Fairbanks Aegis Xtreme-Duty Floor Scale User Manual

Installation Manual
Aegis Xtreme-Duty Floor Scale
© 2008 by Fairbanks Scales, Inc. Revision 1 11/08 All rights reserved
51206
Amendment Record
AEGIS XTREME-DUTY FLOOR SCALE
Document 51206
Manufactured by Fairbanks Scales Inc.
821 Locust
Kansas City, Missouri 64106
Created 9/08 Created Document Revision 1 11/08 Document Release
Disclaimer
Every effort has bee n made to provide com plete and accurate inform ation in this manual. However, although this manual m ay include a specifically identi fied 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 shal l not be liable f or any loss, damage, cost of repairs , incidental or c onsequential damages of any kind, whether or not based on express or implied warrant y, contract, negligence, or strict liability arising in connection with the design, development, installation, or use the scale.
© Copyright 2008
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.
11/08 4 51206 Rev. 1
Table of Contents
SECTION 1: GENERAL INFORMATION .................................................................. 7
1.1. Introduction ................................................................................................................ 7
1.1.1. Specifications ....................................................................................................................... 7
1.1.2. Accessories.......................................................................................................................... 9
SECTION 2: GENERAL SERVICE POLICY............................................................ 10
2.1. General Service Policy ............................................................................................. 10
2.1.1. Service Technician’s Responsibilities ................................................................................ 11
2.1.2. Users’ Responsibility ......................................................................................................... 11
SECTION 3: SCALE INSTALLATION ...................................................................... 12
3.1. Conferring with Our Client ........................................................................................ 12
3.2. Standard Installation Steps ...................................................................................... 14
3.2.1. Unpacking .......................................................................................................................... 15
3.2.2. Positioning the Scale ......................................................................................................... 16
3.2.3. Positioning Steps ............................................................................................................ 17
3.2.4. Installing the Platform ........................................................................................................ 18
3.2.5. Wiring the Junction Box ..................................................................................................... 20
3.3. Installing Accessories .............................................................................................. 21
3.3.1. Ramp Installation ............................................................................................................... 21
3.3.2. Pillar Installation Steps ...................................................................................................... 22
SECTION 4: SERVICE & MAINTENANCE .............................................................. 23
4.1. General Troubleshooting .......................................................................................... 23
4.2. Scale Platform Troubleshooting ............................................................................... 24
4.2.1. Scale Platform Testing ....................................................................................................... 24
4.2.2. Load Cell Testing ............................................................................................................... 24
4.2.3. Load Cell Replacement Steps ........................................................................................... 25
SECTION 5: PARTS ................................................................................................. 26
5.1. Parts Lists #107979 – 5’ x 5’ X8”, 20K ..................................................................... 26
5.2. Parts List #106966 – 6’ X 8’ X 8”, 40K ..................................................................... 26
5.4. Parts Diagram .......................................................................................................... 27
5.5. Accessory Part Numbers ......................................................................................... 28
5.5.1. Aegis Xtreme-Duty Ramp Assembly .................................................................................. 28
5.5.2. Aegis Xtreme-Duty Pit Frame Assembly ............................................................................ 28
5.5.3. Mild Steel Stand-alone Instrument Pillar ........................................................................... 28
5.3. PLATFORM MODEL MATRIX .......................................................................... 29
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Section 1: General Information
Gene ral Industrial
Heavy-Duty Industr ial
Extremely large fork lifts
Large freight containers
Warehousing
Feature
Description
Standard Platform Sizes
4’ x 4’ thru 6’ x 8’
Custom Platform Sizes
4’ x 2’ thru 12’ x 15’
8” to 9” Diamond Tread
150%
100%
100%
10 to 100%
Meets or exceeds Handbook 44 tolerances
5 to 15 VDC
Less than 3 Ohms to True Earth Ground
1.1. INTRODUCTION
The Aegis Xtreme-duty Scale is an extremely rugged floor scale, designed for high capacities and a wide variation of dimensional sizes. This is because of the additional I-beam supports under the platform that run both along the scale’s “X” and “Y” axis.
It has an extremely low-profile design. The scale’s floor height is 8 or 9 inches, depending on the capacity.
The Aegis Xtreme-duty Scale is designed for applications with high load concentrations.
1.1.1. Specifications
Platform Height Scale Capacities
Overload Capacity Point Loading Endloading Temperatures
Humidity Accuracy Load Cell Excitation Grounding
20,000, 40,000, and 60,000
2,500 up to 95,000
Operating: 10°C to 40°C (14°F to 104°F)
Storage: -20°C to 70°C (14°F to 158°F)
11/08 7 51206 Rev. 1
1.1.1. Specifications, Continued
Feature
Description
Interface Cable
31’ PVC Jacketed
Standard Platform dimensions: 4’ x 4’ thru 6’ x 8. Height: 8” or 9”.
