Page 1
Installation Manual
3500 Series Yellow Jacket
Mild Steel Floor Scale
51233
© 2009-2010 by Fairbanks Scales, Inc. Revision 4 11/10
All rights reserved
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Page 3
Amendment Record
3500 SERIES MILD STEEL FLOOR SCALE
Document 51233
Manufactured by Fairbanks Scales, Inc.
821 Locust
Kansas City, Missouri 64106
Created 12/09 Created Document
Revision 1 12/09 Document Release
Revision 2 01/10 Added NTEP number to Appendix II. Format corrections.
Revision 3 07/10 Corrected bumper guard part number.
Revision 4 11/10 Page 22 - corrected part numbers
11/10 3 51233 Rev. 4
Page 4
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.
Fairbanks Scales shall not be liable for any loss, damage, cost of repairs, incidental or consequential
damages of any kind, whether or not based on express or implied warranty, contract, negligence, or
strict liability arising in connection with the design, development, installation, or use of the scale.
© Copyright 2009-2010
This document contains proprietary information protected by copyright. All rights are reserved; no part
of this manual may be reproduced, copied, translated or transmitted in any form or by any means
without prior written permission of the manufacturer.
11/10 4 51233 Rev. 4
Page 5
Table of Contents
SECTION 1: GENERAL INFORMATION .................................................................. 6
Introduction .......................................................................................................................... 6
Description ........................................................................................................................... 6
SECTION 2: COMPANY SERVICE INFORMATION .................................................. 7
General Service Policy ........................................................................................................ 7
Overview .............................................................................................................................. 8
Physical Installation Notes .............................................................................................................. 8
Conferring with Our Client............................................................................................................... 8
Pre-Installation Checklist ................................................................................................................ 9
Unpacking ....................................................................................................................................... 9
Equipment Checkout ..................................................................................................................... 10
Users’ Responsibility ..................................................................................................................... 10
SECTION 3: SCALE INSTALLATION ...................................................................... 11
Installing the Scale ....................................................................................................................... 12
Platform Interface Cable Wiring .................................................................................................... 12
Calibration Steps ........................................................................................................................... 13
SECTION 4: INSTALLING ACCESSORIES ............................................................ 15
Installing Bolt-Down Plates ........................................................................................................... 15
Installing Ramps ........................................................................................................................... 16
Installing Bumper Guards ............................................................................................................. 16
SECTION 5: PARTS REPLACEMENT ..................................................................... 17
Load Cell Replacement Steps ...................................................................................................... 17
Load Cell Specifications ................................................................................................................ 18
Junction Box Replacement Steps ................................................................................................. 19
Foot Assembly Replacement Steps .............................................................................................. 19
SECTION 6: PARTS ................................................................................................. 20
Parts List ....................................................................................................................................... 20
Parts Diagram ............................................................................................................................... 21
APPENDIX I: LOAD CELLS ..................................................................................... 22
APPENDIX II: SPECIFICATIONS ............................................................................. 23
APPENDIX III: ACCESSORIES ................................................................................ 24
Ramps and Bumper Guards ......................................................................................................... 24
Bolt-down Plates, Eyebolts and Hole Plugs.................................................................................. 24
11/10 5 51233 Rev. 4
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Section 1: General Information
INTRODUCTION
The 3500 Series Floor Scale uses a summing junction box for interfacing to all
analog weight instruments.
NOTE: It is the owner's responsibility to document, notify, and follow-up regarding
shipping damage with the carrier.
DESCRIPTION
The scale platform is shipped in a crate, fully assembled and wired.
The floor scale size is 4’ x 4’ (both smooth and safety tread).
The floor scale capacities range from 2.5k to 5k (lbs).
Both scale types are equipped with a 30 foot interface cable.
All models have threaded holes in the deck for attaching eyebolts to facilitate
installation and cleaning.
NOTE: Specifications and sizes are shown in Appendix II.
11/10 6 51233 Rev. 4
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Section 2: Company Service Information
GENERAL SERVICE POLICY
Prior to installation, always verify that the
equipment satisfies the customer's
requirements as supplied, and as described
in this manual.
