Fairbanks 12-1492 User Manual
Installation Manual
A.A.R. Combination
Railroad Track / MTS
Scale
Model(s): 12-1492
12-1493
12-1494
12-1495
12-1496
50538
Revision 7 4/12
© 1999-2012 by Fairbanks Scales Inc.
All rights reserved
04/12 3 50538 Rev. 7
Amendment Record
A. A.R. Railroad
Combination MTS Scale
Model(s): 12-1492,12-1493,12-1494,12-1495
50538
Manufactured by Fairbanks Scales Inc.
821 Locust
Kansas City, Missouri 64106
Created 9/99
Issue #1 9/99 Software Update.
Issue #2 12/01 Update arrangement/flow.
Issue #3 10/03 Updated Information and Drawings
Revision 4 05/08 Updated Load Cell Assembly image and corresponding parts information;
Added special Load Cell Appendix with parts list
Revision 5 05/08 Updated information and drawings according to notes from Engineering Dept.
Revision 6 03/10 Updates per ECO 626.
Revision 7 04/12 Updated information and drawings according to notes from Engineering Dept.
Table of Contents
Section 1: General Information
1-A: Introduction & General Description Page 9
1-B: Specifications Page 9
1-C: Rails & Anti-Creep Devices Page 10
1-D: Regulations from the AAR Scale Handbook Page 11
1-E: Foundation Construction & Installation Page 13
1-F: Ground Rods Page 14
1-G: Load Cell Base Plates Page 14
1-H: Check Stands Page 15
1-I: Weighbridge Page 15
1-J: Deck Construction Page 15
1-K: Load Cell Flexure Assembly Page 16
Section 2: Installation
2-A: General Service Policy Page 17
2-B: Pre-Installation checkout Page 17
2-C: Unpacking Page 18
2-D: Safety Page 18
2-E: Recommended Installation Sequence Page 19
2-F: Foundation Inspection Page 20
2-G: Foundation Inspection Check List Page 21
2-H: Base Plate Assemblies Page 22
2-I: Check Stands Page 22
2-J: Weighbridge Steel Page 23
2-K: Weighbridge Hardware Page 24
2-L: Assembling Weighbridge Sections Page 25
2-M: Installing Weighbridge Sections Page 27
2-N: Load Cell Flexure Assembly Page 29
2-O: Adjusting Elevation Page 31
2-P: Leveling Load Cell Flexure Assemblies Page 33
2-Q: Grouting Load Cell Baseplates Page 36
2-R: Checkrods Page 39
2-S: Check Rod Adjustment Page 41
2-T: Deck Forming Page 42
2-U: Junction Boxes Page 47
2-V: Grounding Page 47
Section 3: Service & Maintenance
3-A: Basic Maintenance Page 49
Section 4: Parts list
Parts List Page 50
04/12 5 50538 Rev. 7
Table of Contents, Continued
Appendix I: Recommended Tools & Equipment Page 54
Appendix II: Required at Jobsite Page 55
Appendix III: Materials Page 55
Appendix IV: Torque Values Chart Page 56
Appendix V: Tolerances Page 56
Appendix VI: Load Cell Specifications Page 56
Appendix VII: Concrete & Sump Testing Page 57
Appendix VIII: About the AAR, AREMA, & AREA Page 58
Appendix X: Special Product Applications --
Short Load Cell Assembly Page 59
04/12 6 50538 Rev. 7
Index of Illustrations:
50538-1 Deck with recessed rail Page 9
50538-2 Anti-Creep Device Page 10
50538-3 Rail Miter Cut Gaps Page 10
50538-4 Ground Rod Locations Page 14, 47
50538-5 Load Cell Flexure Assembly Page 16
50538-3A Foundation Inspection Check list Page 21
50538-6 Base Plate Installation Page 22
50538-7 Weighbridge Steel: Assembled Section Page 23
50538-7A Weighbridge Steel: Component Identification Page 23
50538-7B Weighbridge Hardware Page 24
50538-8 Weighbridge Steel Layout Page 25
50538-9 Weighbridge Steel Assembling Page 25
50538-10 Installing Weighbridge Checkbracket Page 25
50538-11 Installing Stiffener Plate & Top Bearing Plate Assy Page 26
50538-12 Centering Weighbridge Sections Page 27
50538-13 Centering Main Beams Page 28
50538-14A Load Cell Flexure Assembly; Exploded View Page 29
50538-15 Load Cell Flexure Assembly Orientation Page 30
50538-16 Load Cell Flexure Assembly; Centering Page 30
50538-17 Leveling End Section Page 32
50538-18 Leveling Middle Sections Page 32
50538-19A Load Cell Flexure Assembly; Leveling Page 33
50538-20 Load Cell Locations Page 34
50538-21 Base Plate Forming & Grouting Page 37
50538-22 Base Plate Forming & Grouting Page 38
50538-23 Base Plate Forming & Grouting: Sloping Grout Page 38
