-On System (L-Cell) This chapter describes some common problems. For each problem, one or more possible explanations are listed. For each explanation, an indication of when the problem is likely to be noticed and suggested solutions are provided.
Appendix E. Troubleshooting Problem Problem Details Solution Small Amplitude Changes or Erratic Fluctuations in display readings Small amplitude drift or oscillation, with peak-topeak disturbance of 0.1% to 0.3% of full scale, is normal. Reduce drift or oscillation by setting ‘count by’ and ‘averaging’ appropriately on signal processor (refer to signal processor manual). Erratic fluctuations can be caused by moisture in cable conduit, junction boxes, or junction box PCBs.
Appendix E. Troubleshooting Problem Small Amplitude Changes or Erratic Fluctuations in display readings Problem Details Fluctuations can be caused by short to ground Solution Using a Digital Multimeter (DMM) or ohmmeter, check for shorts to ground as follows: 1. Set meter resistance scale to accommodate maximum measured range. 2. Disconnect junction box wires from signal processor. 3.
Appendix E. Troubleshooting Problem Small Amplitude Changes or Erratic Fluctuations in display readings Problem Details Fluctuations can be caused by problems with signal processor. Solution Check signal processor excitation voltage and incoming AC voltage for accuracy and stability (refer to signal processor manual). Repeatable Drift over 24-hour Period Periodic drift is most likely caused by vessel thermal expansion due to sun’s radiation or vessel’s response to its own heating cycles. 1.
Appendix F. Spare Parts Recommendations Appendix F.
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Appendix G. Alternate Method Appendix G: Alternate Method of Checking Output Microcell If you do not have a K-M Test Meter, use a Digital Multimeter (DMM) to monitor the voltage output of each Microcell during installation. Set up the DMM as described below and then follow the installation procedure for Mounting Microcell. Note The junction box must be mounted and wired to the signal processor and powered up before following this procedure.
Appendix G. Alternate Method L-Cell If you do not have a Kistler-Morse Test Meter, use a Digital Multimeter (DMM) to monitor the voltage output of each L-Cell during installation. Set up the DMM as described below and then follow the installation procedure for Mounting L-Cell. Note The junction box must be mounted and wired to the signal processor and powered up before following this procedure.
Appendix H. Technical Drawings Appendix H: Technical Drawings This appendix contains the following technical drawings for the L-Cell and the Microcell: Drawing No. Drawing Title TI-LCELL-02 L-Cell Sensor FM Approved Intrinsically Safe Inteconnect Diagram TI-MC.
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