If the equipment cannot satisfy the application and the application cannot be
modified to meet the design parameters of the equipment, the installation
should NOT be attempted.
It is the customer/operator's responsibility to ensure the
equipment provided by Fairbanks is operated within the parameters
of the equipment's specifications and protected from accidental or
malicious damage.
WARNING
Absolutely NO physical, electrical, or program modifications
other than selection of standard options and
accessories can be made to this equipment by customers.
Repairs performed by Fairbanks Scales service technicians
and authorized distributor personnel ONLY!
Failure to comply with this policy
voids all implied and/or written warranties.
11/10 7 51233 Rev. 4
Page 8
Section 2: Company Service Information
OVERVIEW
Physical Installation Notes
Check all devices for proper operation. If any error messages occur, refer to
Troubleshooting or the proper manual of that device.
Only those charges which are incurred as a result of the equipment's
inability to be adjusted to performance specifications may be charged to
warranty.
No physical alterations (mounting holes, etc.) are allowed during installation.
The installing technician is responsible that all personnel are fully
trained and familiar with the equipment's capabilities and
limitations before the installation is considered complete.
All electrical assemblies must be replaced as assemblies or units.
─ Replacement of individual components is not allowed.
─ These components must be returned intact for replacement credit per normal
procedures.
All electronic and mechanical adjustments are considered to be part of the
installation, and are included in the installation charge(s).
─ Included is any required computer programming or upgrades.
─ Included are any accuracy and/or operational specification changes.
The AC receptacle / outlet shall be located near the Instrument and easily
accessible.
Electrical connections other than those specified may not be performed.
Conferring with Our Client
The technician must be prepared to recommend the arrangement of components
which provide the most efficient layout, utilizing the equipment to the best possible
advantage.
The warranty policy must be explained and reviewed with the customer.
11/10 8 51233 Rev. 4
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Section 2: Company Service Information
Pre-Installation Checklist
The following points should be checked and discussed with the Area Sales Manager
and/or customer, if necessary, before the technician goes to the site and installs the
equipment.
Check the customer's application to make certain it is within the capabilities and
design parameters of the equipment.
If the installation process might disrupt normal business operations, tell the
customer and ask that they make ample arrangements.
Be sure that the equipment operator(s) are available for
training.
The service technician reviews the recommended setup with
the Area Sales Manager or Area Service Manager, and
together they identify all necessary variations to satisfy the
customer's particular application.
Unpacking
Follow these guidelines when unpacking all equipment:
Check in all components and accessories according to the customer's order.
Remove all components from their packing material, checking against the invoice
that they are accounted for and not damaged.
Advise the shipper immediately, if damage has occurred.
Order any parts necessary to replace those which have been damaged.
Keep the shipping container and packing material for future use.
Check the packing list.
Collect all necessary installation manuals for the equipment
and accessories.
Open the equipment and perform an inspection, making
certain that all hardware, electrical connections and printed
circuit assemblies are secure.
Do not reinstall the cover if the final installation is to be
performed after the pre-installation checkout.
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Section 2: Company Service Information
Equipment Checkout
Position the equipment with these points in mind:
Intense direct sunlight can harm the display.
Do not locate near magnetic material or equipment/Instruments which use
magnets in their design.
Avoid areas which have extreme variations in room temperatures. Temperatures
outside the Instrument’s specifications will affect the weighing accuracy of this
product.
Do not load the platform if there is any evidence of damage to the platform or
supporting structure.
Users’ Responsibility
All electronic and mechanical calibrations and/or adjustments required for making
this equipment perform to accuracy and operational specifications are considered
to be part of the installation.
─ They 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.
Absolutely no physical, electrical or program modifications other than selection of
standard options and accessories are to be made to this equipment.
The equipment consists of printed
circuit assemblies which must be
handled using ESD handling
procedures, and must be replaced as
units.
─ Replacement of individual
components is not allowed.
─ The assemblies must be properly
packaged in ESD protective material
and returned intact for replacement
credit per normal procedures.
11/10 10 51233 Rev. 4
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Section 3: Scale Installation
Installing the Scale
2. Select a location that is flat, solid, level, and one that fully supports the weight of
the platform plus a full capacity load.
