Fairbanks 2000 User Manual

Installation Manual

2000 SERIES

Rocker Column

Railroad Scale

50614

Revision 5 03/10

© 2001-2010 by Fairbanks Scales Inc.

All rights reserved
03/10 2 50614 Rev. 5

Amendment Record

2000 Series

Rocker Column

Railroad Scale

50614

Manufactured by Fairbanks Scales Inc.

821 Locust

Kansas City, Missouri 64106

Created 5/01

Issue #1 5/01 New Product

Issue #2 5/02 Update Part Numbers

Issue #3 6/02 Update Specifications

Issue #4 10/03 Updated entire Manual

Revision 5 03/10 Updated entire manual per engineering and ECO 636.

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.

Table of Contents

Section 1: Introduction

1-A: Introduction & General Description Page 5
1-B: Specifications Page 6
1-C: Rails & Anti-Creep Devices Page 7
1-D: Regulations; Excerpts from the AAR Scale Handbook Page 8
1-E: Foundation Construction & Installation Page 11
1-F: Grout Plates Page 11
1-G: Rocker Column Loadcells Page 11
1-H: Ground Rods Page 11

Section 2: Installation

2-A: General Service Policy & Overview Page 13
2-B: Pre-installation checklist Page 13
2-C: Unpacking Page 14
2-D: Safety Page 14
2-E: Recommended installation sequence Page 15
2-F: Foundation Construction & Installation Page 16
2-G: Foundation Inspection Page 18
2-H: Foundation Inspection Check List Page 19
2-I: Grout plates Page 20

Check brackets Page 21
Centering section Page 23
Loadcell installation Page 23
Leveling & elevation Page 25

Final adjustments Page 26
2-J: Grouting the grout plates Page 28
2-K: Grounding Page 30

Section 3: Maintenance Page 31

Section 4: Parts list Page 32

Appendix

Appendix I: Recommended Tools & Equipment Page 35
Appendix II: Required at the jobsite Page 35
Appendix III: Materials Page 36
Appendix IV: Torque Values Chart Page 36
Appendix V: Tolerances Page 37
Appendix VI: Loadcell specifications Page 37
Appendix VII: Grounding Rod Kit Packing List Page 37
Appendix VIII Concrete & Slump Testing Page 38
Appendix IX: About the AAR, AREMA, & AREA Page 39
Appendix X: 2000 Series J-Box Bracket Accessory Page 40

03/10 3 50614 Rev. 5

Index of Illustrations:

50614-1 Single module end view Page 5
50614-2 Side view Page 6
50614-3 Different wheelbase lengths Page 6
50614-4 Component identification Page 6
50614-5 Anti-creep device Page 7
50614-6 Suggested anti-creep installation Page 7
50614-7 Rail miter gap Page 8
50614-8 Ground rods, Single - Single Page 12
50614-9 Ground rods, Single - Double Page 12
50614-10 Ground rods, Double - Double Page 12
50614-11 Foundation forming Page 16
50614-12 Foundation forming - Pier bolts Page 16
50614-13 Foundation forming - Check posts Page 17
50614-14 Foundation forming - Embedded Posts Page 17
50614-15 Foundation Inspection Checklist Page 19
50614-16 Grout plates Page 20
50614-17 Grout plate detail Page 20
50614-18 Grout plate leveling screws Page 21
50614-19 Check bracket placement Page 21
50614-20 Check bracket adjustment details Page 22
50614-21 Checking bracket - adjustment Page 22
50614-22 Centering the module Page 23
50614-23 Loadcell & hardware list Page 23
50614-24 Loadcell & hardware placement Page 24
50614-25 Loadcell & hardware adjustment Page 24
50614-26 Leveling Page 25
50614-27 Same plane Page 25
50614-28 Adjusting elevation Page 26
50614-29 Final adjustments - Double Page 26
50614-30 Final adjustments - Single Page 27
50614-31 Grout plate forming & grouting Page 28
50614-32 Grout plate forming & grouting Page 29
50614-33 Ground rod locations Page 30
50614-34 Parts list Page 32
50614-35 2000 Series J-Box Bracket Installation Page 40

03/10 4 50614 Rev. 5

03/10 5 50614 Rev. 5

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 2000 Series Rocker Column Railroad Track Scale is a factory assembled, fully electronic
scale available in single 12' 6" long, and double 25' long welded steel modules. The 2000
Series is designed for above ground or shallow pit installation, and is configured to accept a
115# ARR rail. The scale can be configured to accept other sizes of rail as a special order.

50614_1

The design of the 2000 Series Railroad Track Scale incorporates hermetically-sealed, stain­less steel rocker column load cells, each with a capacity of 110,000 lbs. The combination of a
level approach, rocker column load cells, and checking system permits the scale slight move­ment to mitigate the forces applied to it.

Each module features four removable panels for service access. Interface to a Fairbanks
2500 Series Digital Weight Indicator with INTALOGIX technology is standard.
The purchased scale will include the modules, anchor bolts, loadcells, checking system,
smart sectional controllers, power supply, and ground rods.

