Microcell™ Installation Manual 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® Corporation. Any reproduction or translation of this document without the written authorization of a Kistler-Morse® corporate officer is prohibited. CAUTION Follow these rules if welding is done on the vessel after installation of the Microcell™ system. The electrical current of the welder may pass through the Microcell™, causing damage to the sensor and possibly to the signal processor.
TABLE OF CONTENTS CHAPTER 1. INTRODUCTION................................................................................................................. Equipment Description.......................................................................................................................... Applications........................................................................................................................................... Manual Conventions...........................................
TABLE OF CONTENTS Mounting Junction Box............................................................................................................................. Mounting Location.............................................................................................................................. Junction Box Installation..................................................................................................................... Wiring Microcell™ Sets to Junction Box......................
CHAPTER 1. INTRODUCTION APPLICATIONS The 3” Microcell™ can be installed on carbon steel, stainless steel, or aluminum vessel supports. The 2” Microcell™ can be installed on carbon steel vessel supports only. Refer to Appendix A (Microcell™ Specifications) for stress limits on each type of Microcell™. Microcell™ sets can be installed on leg-supported and beam-supported vessels. Refer Chapter 3 for installation details on installing Microcell™ on vertical column legs.
CHAPTER 2. PRE-CHECK PROCEDURES INTRODUCTION ORDER VERIFICATION This chapter describes the pre-check procedures for Microcell™ sets. Verifying the application and checking the Microcell™ sets before installation will ensure installation of properly working equipment that will provide accurate monitoring of vessel contents. Prior to beginning installation, verify the order is complete and assemble additional equipment needed for the installation.
CAUTION Only use Sikaflex 1A polyurethane sealant or Dow Corning RTV 738 or RTV 739. Other sealants may contain acetic acid, which is harmful to sensors and electronics.
A. Proceed to TESTING WITH A DIGITAL MULTIMETER (DMM) to determine the resistance values for that Microcell™, and B. Contact Kistler-Morse® for assistance after determining the resistance values and before proceeding with installation. 3. Put one DMM lead on the Microcell™ white wire and the other lead on the black wire. Place the Microcell™ on a stable surface.
CHAPTER 3. MICROCELL™ INSTALLATION ON VERTICAL COLUMN LEGS INTRODUCTION Follow the instructions in this chapter only if installing Microcells™ on vertical column legs. This chapter describes the mounting locations, installation details, and wiring details for Microcells™ and junction boxes. Follow all instructions carefully to ensure proper system operation. Note Do not mix different types of Microcells™ on one vessel.
HORIZONTAL DISTRIBUTION OF MICROCELL™ SETS Microcell™ sets are placed on each support leg. Refer to Figure 3-3 for the mounting locations for each shape. VERTICAL LOCATION OF MICROCELL™ SETS Note Microcell™ locations may be adjusted up to 12 in (305mm) vertically to avoid obstacles. If adjusting locations, maintain the configuration of the Microcell™ set (i.e., if one Microcell™ in the set is moved from its ideal location, move the other(s) as well). COLUMN LEGS WITHOUT X-BRACES See Figure 3-4.
For an alternate location, measure the free leg between the top of the top X-brace or horizontal brace and the beam supporting the vessel. See Figure 3-6. If the free leg distance is less than 12 in (305mm), mount the Microcell™ sets at the mid-height between the lowest braces. When mounting between the braces, insulation around the adjacent braces is required for best performance. This insulation will reduce the effect of sun-induced stresses on the support metal. Figure 3-5.
4. Replace the coarse grit sandpaper with the fine grit sandpaper. Grind until the surface(s) is completely down to bare metal and smooth to the touch. INSTALLING MICROCELL™ SETS Note 1. 2. Use lubricating fluid (Relton RapidTap® Heavy Duty Cutting Fluid or equivalent) when drilling and tapping. Drilling and tapping instructions assume metal thickness greater than ¾” (19mm).
5. Loosen the screw securing the template and rotate the template until the two tap guides line up with the drilled holes. Push the #8-32 tap into one of the tap guide holes to align the template. Retighten the screw securing the template. 6. Using the #8-32 tap, thread the two holes through the template tap guides. Tap to a minimum 5/8” (16mm) depth, full threads. Remove the template from the leg. 7. If installing a rosette array, repeat Steps 1 through 6 for the horizontal Microcell™. 8.
Note If the following occurs while tightening screws, check Microcell™ resistance using a DMM (described in Problem 1 in Chapter 6): A. Voltage does not change or changes less than 25mV as you turn a screw, or B. Voltage changes randomly as you turn a screw (i.e., not in a consistent direction). 7.