50538-24 Weighbridge Check Stands Page 39
50538-25A Check Rod Washer Sets Page 39
50538-26 Pier Check Stands Page 40
50538-27 Check Stands: Leveling Page 40
50538-28 Check Rods: Adjusting Page 41
50538-29 Deck with recessed rail Pocket Page 42
50538-30 Deck Forming: Hex Nut Spacers Page 42
50538-31 Deck Forming: Placing and Welding Deck Coping Page 43
50538-32 Deck Forming: Placing and Welding Deck Coping Page 43
50538-33 Deck Forming: 12 Corner Junctures Page 44
50538-34 Deck Forming: Deck Coping at Rails Page 44
50538-35 Deck Forming: Installing Corrugation Page 44
50538-36 Deck Forming: Installing Corrugation Page 45
50538-37 Deck Forming: Installing Rebar Page 45
50538-38 Deck Forming: Installing Bituminous Mastic Page 46
50538-39 Deck Forming: Steel Plates at End of Rail Pockets Page 46
50538-40 Junction Boxes Page 47
50538-41 Grounding Page 47
50538-42 Parts List Page 50
50538-14 Previous Load Cell Revision -- Before 1992 Page 59
04/12 7 50538 Rev. 7
04/12 9 50538 Rev. 7
A.A.R. Combination Railroad Track / MTS Scale
NOTE: This manual is intended to compliment and be used in conjunction with the Certified
Prints provided by FAIRBANKS SCALES. Installation should be attempted only with the presence and guidance of experienced personnel who are fully familiar with the assembly of these
scales. Please read this Bulletin in its entirety BEFORE setting scale hardware.
SECTION 1-A: Introduction & General Description:
The Fairbanks Model A.A.R.* Combination Railroad Track / Motor Truck Scale is fully electronic in design, and utilizes eight 200,000 lb capacity compression loadcells that are constructed of Stainless Steel and hermetically sealed for protection against moisture. The four
(4) section Scale is pit installed, and is offered in five (5) different standard Models that provide a sectional capacity of 180 Tons, and a total capacity of 360 Tons.
50538-1
The full platform of the scale is arranged to accommodate a railroad car or a motor truck for
weighing. The track rails are installed in a recessed rail pocket below grade, thus presenting
no obstruction to rubber tires. Interface to a Fairbanks 2500 Series Indicator with INTALOGIX technology is standard.
1-B: Specifications:
Product # Description Shipping Weight
145960 (90840**) Model 1492: 60' X 10' Platform 36,500 lb.
145966 (90841**) Model 1493 66' X 10' Platform 41,700 lb.
145970 (90842**) Model 1494 70' X 10' Platform 48,700 lb.
145972 (90843**) Model 1495 72' X 10' Platform 49,900 lb.
145980 (99179**) Model 1496 80’ X 10’ Platform 60,900 lb.
* The Association of American Railroads (AAR)
** These Item Numbers are now obsolete, replaced by the Item Numbers to the left.
04/12 10 50538 Rev. 7
1-C: Rails & Anti-Creep Devices
The Scale is designed to accept a 115 lb. rail with Foster #62 rail clip. The approach rails
and Scale Weigh Rail should be the same weight. The approach anchor bolts, approach rail
plates, rail clips, and anti - creep devices are all optional items. They can be supplied by
Fairbanks Scales when ordered as accessories, otherwise they are not supplied.
Positive means must be provided by others to prevent the creeping of the approach rails and
to maintain a clearance which shall be not less than 1/8 inches or more than 5/8 inches
between the approach rails and the weigh rails. Switch points are highly recommended for
this purpose. A minimum of seventy five (75) feet of tangent track at each approach is
required by the A.A.R.
50538-2
Rail
Weldment
Anti-creep devices are constructed of angle iron with a flat iron weldment to fit to the rail as
shown above, The rail is side drilled through its web and bolted to the anti - creep device,
effectively securing it from any movement.
The AAR Scale Specifications state that the rail on the approach and the weighbridge shall be
properly anchored to prevent creeping of the rails. This is done in order to maintain the proper gap between the approach rail and the weighrail.