3. Remove the top of the crate and all packing material.
4. Screw two (2) eyebolts into the threaded adapters in the platform top.
5. Use a forklift or other lifting means, along with chains, cables, or nylon straps to
remove the scale from the crate bottom.
TWO TYPES of EYE BOLTS
Closed Gap Eyebolts
Open Gap Eyebolts (NOT USED)
Lifting Hooks (NOT USED)
CAUTION
DO NOT use hooks or unclosed eyebolts.
Failure to use proper lifting tools
may result in personal injury.
6. Set the scale so that the interface cable exits in a direction where it can be
protected.
─ If possible, use a cable protector to reduce 'trip' hazards and to protect the
interface cable from being damaged.
7. Level the scale using a screwdriver to turn the threaded 'leg' of the foot assembly.
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Section 3: Scale Installation
INSTALLATION, CONTINUED
8. Wire the scale cable to the proper type instrument, as shown in the chart below.
9. Once the scale platform is completely wired to the instrument, calibrate the unit.
─ Follow the appropriate instrument service manual to ensure a good calibration.
Platform Interface Cable Wiring
WIRE COLOR FUNCTION
Black (─) Excitation
Red (+) Excitation
Yellow Shield
Green (+) Signal
White (─)Signal
11/10 12 51233 Rev. 4
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Section 3: Scale Installation
s
p
s
Calibration Steps
Adjust the analog interface instrument to the platform.
Adjust all the corners to within one (1) division of each other at 25% of
rated capacity.
Follow the appropriate instrument service manual to ensure a proper calibration.
STEPS
1. Remove the two inside bolts on the side of the scale and remove access panel,
exposing the quick-access potentiometers.
─ Total number of turns is twenty.
Quick-acces
otentiometer
1
+S-SSH-E+E
1
RV1
1 2
2
-E -SSH +S+E
SW1 SW2 SW3
234
1
OPEN
1
+SIG
Inside bolts
Outside bolts
-SIG
+E -E +S-SSH
TB1
TB2
-SEN
SHLD
3
+E SH -S-E
432
1
RV3 RV4RV2
+EXC
+SEN
-EXC
3
1
OPENOPEN
4
+S
Yellow Jacket
summing card
234
4
2. Identify the platform corner numbers.
2
3
3. Place a concentrated weight (25% of platform capacity) on
corner #1, then move it to #2, #3 and #4, noting the displayed
reading on each corner.
1
50612-1
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4
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Section 3: Scale Installation
If corners do require adjustment, complete the following steps:
1. Remove the outside bolts on the quick access plate. This removes the J-box cover.
2. Safely lift scale on its end with forklift or heavy pry bar.
3. In order to adjust the potentiometers, the DIP switches are set as follows:
SW1 = OPEN SW2 = CLOSED SW3 = OPEN
The factory default settings have these switches set to bypass the potentiometers.
4. Center the four Junction Box Potentiometers by turning the adjustment screw
counter-clock-wise position until a clicking sound is heard, then turning each of
them back clock-wise ten (10) turns.
5. Identify the lowest reading, and then place the concentrated weight on this corner.
6. Place the concentrated weight on the corner displaying the lowest weight.
7. Turn the adjustment on the potentiometer clockwise (CW) to the displayed weight
so it reads the same as the highest reading.
8. Repeat this procedure while rechecking all corners until they are equal.
Important Note: When moving the weight(s) from corner to corner, DO NOT
zero the scale. The purpose is to adjust the corners to be the same, and not to
perform a correct calibration.
9. Perform a zero reference check with an unloaded platform.
10. Repeat the corner test to ensure all readings are the same before proceeding.
11. Replace J-box cover with outside bolts, replace quick-access cover with inside bolts,
and perform final calibration using the appropriate instrument’s service manual.
If corners do not require adjustment, complete the following steps:
1. Remove all weights.
2. Zero the instrument.
3. Perform a final calibration with test weights.
4. Follow the appropriate instrument service manual to ensure a proper calibration.
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Section 4: Installing Accessories
Installing Bolt-Down Plates
Bolt down plates are used to keep the scale from sliding or moving when loads are
applied. The plates are bolted using anchors at each of the scales feet.