Figure 3-10. Possible Junction Box Mounting Locations. JUNCTION BOX INSTALLATION 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 that no moisture enters the junction CAUTION Do not install junction boxes in the rain. Moisture in the junction box will cause corrosion and system errors. box. Note Junction box mounting hardware is not supplied by Kistler-Morse®.
CAUTION Only use Sikaflex 1A polyurethane sealant or Dow Corning RTV 738 or RTV 739. Other sealants may contain acetic acid, which is harmful to sensors and electronics. Figure 3-12. Inserting Microcell™ Cable Through Watertight Fitting and Cap Figure 3-13. Wiring Microcells™ to Junction Box. 4. See Figure 3-13. In the bottom of the junction box, locate one of the four small holes closest to the terminal being used for that Microcell™. Screw the watertight fitting into the hole.
Note A. The following procedure assumes the conduit/cable tray has been installed. B. Seal all conduit fittings against water entry. Install drain holes at the conduit’s lowest elevation(s) to allow condensation to drain. C. 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 ft (305m), use 18 gauge Belden™ 8791 cable.
2. See Figure 3-15 (for a conduited installation) or Figure 3-16 (for a 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 TB3 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. Route the cable through conduit/cable tray to the next junction box.
2. See Figures 3-17 ad 3-18. Lay the wrap on a flat surface. Mark and cut it at the distance from Step 1. 3. See Figure 3-19. The goal is to cover most of the brace with wrap. Covering the brace where it crosses another brace in the middle is unnecessary. Depanding on the brace lenth, multiple sections of wrap may be required, with each section overlapping the one below it by a minimum of 2 in (51mm). Measure and record the space available for each section of wrap. If the space is more than 60 in (1.
Figure 3-18. Cutting Wrap Width. Figure 3-19. Installing Brace Wrap.
CHAPTER 4. MICROCELL™ INSTALLATION ON HORIZONTAL BEAMS INTRODUCTION Follow the instructions in this chapter only if installing Microcells™ on horizontal beams. This chapter describes the mounting locations, installation details, and wiring details for Microcells™ and junction boxes. Follow all instructions carefully to ensure proper system operation. Note Do not mix different types of Microcells™ on one vessel.
Figure 4-2. Microcell™ Mounting Locations.
Figures 4-3, 4-4, and 4-5 show the location of a Microcell™ set on a beam. The ideal location is midway between the vessel support bracket and the support column (or supporting beam). This places the shear mounting set away from joints and load points. The minimum distance between the load point and the support column or beam is 18 in (457mm). If less space is available, this is a special application. Consult Kistler-Morse® before proceeding further.
INSTALLING MICROCELL™ SETS Note 1. 2. 3. 2. See Figure 4-7. Starting with the location of Microcell™ A, fasten the drill template to the template mounting hole through the center hole, using the captive #8-32 socket head cap screw. Use a level to ensure correct orientation (45° angle to the horizontal). 3. Using the #29 drill bit, drill two ¾” (19mm) deep holes in the web through the template drill guides. 4.
CAUTION For proper installation, tighten each screw until the T-handle driver flexes in torsion ¼ turn past the point where the screw stops turning. Repeat this flexing procedure several times to ensure the screw is tight. When both screws are tight, the voltages must be in the range of -100mV to +100mV. Follow the procedure in Steps 6 through 8 to achieve this goal. MOUNTING MICROCELL™ SETS CAUTION Do not install Microcells™ in the rain.
12.If you created any holes that go completely through the web, spread sealant (Sikaflex 1A polyrethane sealant or Dow Corning RTV738 or RTV 739) over the open holes. Use your finger to press sealant into each hole. 8. To complete installation, ensure that both screws are tightened until the T-handle driver flexes in torsion, ¼ turn past the point where the screw stops turning, with this flexing procedure repeated several times to ensure the screw is tight, and the voltage is in the range -100mV to +100mV.
Note Junction box mounting hardware is not supplied by Kistler-Morse®. Kistler-Morse® recommends #8-32 socket head cap screws and flat washers. The instructions below reflect this recommendation. WIRING MICROCELL™ SETS TO JUNCTION BOX Note A. Junction box PCB 63-1135-03 is used for Microcell™ sets on beams. Ensure you have this PCB in the junction box (See Figure 4-13). B. The four small holes in the bottom of the junction box are for wiring the Microcells™ to the junction box. 1.