Rails should be miter cut at the ends of the weighrails and approach rails to assure a smooth
transfer of wheels in order to reduce impact loading to the scale.
NOTE: It is strongly recommended that any anti-creep device(s) be installed by qualified rail-
road maintenance and repair service personnel.
45
3/8 inch gap
1
2
50538-3
04/12 11 50538 Rev. 7
1-D: Regulations:
This Scale is designed and manufactured in accordance with regulations established by
Handbook 44 as adopted by the National Conference of Weights and Measures (NCWM), the
Association of American Railroads (AAR), and the National Institute of Standards and
Technology (NIST). If the Scale is intended to provide weights to the serving railroad for the
purpose of revenue, it shall be installed, repaired, tested, and maintained in accordance with
the Association of American Railroads Scale Handbook, which contains the rules and specifications for the construction and maintenance of track scales for the weighing of railroad vehicles.
Excerpts from the Association of American Railroads Scale Handbook
Location: Scale shall be so located that an adequate foundation and at least 75 feet of
tangent track at each approach to the weighrails can be provided.
Elevation:
In areas with poor drainage, the scale shall be raised to such an elevation that
drainage of the surface water shall be away from it. Means shall be provided to prevent
accumulation of water at the scale site. Solutions for saturated areas with poor drainage shall
be determined by a competent soils engineer.
Drainage:
The pit floor shall be pitched to a common point for drainage and shall be
smooth and free from pockets in which water may stand. If the pit floor is below substrate
water lever, the pit shall be drained from its lowest point into a sump adequately equipped
with automatic means for removal of water as it collects.
Footing or Piers for loadcells:
Concrete footings or piers supporting load cell base plates
shall not be less than 18 inches thick. Their tops shall be above the floor a sufficient distance
to prevent the accumulation of water around or under the base plates.
Pit floor: The floor of the pit may be a mat of concrete approximately as thick as that
required to support the load cell base plates or, if local conditions permit, the thickness may
be reduced to no less than 6 inches.
Ventilation:
All scale pits shall be ventilated to meet the needs of each particular case to
minimize the relative humidity in the pit and to retard corrosion of scale parts and structural
steel.
Entrance to the Scale Pit:
Suitable access to the Scale pit shall be provided. The entrance
shall be closed by a suitable closure fastened to prevent the entry of unauthorized persons.
AAR Scale Handbook
Safety Piers:
Suitable piers, columns, or other supports should be provided to prevent
excessive drop of the girders if there should be a failure of other Scale parts. Clearance
should be maintained at full scale capacity.
04/12 12 50538 Rev. 7
Bearing Pressures Under Foundations: The bearing areas of the foundation footings
shall be such that the pressure under the footings will not exceed:
For fine sand and clay .................................. 4,000 lb. per square foot
For coarse sand or hard clay ....................... 6,000 LB per square foot
For boulders or solid rock ........................... 20,000 LB per square foot
If the soil does not have a bearing capacity of at least 4,000 pounds per square foot, and its
bearing capacity cannot be increased by drainage, stabilization, or other means, pile foundations shall be provided. Careful soil exploration, including borings, is always desirable.
Leveling:
Load cell assemblies shall be raised or lowered, as required, by means of leveling screws, shims, or other methods to bring the weighbridge into level traversely and on
grade longitudinally. After leveling the load cell baseplates, to a tolerance of not more than
1/64” per foot, they shall be grouted as required.
Scale House Design:
Except where the indicating elements are mounted in a separate
building, a Scale house large enough to install, observe and service the indicating elements
shall be provided. It should have windows of sufficient size and so located as to give the
weigher an unobstructed view of the Scale deck and approaching cars or trucks.
Where a special scale house is required, a suitable and substantial building shall be provided. To insure proper operation of the indicator and/or recorder, the house shall be equipped
with proper environmental control.
Scale House Location:
The lateral clearance between the Scale house and centerline of
Scale or any track shall not be less than 8 feet, unless otherwise required by law, or the serving railroad.
Indicator - Recorder Shelf: If a shelf is required for mounting the indicator and/or recorder, it
shall be so located as to provide for ease of operation without obscuring the weigher's view
of the Scale deck and approaching cars or trucks. The shelf must not limit ready access to
the instrument for maintenance purposes.
Power Source
The power source of the electronic instrumentation and load cell circuitry
shall conform to the following:
Voltage - 115 v AC +/- 10 v
Frequency - 60 Hz, +/- 0.25 Hz
The power source must be reasonably free from harmonics and electrical transients.