Section 1: Gen er al Information
Scale Construction
Junction Box
Load Cells
Approvals
Type A36 carbon steel
Deck plate – ¼” to ½”
Full I-beam support
Diamond Tread
Watertight Analog
Stainless Steel
NEMA 4X
Four (4) Rocker Column Design
IP69K “True” Hermetically Sealed
17-4 ph Stainless Steel
15,000 to 50,000 Capacity
Combined Error -- +/< 0.02% of Rated Capacity
FM Approved
NTEP Approval CC# 07-097 (for 6,000 divisions)
Load Cell NTEP Approval CC# 07-037
Scale Capacities: 20K, 40K & 60K. Steel Deck: ¼” – ½”. J-Box: NEMA 4X.
11/08 8 51206 Rev. 1
Section 1: Gen er al Information
Aegis Xtreme-Duty Ramp
Stand-alone Instrument Pillar
Flush-Grade Pit Frame
1.1.2. Accessories
Available modifications and accessories include the following:
11/08 9 51206 Rev. 1
Absolutely NO physical, electrical or program modifications other
Section 2: General Service Policy
2.1. 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 par a m e ters of the equipment's speci fi c a ti ons and pr ot ec t e d fr om ac c idental or malicious damage.
than selection of standard options and accessories can be made by customers to this equipment
Repairs are performed by Fairbanks Scales Service Technicians and Authorized Distri but or P er s onne l ONLY!
WARNING!
Failure to comply with this poli c y voids al l im pli e d a nd/or written warranties
11/08 10 51206 Rev. 1
Section 2: General Servic e P olicy
2.1.1. Service Technician’s Responsibilities
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 original installation.
They are included in the installation charge. Only those charges which are incurred as a result
of the equipment's inabi lity to be adjusted or calibrated to per for ma nc e spec ifications may be charged to warranty.
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.
2.1.2. Users’ Responsibility
Absolutely no physical, electrical or program modifi cations ot he r
than selection of standard options and accessories are to be made to this equipment.
11/08 11 51206 Rev. 1
Section 3: Scale Installation
3.1. 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.
Assist the customer in selecting a site which allows easy access to and from the scale, ensuring enough area for straight and level approaches, if applicable.
The site needs good drainage away from the scale, elevated enough so the
surrounding areas drain away from the scale.
Obtain all the necessary permits and licenses prior to beginning construction.
Explain and review the warranty policy with the customer.
The installing technician is responsible that all per sonnel a re fully trained and familiar wit h the equipment's capabilities and limitations before the installation is considered complete.
All electrical assemblies must be returned intact for replacement credit using the standard procedures.
At the time of installation, all electr o ni c and mech ani cal adj ustments are considered to be part of the installation, and are included in the installation charge(s).
The AC receptacle/outlet shall be located near the Indicator and easily accessible.
Electrical connections other than those specified may not be performed.
11/08 12 51206 Rev. 1
Section 3: Scale Installation
 
All load cells, load cell cables and interconnecting cables used to connect all scale components shall be located a minimum of thirty-six (36”) inches
distance away
electric current carrying conductors.
This includes digital weight indicators, junction boxes, sectional controllers, and power supplies.
This includes any peripheral devices, such as printers, remote displays, relay boxes, remote terminals, card readers, and auxiliary data entry devices.
Also included is the scale components themselves, such as 120 volt AC, 240 volt AC, 480 volt AC and electric supply of higher voltage wiring runs and stations, AC power transformers, overhead or buried cables, electric distribution panels, electric motors, florescent and high intensity lighting which utilize ballast assemblies, electric heating equipment, traffic light wiring and power, and relay boxes.
IMPORTANT INSTALLATION NOTICE  
from all single and multiple phase high energy circuits and
All scale components, including digital weight indicators and peripheral devices are not des igned to operate on internal combustion engine driven electric generators and other similar equipment.
Electric arc weld i ng can severely damage scale components such as digital
weight indicators, junction boxes, sectional controllers, power supplies, and load cells.
NOTE: For additional information, please contact your Fairbanks Scales
Service Representative.
11/08 13 51206 Rev. 1
Section 3: Scale Installation
3.2. STANDARD INSTALLATION STEPS
The Aegis Xtreme-Duty Scale Platform is shipped fully assembled and wired. The standard scale installation consists of the following steps.
Unpack the Scale, and any components.
Selecting the best Platform Site Location.
Connect lifting straps or chains to the lifting lugs on the sides of the platform,
then move it to the designated site using a crane.
Install the Ramps (if applicable).
Level the Platform.
Install and wire the Instrument to the Platform.
Adjust and Calibrate the Scale according to the appropriate Indicator Service
Manual.
11/08 14 51206 Rev. 1
Section 3: Scale Installation
3.2.1. 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 damag e d .