STEPS
1. Place the platform into the correct position.
2. Place the bolt-down plate under the foot. The plate edge extends out from under
the scale.
3. Drill two (2) 7/16” attachment holes using a hammer drill.
4. Insert anchors with the nut and washer already on them.
5. Tap the anchor into the hole, then tighten the nuts securely.
6. Repeat this process for each plate.
Note: If ramps are not installed and bolt-down plates are needed, then a full set of
four bolt-down plates is required.
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Section 4: Installing Accessories
Installing Ramps
Each mild steel ramp accessory comes with two integral bolt-down plates and four
anchors.
STEPS
1. Place the ramp in position, then lift and set the platform feet into the bolt-down
plate holes.
2. Drill the two (2) 7/16” holes using a hammer drill. Insert the anchors with the nut
and washer already on.
3. Tap the anchor into the hole, then tighten the nuts securely.
IMPORTANT TIPS
If two ramps are installed, then no other bolt-down plates are needed.
If only one ramp is installed, then a set of two bolt-down plates is necessary.
Only two ramps (total) may be installed on opposite sides of a scale platform.
Installing Bumper Guards
Bumper Guards help protect the platform from direct hits from forklift traffic. The
guards are slightly higher than the scale and help deflect the forks.
STEPS
1. Place the bumper guard into a position so it protects the platform from non-scale
traffic.
─ Place the bumper guard so it does not touch or interfere with the platform’s
movement.
2. Drill the 7/16” fastening holes using a hammer drill.
3. Insert the anchors with the nut and washer already on it.
4. Tap the anchor into the hole.
5. Tighten the nuts securely.
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Section 5: Parts Replacement
Load Cell Replacement Steps
1. Cycle-down the power to the instrument, and then unplug the unit.
2. Remove potentiometer cover.
3. Lift the platform end with a forklift or heavy pry bar, using wood blocks for safety.
4. Remove J-box cover.
5. Disconnect the failed load cell cable(s) at the junction box.
6. Loosen the gland bushing, and tie a string or wire to the end of the cable to act as
a pull wire.
7. Place wire markers on the cable ends.
─ Masking tape is an effective alternative
8. Disconnect the faulty load cells wires from the terminal block.
9. Remove the load cell mounting bolts with a 3/4" socket.
10. Remove the load cell, pulling the cable through the scale while leaving the pull
string/wire in the scale.
11. Remove the foot assembly from the old cell, then install it onto the new load cell.
─ Use anti-seize on the threads.
12. Disconnect the pull string/wire from the old cell's cable, then attach to the new
cell's cable end.
13. Pull the cable from the new cell through to the junction box.
14. Mount the cell to the scale platform.
─ Torque it to
15. Connect the load cell wires into the junction box, then tighten the box gland
bushing(s).
16. Lower the scale to the surface removing the safety blocks.
90 ft/lbs, using anti-seize on the mounting bolts.
17. Distribute the scale’s weight evenly by all four (4) feet.
18. Recalibrate the unit as necessary.
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Section 5: Parts Replacement
Load Cell Replacement Steps, Continued
IMPORTANT NOTE: See Appendix I for specific load cell color code and
wiring information.
Load Cell Specifications
DESCRIPTION SPECIFICATION
Material
Rated Output
Impedance
Safe Overload
Compensated Temperature Range
Safe Operating Temperature Range
Mild Steel
3mV/V
350 ohm
150%
-10° C to 40° C
-10° C to 40° C
11/10 18 51233 Rev. 4
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Section 5: Parts Replacement