Fusing shall be provided at 15 amp unless otherwise specified by the manufacturer.
The power source shall be a separate circuit back to the distribution transformer.
One side of the 115 v power source shall be at a ground potential.
Power surge protection shall be provided for load cells and instrumentation circuit.
Adequate protection of shielding should be provided to eliminate radio frequency and electromagnetic interference. The scale must satisfy the tolerance requirements when the scale
equipment is subjected to RFI and EMI influences.
04/12 13 50538 Rev. 7
Cabling:
All cabling between loadcells, junction boxes, and electronic instrumentation shall conform to
the following:
All cable shields shall be interconnected and carried to a single ground. This should be a separate ground from the power source ground and be provided for the loadcells and instrumentation circuits only. It should be a copper rod which, when possible, is driven to the depth of
the water table.
The connection between the ground rod and the common ground point of the load cell and
instrumentation circuits shall be made with copper wire, or the equivelant, of No. 10 gauge or
larger.
All cable shields in the load cell circuits shall be grounded at one end only.
Homerun cables shall be physically separate from power cables and never run in the same
conduit system.
(NOTE: A 24 inch to 36 inch separation is required by Fairbanks Scales)
All cable connections, junction boxes, etc., in the load cell circuits shall be properly protected
against the effects of moisture.
All multi - conductor cabling shall be color - coded, or provided with other means of identification of the individual conductors.
1-E: Foundation Construction & Installation
Use only certified prints that are marked for the particular installation, customer, and scale.
All the dimensions indicated on the certified prints must be rigidly and faithfully followed during all phases of construction. There is very little tolerance for misplacements and mistakes.
Pier heights are especially critical as there must be enough space for finishing grout under all
stands (per certified drawings) while rails on the scale weighbridge and approach rail must be
absolutely level.
Placement of foundation bolts is absolutely critical to the successful installation of the scale.
The use of a template or form that matches the design called for can be used. Foundation
bolts must NOT be installed at an angle, too deep, or too shallow. Very close tolerances must
be met on all aspects of pit construction.
04/12 14 50538 Rev. 7
1-F: Ground Rods:
Ground rods are essential in providing protection to the electronic components and loadcells
from both lightning surges and static discharges. Pit ground rods shall be tied to the foundations steel reinforcement rod (rebar) prior to pouring, and shall protrude 4 inches above the
pit floor.
Ground rods for approach rails shall be installed in the approach rail cut-outs and tied to the
rebar assembly. Fairbanks provides the three ground rods located in the pit as part of the
standard foundation kit. The two ground rods in the approach must be provided by others.
There are five (5) rods with the locations specified as below:
One (1) ground rod at each end, in the approach rail-cuts, for approach rail grounding. *
One (1) ground rod at each end, in the pit, for steel weighbridge grounding. *
One (1) ground rod at the pit load cell conduit location for the pit power supply. *
The following drawing shows correct placement of ground rods.
1-G: Load cell Base Plates:
The Load cell base plates are the foundation upon which the scale structure rests, and their
level, accurate position is basic to the entire structure. Base plates must be installed at proper
height and in the same plane. All base plates must be level within 1/64” per foot. All pier bolts
must have enough height to allow vertical adjustment of the base plate's, but not so high as
to interfere or to have insufficient depth into the pier.
* Fairbanks provides the three (3) ground rods located in the pit as part of the standard
foundation kit. The two (2) ground rods in the approach must be provided by others.
Top View of Scale
#2
#4
#5
#3
#1
= Ground Rod
In Pit Floor
In Pit FloorIn Pit Floor
Conduit
In approach rail cutout
Supplied by others
In approach rail cutout
Supplied by others
#4 & #5 Ground Rods Not supplied or Installed by FAIRBANKS
50538-4
04/12 15 50538 Rev. 7
1-H: Check Stands:
Check rods allow for vertical movement in order to transfer weight force to the load cells but
they do not allow for lateral or side movement. Checking stands must be level and on the
same plane. All check rods must be level within 1/100” per foot when weighbridge is at correct elevation. Grouting the check stands MUST NOT take place until the load cell base
plates are adjusted to their final height.
1-I: Weighbridge:
The weighbridge supports the loads applied to it, and transfers that weight to the load cells.
Properly installed, this transfer allows the load to be shared by all cells and keeps loading in a
vertical direction. For both safety and expediency, it is recommended to assemble the weighbridge steel in sections outside of the pit, then setting the assembled sections into the pit one
at a time with a suitable capacity crane.
