Fairbanks 9120 User Manual
Disclaimer
very effort has been made to provide complete and accurate information in this manual. However,
E
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 2011-2012
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.
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Table of Contents
Section 1: General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Section 2: Company Service Information . . . . . . . . . . . .
General Service Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Physical Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Conferring with our Client . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pre-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Equipment Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Users’ Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 3: Scale Installation . . . . . . . . . . . . . . . . . . . . . .
A. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
B. Preparation for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
C. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Section 4: Electrical Installation . . . . . . . . . . . . . . . .
A. Analog Junction box – Installation for analog instruments . . . . . . . . . . . . . . 42
B. Wiring SSCs and PPSs for Intalogix™ systems . . . . . . . . . . . . . . . . . . . . . . . 44
Section 5: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scale Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Section 6: Parts & Parts Replacement . . . . . . . . . . . . . .
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Replacing an RC load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Appendix I: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
. . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . 42
. . . . . . . . . . . . . . . 46
. . . . . . . . . . . . . . . . . . 47
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Section 1: General Information
INTRODUCTION
This manual provides general installation and maintenance instructions for the
airbanks Scales’ 9120 Series Omnicell. Almost every installation is different, so
F
please adjust the following information, as needed, for your application.
Specifications, parameters and application notes are included.
This manual is meant to give general instructions for applying the Omnicell
considering its inherent capabilities and limitations; it is not meant to be a scale
design manual. Questions concerning specific applications should be directed to the
appropriate Product manager.
For complete 9120 Series installation you will also need to reference the necessary
instrumentation manual.
DESCRIPTION
Fairbanks Scales Omnicells are a combination of two main components:
• Mo
• Load cell (the actual weight detecting device).
The 9120 Series Omnicells will arrive preassembled, excluding the load cells. This
mounting assembly is specifically designed to be installed without the load cell for
easy installation. Load cell installation is done quickly, just prior to calibration.
The 9120 Series Omnicells are available in standard capacities ranging from 7.5 t to
100 t. (t = metric tonne.) Higher capacities are available, contact the appropriate
Product Manager.
The load cells are constructed from stainless steel and are a rocker-column design.
The mounting assembly is available in either a zinc-plated or cast mild steel or
stainless steel construction.
These Omnicells can be welded to the load carrier and the foundation. Welding
eliminates problems of getting holes on the top and bottom line up. These
assemblies are designed for a welded installation, so welding will not cause any
service issues (load cell replacement).
unting assembly (captivates the load cell and provides means to fasten to
the vessel and flooring).
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Sect io n 1: General I nformation
The 9120 Series can be installed using mechanical fasteners (nuts and bolts). This
installation method eliminates the need for onsite welding.
It can also be a combination of welding and mechanical fasteners. For example, the
top plate can use mechanical fasteners and the base assembly can be welded.
Omnicell systems principle causes of problems are because of mechanical restrictions
to, and interaction with, the weigh vessel. The cause is invariable excessive vessel or
support deflection that needs be identified, if possible, during the design phase.
Close attention should be made to ladders, catwalks, piping, and any items that
restrict deflection of the vessel.
The 9120 Series Omnicells are commercially approved for applications in the U.S.,
however Fairbanks Scales recommends contacting your local Weight and Measures
Office prior to beginning any Omnicell installation that requires commercial approval.
CERTIFICATIONS
NTEP CC: 9
7-078
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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
ully trained and familiar with the equipment's capabilities and
f
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
nstallation, and are included in the installation charge(s).
i
─ Included is any required computer programming or upgrades.
─ Included are any accuracy and/or operational specification changes.
/
• The AC receptacle
accessible.
• Electrical connections other than those specified may not be performed.
outlet shall be located near the Instrument and easily
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.
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+ 74,000
200,000
Installation Considerations
Thorough application review should be conducted before, during and after installation:
Determining Omnicell Capacity - Sizing the Omnicell (general rule) – Take
the overall live and dead load of the vessel. Multiply by 2, then divide by the
number of support points (legs, typically). For example:
4 Legs
,000 lbs – dead load
26
74,000 lbs – live load
26,000
100,000
x 2
÷ 4
50,000 lb for
each Omnicell
Loading – The vessel will have 3, or more, tank legs. The Omnicells should be
level and, under extreme cases, shimmed, so that the load is roughly equal on
each Omnicell.
Flooring - A thorough inspection of the flooring’s deflections must be considered
before installing an Omnicell system. Flooring must be rigid enough to handle the
total load without deflection.
Thermal contraction and expansion – Horizontal vessels, in direct sunlight,
can create thermal expansion issues. The floating rocker column design of the
9120 Series Omnicell easily handles most thermal expansion/contraction issues.
Uplift and lateral constraints – In extreme conditions (high winds or seismic
activity) uplift and lateral stresses on the Omnicell system are a concern and
should be considered when choosing the best Omnicell for the application. The
9120 Series Omnicell provides a degree of built-in uplift and lateral checking,
refer to the product QuickFacts for a detailed explanation of the forces. In
extreme conditions, additional checking is recommended.
Isolate vessel – Many external factors affect the accuracy and stability of
an Omnicell system. Load cell signals can be affected by EMF sources such as
electric forklifts, pumps, motors, etc. A well-isolated tank will provide more
reliable results with fewer problems.
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Eliminate mechanical constraints – The vessel should be fully supported on
the Omnicells. Reduce or eliminate any mechanical issues which will interfere with
the vessel’s deflection, such as: rigid vertical or horizontal piping (use flexible
piping when connecting to the vessel whenever possible), ladders, catwalks, etc.
Orientation – Orientation of the 9120 Series Omnicell isn’t critical because of the
rocker load cell design, however it is recommended positioning the load cell
cables away from traffic areas.
Heated or chilled vessels –
Consult with the appropriate Product Manager for
any application with vessels that heat or chill the product inside the vessel.
In these cases, special consideration may be required to isolate the temperatures.
Load cell cabling – The load cell cables should be routed away from areas
where they could be damaged. Use drip loops at both the load cell and the
junction box ends.
Hazardous area – If the Omnicells will be installed in a Hazardous Area, a
document is required from the end user stating the Class, Division, and Group.
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Section 3: Scale Installation
A. Introduction
Installation consists of the following:
• Foundation check, layout, and mounting assembly installation
• Tools, materials, documentation, and a lifting mechanism (crane or hydraulic jack)
• Installation of the mounting assemblies
• Installation of the rocker column load cells
B. Preparation for installation
1. Tools, equipment, and materials required:
a. Hydraulic jacks -- Use hydraulic jacks that have sufficient capacity plus (+)
a safety factor for the size of the vessels you are installing the Omnicells.
b. Blocking material to support lifted vessel.
c. Determination of how the scale system will be calibrated.
• Calibration weights (Only application method for NTEP system)
i. Get calibration weights on site
ii. Dolly, or other method, for moving weights
iii. Means for lifting calibration weights (chains, Come-Along winch, etc.)
iv. Lifting point on vessel for supporting calibration weights
• Substitution – Product measured by other device (scale, flow meter,
etc.) then used as the calibration weight.
i. Schedule product to arrive when needed
ii. Determine how product will be put into, and removed, from vessel
• MilliVolt calibration with Intalogix Technology
i. Check to make sure the correct equipment was ordered (Q
Series instrument and Quad Multiplexer Board or Flash
Instrument, Smart Sectional Controller and Pit Power Supply)
ii. Load cell calibration sheets
d. Determination of how the scale system will be installed.
• Welded
iii. Arc Welding Machine
iv. Welding Rod
v. Steel Brush
vi. Grinder
vii. Chipping hammer
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