Junction Box Replacement Steps
1. Remove power to the instrument.
2. Open the platform access cover, then the junction box cover.
3. Loosen all gland bushing nuts.
4. Place wire markers on all the load cell cable ends.
5. Disconnect the load cells' wires from the terminal blocks.
6. Disconnect the homerun wires.
7. Remove the PCB, clean the junction box, then install the new PCB.
8. Reconnect all load cell and home-run wires to the new PCB.
9. Tighten all gland bushing nuts.
10. Replace the junction box cover, and torque all screws to 18-20 in/lbs.
11. Recalibrate the unit as necessary, including corner adjustments.
12. Replace the platform access cover.
Foot Assembly Replacement Steps
1. Lift the platform end with a forklift or heavy pry bar using wood blocks for safety.
2. Using a standard screwdriver, unscrew the foot assembly.
3. Replace the Foot Assembly, using anti-seize on the screws attaching to the load cell.
4. Lower the scale to the surface removing the safety blocks.
5. Distribute the scale’s weight evenly by all four (4) feet.
11/10 19 51233 Rev. 4
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Section 6: Parts
Parts List
ITEM PART NO. DESCRIPTION
1
2
3 54502 Screw, cap, hex hd .50-20 x 1.75 ALL
4 63913 Foot ALL
5 66754 Spacer plate, load cell SST ALL
6 30139 Box, junction ALL
7 30249 Plate, cover ALL
8 11039 Bullseye level ALL
9 15389 Adhesive ALL
10 30063 PCB assy, summing network ALL
11 17814 Tie, wire ALL
12 12838 Cable assy (30 ft. long) ALL
13 11020 Bushing, strain relief ALL
14 -- ALL
15 14828 Screw, sealing SST 10-32 x .75
16 11119 Washer, plain, flat SST No. 10 ALL
17 11103 Nut, hex SST
18 11146 Screw, Mach, PH, Phil SST 6-32 x .38 ALL
19 11191 Washer, lock, Ext. tooth SST No. 6
20 -- ALL
21 30251 Plate, nameplate
22 10106 Nut, hex 10-32 ALL
23 10311 Washer, plain flat No. 10
24 11926 Adhesive (permanent type) ALL
25 See tab Nameplate
28 12189 Seal wire ALL
29 28498 Screwdriver
30 51233 Manual CD (26461) ALL
*See Appendix I for Load Cell wiring information.
See Appendix II
See Appendix I
Platform weldment
Load cell LC1 LC4
SCALE
CAPACITIES
See Appendix II
See Appendix I
11/10 20 51233 Rev. 4
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Parts Diagram
e
Section 6: Parts
13
4" 8"
2"
30330
30329
LOAD CELLPART NUMBER DESCRIPTION NAMEPLATE
30238 (1K)
30238 (1K)
PLATFORM WELDMENT
30133, DIAMOND DECK
30134, SMOOTH DECK
2500 LB CAPACITY30326
0
30332
30331
St. Johnsbury, Vermont
Fairbanks Scales
DATE
11-9-09
11-9-09
11-9-09
30239 (2.5 K)
30239 (2.5 K)
G.A.L.
B. MONAHAN
CAD/GAL
DR.
CH.
APP.
-
-
-
30133, DIAMOND DECK
30134, SMOOTH DECK
-
UNLESS OTHERWISE SPECIFIED
DIMENSIONS ARE IN INCHES (METRIC)
TOLERANCES: FRACTIONS ±
ANGLES ±
3 PLACE DECIMALS ±
2 PLACE DECIMALS ±
5000 LB CAPACITY
6
10
3
TB1
4
SH -S +S-E+E
+S-E -SSH+E
-SEN
-EXC
+SEN
+EXC
E1
17
(E1)
(DOUBLE NUTS)
29
18 19
15 16
+E -E SH -S +S1+E +SSH -S-E
1
RV1
RV2 RV4RV3
7
2
1
TB2
+SIG
-SIG
SHLD
(SHIPPED LOOSE)
6
DETAIL B
VIEW OF SUMMING NETWORK PCB ASSY BEFORE IT
IS FLIPPED OVER AND INSTALLED INTO THE SCALE.
4
9
8
TOP OF DECK PLATE
3500-111
3500-121
3500-211
DETAIL A
5
2
3
4
1
3500-221
MODEL NUMBER
30325 2500 LB CAPACITY
30328
30327 5000 LB CAPACITY
1 OF 1
30325
SHEET
AND
PART NO.
DRAWING NO.