Note TB3 terminal block has 12 terminals to accommodate up to four Microcells™ (two shear sets). Wire Microcell™ A to terminal A and Microcell™ B to terminal B. If there are four Microcells™ on one beam, wire Microcell™ C to terminal C and Microcell™ D to terminal D. 2. Two large holes for non-conduited installation. The two large holes, which are equipped with PG13.5 cable fittings, are for wiring the junction box to the other junction boxes and to the signal processor.
the excess cable. Connect wires from the cable to the TB1 terminal in the junction box; black wire to the B terminal, white wire to the W terminal, and red wire to the R terminal. Connect the cable shield wire to the the Shield terminal between TB1 and TB2. 4. Route another 3-conductor cable through the fitting into this junction box, and attach wires to the TB2 terminal; black wire to B terminal, white wire to W terminal, and red wire to R terminal.
Figure 4-16. Wiring Junction Boxes Together - Non-Conduited Installation.
CHAPTER 5. SYSTEM CALIBRATION proportional change in digital counts. However, the structure’s actual response to load and interaction with piping, catwalks, roof, discharge chutes, etc. prevents the system from achieving theoretical values. Manual Calibration is a good start, but to obtain the highest accuracy, perform a live load calibration when scheduling permits you to move material into or out of the vessel. The following sections provide procedures for performing live load and Manual Calibrations.
5. Calculate the Manual Calibration values: Scale Factor Weight = maximum live load Scale Factor Counts = S * Counts/mV * Stress Zero_Cal = current live load 6. Refer to the signal processor manual to input the calibration values. REMOVING A KNOWN QUANTITY OF MATERIAL See Figure 5-1. 1. Record the current live load. 2. Input HI Span: HI Span = current live load. 3. Remove known quantity of material to the vessel. Ensure all material has stopped moving before proceeding. 4.
CHAPTER 6. TROUBLESHOOTING This chapter describes some common problems you may encounter while using Microcells™. For each problem, one or more possible explanations are listed. An indication of when the problem is likely to be noticed and suggested solutions are provided for each explanation. EXPLANATION Fluctuations can be caused by a damaged Microcell™. Problem Likely to be Noticed Shortly after initial installation or on system that previously functioned correctly. PROBLEM 1.
EXPLANATION Fluctuations in readings can be caused by short to ground. B. Problem Likely to be Noticed Shortly after initial installation or on system that previously functioned correctly. If no short is indicated, disconnect next Microcell™ wires from junction box and check resistances. Repeat for each Microcell™ wired to junction box until short is located. Replace the shorted Microcell™. EXPLANATION Fluctuations in readings can be caused by problems with signal processor.
PROBLEM 3. SUDDEN CHANGE IN DISPLAY READING OR SYSTEM REQUIRES FREQUENT CALIBRATION. CAUTION Only use Sikaflex 1A polyurethane sealant or Dow Corning RTV 738 or RTV 739. Other sealants may contain acetic acid, which is harmful to sensors and electronics. EXPLANATION A single broken Microcell™ can cause indicated weight to shift up or down by a large amount, up to 100% of full-scale live load. EXPLANATION Sudden change in weight reading can be caused by problems with signal processor.
APPENDIX A. MICROCELL™ SPECIFICATIONS. MECHANICAL Stress Level 3” Microcell™ Maximum 10,000 psi (7.0kg/mm2) Recommended* 5,000 psi ± 2,500 psi (3.5kg/mm2 ± 1.75kg/mm2) 2” Microcell™ Maximum 15,000 psi (10.5kg/mm2) Recommended* 7,500 psi ± 3,750 psi (5.3kg/mm2 ± 2.6kg/mm2) Fatigue Life > 20 million cycles; load and unload at 0 to 5,000 psi (0kg/mm2 to 3.5kg/mm2) *Consult factory for application assistance for stress levels outside the recommended range.
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APPENDIX B. GLOSSARY CALIBRATION CURVE A graph of load versus output. Typically, it is a straight line and relates live load to a voltage or digital count output. 6. Some type of indicator or display, such as numerals, needle movement, discrete LED array, etc. LIVE LOAD The weight of the material to be measured; in other words, the weight of the contents of the vessel.
APPENDIX C. ALTERNATE METHOD FOR CHECKING OUTPUT If you do not have a Kistler-Morse® 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 the Microcell™. Note The junction box must be mounted and wired to the signal processor and powered up before proceeding with the following procedure.
APPENDIX D.
APPENDIX E. TECHNICAL DRAWINGS This appendix contains the following technical drawing(s): DRAWING NUMBER TI-MC.
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