03/10 6 50614 Rev. 5

Both the combination and placement of the scale modules will accommodate rail cars with dif­ferent wheelbase lengths. A single 12' 6" Module weighs 5000 lbs, and has a Sectional
Capacity of 85 Tons.

1-B: Specifications:

Product # Nominal No of # Load # Ground
& Type Length(s) Capacity Sections Cells Rods

(Supplied by Fairbanks)

91651 Single 12'6" 170,000 lbs 2 4 3
91652 Double 25' 340,000 lbs 3 6 3
91653 Single/Single 12'6" + 12'6" 340,000 lbs 4 8 5
91654 Single/double 12'6" + 25' 340,000 lbs 5 10 5
91655 Double/double 25' + 25' 340,000 lbs 6 12 5

1

2

50614_2

50614_3

1: A single consists of one 12' 6" long pre-assembled module.

2: A double consists of two 12' 6" long modules that are configured to assemble together.
The double is supported by three sections, and is 25' long.

1

2

3

5

4

50614_4

1: Check Brackets limit the platform movement, and the Check Posts serve as safety piers.
2: The Approach column secures the approach rail. It is bolted to the grout plate.
3: Grout plate.
4: Upper & lower bearings are 1" thick, and hardened to Rockwell 50 - 55 C.
5: Stainless Steel, hermetically sealed Rocker Column Loadcell.

03/10 7 50614 Rev. 5

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, rails, 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 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 the purpose. A
minimum of seventy five (75) feet of tangent track at each approach is required by the A.A.R.
(Association of American Railroads).

Rail

Weldment

50614_5

For Ground Strap

Connection

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.

ANTI-CREEP WELDMENT
FOR LIVE RAIL

ANTI-CREEP WELDMENT
FOR APPROACH

10"

1'

1'

10"

C

50614_6

For Ground Strap

Connection

03/10 8 50614 Rev. 5

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.

45

3/8 inch gap

1

2

50614_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
American Association of 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 loadcell 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 loadcell base plates or, if local conditions permit, the thickness may be
reduced to no less than 6 inches.

03/10 9 50614 Rev. 5

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.

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 lb.. 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:

Loadcell 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 loadcell baseplates, to a tolerance of not more than

0.015 inches 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.

03/10 10 50614 Rev. 5

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.

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 loadcell and
instrumentation circuits shall be made with copper wire, or the equivelant, of No. 10 gauge or
larger.

All cable shields in the loadcell circuits shall be grounded at one end only.

Loadcell 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 loadcell 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.

Cables from the loadcells to the first junction box shall be in one unspliced length. Junction
boxes shall be located near the top of the pit but not on the weighbridge. Cabling from the
first junction box to a common master junction box shall be in one length unspliced.

This concludes excerpts from the Association of American Railroads Scale Handbook

03/10 11 50614 Rev. 5

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.

1-F: Grout Plates

The Grout 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 grout plates must be level within .015" 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.

1-G: Rocker Column Loadcells

The 110,000 lb capacity compression loadcells are designed to meet the most stringent
accuracy requirements. They offer total stainless steel construction and complete hermetic
sealing, making them suitable for use in the toughest of environments. They are rated IP 68.

The load cell's Rocker Column design permits it to be self aligning, always returning to its
original plumb, square, and level position after loading and unloading disturbances.

1-H: 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 tied to the rebar assembly. There are five (5) rods
with the locations specified as below:

03/10 12 50614 Rev. 5

The following drawing shows correct placement of ground rods.

Above example #3: Double / Double

1: Clean all ground rod end(s) with abrasive to assure a good electrical connection. Keep all
ground straps untwisted, clear of standing water, with a drip loop, and as short as possible.
Secure the strap to the ground rods with the provided clamp and coat with grease.
Cover the connections to protect from condensation.

2: Connections to the weighbridge are installed by bolting to the provided bracket at the end
of each Scale Module. Scrape / sand enough paint / coating away to make a good electrical
connection, and coat with grease AFTER the connection has been made.

3: Ground rod #5 should be located near the interface conduit. It is used to connect to the
isolated ground of the Pit Power Supply (PPS) Acc 2001-1 only.

4: #1, ,2, 3, 4, and 5 Ground Rods are provided. These should be installed and correctly
connected with ground braid to the Anti-creep assy's with the provided hardware. Refer to
illustrations 50614_5, 50614_6, and Appendix VII. Ground rod connections 6, 7, and 8 are
not shown and are not provided by Fairbanks. Refer to 2-K: Grounding on page 30 for further
details.

2

1

3

4

5

Conduit

Instrument

Conduit to

= Ground Rod

X

between Modules

Single Module

Single Module

50614_8 A

1

45

Conduit

Instrument

Conduit to

= Ground Rod

X

between Modules

Single Module D ouble Module

50614_9 A

2

3

Above example #1: Single / Single

Above example #2: Single / Double

Conduit

Instrument

Conduit to

= Ground Rod

X

between Modules

Double M odule

Double M odule

50614_10 A

1

4

5

2

3

03/10 13 50614 Rev. 5

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?