FLOOR SCALE ASSY
4' X 4' 3500 SERIES
1/4
WITH SUMMING NETWORK
D
SIZE
SCALE
TIAL AND IS THE PROPERTY OF
FAIRBANKS SCALES, AND IS NOT
TO BE USED, DISCLOSED, COPIED,
TRANSFERRED OR REPRODUCED
WITHOUT THE PRIOR WRITTEN
PERMISSION OF FAIRBANKS.
THE MATERIAL AND INFORMATION
CONTAINED HEREIN IS CONFIDEN-
-
-
FINISH
MATERIAL
USED ON
3500 SERIES
FLOOR SCALES
APPLICATION
FINAL
NEXT ASSY.
SEE DETAIL A
CORNER NO. 3
CORNER NO. 4
CORNER NO. 2
11
LC-1
LC-2
LC-3
LC-4
E1
CORNER NO. 1
24 25
5
21 22 23
(W1)
12
SEE DETAIL B
Made in U.S.A.
C-O-C
CAN
MAX
H000323CB
MIN
SERIAL
n
CLASS
TEMP
MODEL
CAP
Fairbanks Scales
RATING
TO ASSEMBLING AND TORQUE SCREWS TO 90 FT-LBS.
NOTES:
2. SCREW CONNECTIONS.
1. APPLY ANTI-SEIZE SEALING COMPOUND TO THE SCREWS (ITEM 3) PRIOR
HOLE IN THE TOP OF THE PLATFORM.
3. SHIP ITEMS 28, 29, AND 30 LOOSE WITH THIS SCALE ASSY.
4. INSTALL BULLSEYE LEVEL (ITEM 8) USING ADHESIVE (ITEM 9) INTO THE
5. LOCATE THE NAMEPLATE (ITEM 25) ONTO PLATE (ITEM 21).
THE FOLLOWING: SW2 (ALL 4 OPEN), SW1 (ALL 4 CLOSED), SW3 (ALL 4 CLOSED)
6. SET THE DIP SWITCHED ON THE SUMMING NETWORK PCB ASSY (ITEM 10) TO
11/10 21 51233 Rev. 4
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Appendix I: Load Cells
ITEM PART NO. DESCRIPTION SCALE
CAPACITY
2 30238
2 30239
WIRE COLOR FUNCTION
Black (─) Excitation
Red (+) Excitation
Yellow Shield
Green (+) Signal
White (─)Signal
1K lb Capacity Load Cell
350 Ohm, 3 mV/V, Plated Tool Steel
2.5K lb Capacity Load Cell
350 Ohm, 3 mV/V, Plated Tool Steel
2.5k
5k
11/10 22 51233 Rev. 4
Page 23
Appendix II: Specifications
PRODUCT NO. SIZE CAPACITY
30325 4’ x 4’
30326 4’ x 4’
30327 4’ x 4’
30328 4’ x 4’
2,500 lbs 30133 Diamond
2,500 lbs 30134 Smooth
5,000 lbs 30133 Diamond
5,000 lbs 30134 Smooth
Device Approvals
Platform NTEP CC# 10-008
Load Cell NTEP CC# 06-079, Factory Mutual
PLATFORM
WELDMENT
DECK
11/10 23 51233 Rev. 4
Page 24
Appendix III: Accessories
Ramps and Bumper Guards
SIZE CAPACITY RAMP BUMPER GUARD
4’ x 30”
4’ x 30”
4’ x 30”
4’ x 30”
2,500 lbs 30256 safety tread 30639
2,500 lbs 30257 smooth tread 30639
5,000 lbs 30256 safety tread 30639
5,000 lbs 30257 smooth tread 30639
Bolt-down Plates, Eyebolts and Hole Plugs
SIZE CAPACITY
ALL
ALL 63777 (Set of 4) 70895 (2) 70896 (2)
63779 (Set of 2)
BOLT-DOWN
PLATES
EYEBOLTS
EYEBOLT
PLUG
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Page 26
3500 Series Floor Scale
Manufactured by Fairbanks Scales, Inc.
821 Locust St.
Kansas City, MO 64106
www.fairbanks.com
INSTALLATION MANUAL
DOCUMENT 51233
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