The weighbridge must be square and the main girders must be vertically plumb so that the
bottoms of the main girders are level. Do NOT weld the "X" bracing at the ends of the weighbridge or use impact wrench on steel structure bolts until girders are in place and are plumb.
Main beams must be joined at sections so that the top flanges are level to accommodate the
track rails with full contact support without shimming. Due to steel manufacturing tolerances,
the height of the main beams may be slightly unequal making the bottom flanges uneven. If
shims are required, place between the stiffener plate and the main girder. Full contact shimming is required for stiffener plates. Shims are not supplied with the scale hardware. The
resulting upper stiffener plate and top bearing plate must be level within 1/64” per foot.
1-J: Deck Construction:
The construction of the deck will cover the areas alongside and in-between the main beams
and Rails, and will provide a custom fitted concrete deck for motor truck and vehicle weighing.
All concrete workmanship shall be performed in accordance with the best practice as
described by the American Concrete Institute. The recommended slump is four to six inches
(4" to 6").
Allow concrete to cure thoroughly. Do not use, or subject the deck to any traffic until the concrete has attained its ultimate compressive strength of 3000 psi after 28 days.
The steel supplied for the deck construction is precut at the factory to fit an exact dimension
pit, as indicated on the prints.
04/12 16 50538 Rev. 7
1-K: Load Cell Flexure Assembly:
The Load cell flexure assemblies maintain the load cells in a vertical position. In application,
the design uses a 200,000 lb capacity compression load cell mounted in a support assembly.
The support assembly contains an upper flexure assembly protected by a wear plate, and
weight(s) applied to the scale are transferred to them from the top bearing plate assembly.
Support Assembly
Shims (as required)
Main Girder
Stiffener Plate
Top Bearing Plate Assy
Wear Plate
Lower Bearing Plate
Spacer (4)
Lower Button
Lower Flexure
Load Cell Spacer
Load Cell
Upper Button Bearing Assy
Upper Flexure Assy
Base Plate
50538-5
The flexure assembly isolates any lateral movement of the main girder from the top of the
load cell. This arrangement allows the cell to remain vertical under all loading conditions, and
to minimize the side-load effects of thermal expansion and contraction of the weighbridge.
04/12 17 50538 Rev. 7
Section 2: Installation:
2-A: General Service Policy
Prior to installation, it must be verified that the equipment will satisfy 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.
Overview:
1. These instructions apply to the Scale Platform only; installation procedures for instrumenta-
tion, printers and other peripherals are given in manuals specifically provided for those units.
The instructions include a pre-installation checkout, which must be performed before the
installation.
2. All electronic and mechanical calibrations and or adjustments required to make this equipment perform to accuracy and operational specifications are considered to be part of the
installation, and 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.
3. Absolutely no physical or electrical modifications are to be made to this equipment.
Electrical connections other than those specified may not be performed, and no physical
alterations (mounting holes, etc.) are allowed.
4. The installing technician is responsible to make certain that personnel are fully trained and
familiar with the capabilities and limitations of the equipment before the installation is considered complete.
2-B: 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 to install the equipment.
1. Has the customer's application been checked to make certain that it is within the capabilities and design parameters of the equipment?
2. If the installation will disrupt the customer's normal operations, is he aware and has he
made arrangements?
3. Is properly-grounded power available at the installation location?
4. Will the equipment operator(s) be available for training?
04/12 18 50538 Rev. 7
5. Has the service technician thoroughly reviewed the installation procedures?
6. Has the service technician reviewed the recommended setup with the Area Sales Manager
or Area Service Manager, and identified all necessary variations to satisfy the customer's particular application?
2-C: Unpacking:
1. Check that all components and accessories are on hand, and agree with the customer's
order.
2. Remove all components from their packing material, checking to make certain that all parts
are accounted for and no parts are 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.
3. Collect all necessary installation manuals and prints, including Certified Prints, for the
Scale being installed.
2-D: Safety:
As is the case with any material handling equipment, certain safety precautions should be
observed during operation:
1. Never load the platform beyond its rated capacity. Refer to the rating on the serial number
plate if in doubt.
2. Ensure that any structure which supports the platform is capable of withstanding the weight
of the platform plus its rated capacity load.
3. Do not load the platform if there is any evidence of damage to the platform or supporting
structure.
4. 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 load receiver.
5. Do not leave the platform unattended when it is loaded.
Loading...