 Advise the shipper immediately, if damage has occurred.  Keep the shipping container and packing material for future use.  Order any parts necessary to replace those which have been damaged.  Check the packing list.
The CUSTOMER is the receiving party if the equipment was shipped to the Customer’s address.
FAIRBANKS is the receiving party if the equipment was shipped to the
Fairbanks Service Center.
Collect all necessary installation manuals for the
equipment and accessor i es.
Open the equipment and perform an inspection, m aking
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.
Do not load the platform if there is any evidence of damage
to the platform or supporting structure.
NOTE: It is the owner's responsibilit y to document, notify, and follow-up
regarding shipping damage with the carrier.
11/08 15 51206 Rev. 1
Section 3: Scale Installation
3.2.2. Positioning the Scale
Position the Scale with these points in mind:
Use the proper lifting equipment to position and place the scale. The scale is to be placed on a flat, solid, level surface, one that fully supports the
weight of the platform plus a full capacity load.
The smooth surface must be within 1/8”, and on a level plane, within ¼” across
both the length and width of the platform.
The four corners of the Platform must rest solidly on the surface, and not rock.
Irregular bumps and foreign material under the Platform can cause an “out-of­level” condition, which will affect the weight accuracy.
Platform vibrations ma y also affect the weighing accuracy. Wherever possible,
locate the platform as far away from heavy, low frequency vibrations as much as possible.
Do not load the platform if there is any evidence of damage to the platform or
supporting structure.
Ease of access is very important. Allow plenty of room for maneuvering a fork lift. Reading the Indicator is also important to workers, so place it in a very visib le
position.
When installing the Scale and Indicator in an outdoor location, set it up so the
snow, ice accumulation, rain and other conditions do not affect the platform operations.
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Section 3: Scale Installation
To lift and move the Platform, place strap hooks into brackets
3.2.3. Positioning Steps
1. Position the Scale into its final location.
2. Place the hooks of the straps or chains into the specific lifting points of the Scale. The straps or chains should be long enough to f orm a minimum 45° angle
with the platform while lifting.
on each side of it, and also into each hole of the ramp.
3. Place the platform in the desired location.
The platform should be made stable and level. Shims are not included with the platform and must be supplied locally as
needed.
11/08 17 51206 Rev. 1
Section 3: Scale Installation
3.2.4. Installing the Platform
1. Remove the four (4) triangular cover plates, found on each corner.
2. Remove the nut from the shipping bolts in each corner.
3. Drill and secure the platform using the supplied ¾” wedge anchors.
4. Adjust the checking bolts to a 1/16” to
1/8” clearance.
11/08 18 51206 Rev. 1
Section 3: Scale Installation
Bolts
Anchor
3.2.4. Installing the Scales, Continued
5. Verify that the platform is plumb, square and level.
If Ramps are to be installed, do it at
this time.
6. Replace the nut on the shipping bolt, then loosen it two (2) full threads.
7. Replace the four (4) triangular cover plates, found on each corner .
8. Calibrate the unit according to the appropriate indicator service manual.
Checking
Shipping Bolts
Wedge
11/08 19 51206 Rev. 1
Section 3: Scale Installation
WIRE COLOR
FUNCTION
3.2.5. Wiring the Junction Box
Load Cells are preinstall ed, pl um be d, and pr e-wired to the Junction Box at the factory, prior to shipping.
Dip Switches are not set. Interconnecting cables are not installed.
1. Open the platform access cover, then the junction box cover.
2. Loosen all gland bushing nuts.
3. Wire the Indicator to Junction Box according to the chart below.
4. Follow the indicator installation manual to properly connect it with the platform.
5. Tighten all gland bushing nuts.
IMPORTANT NOTE: Leave the Junction Box Cover off until all corner
adjustments are completed.
Red White (+) Signal Black Green (+) Excitation Yellow Ground
() Signal
() Excitation
11/08 20 51206 Rev. 1
Sect ion 3: Scale I ns ta llation
CAUTION
Aegis Xtreme-Duty Ramp
Stand-alone Instrument Pillar
Intrinsically Safe Controllers
Smart Sectional Controllers
Flush-Grade Pit Frame
Intalogix Technology (QMB)
3.3. INSTALLING ACCESSORIES/MODIFICATIONS
Listed below are the standard Aegis Xtreme-Duty Scale Accessories.
Absolutely NO ARC WELDING i s t o be perform e d on, or ne ar this scale while the Load Cells are in pl a c e and/ or c onne c t e d.
Disconnected and removed ALL the Loa d Ce lls during ANY welding.
3.3.1. Ramp Installation
The ramps are optional, and used different ways in varied applications.
Each ramp has two (2) bolt down tabs, one on each side.
1. Place the ramp against the platform frame The ramp’s slot is fits inside the scale’s
lifting point.
Level and stabilize the ramp against the platform. Shims are not included with the ramps and must be
supplied.
2. Drill and anchor the ramp(s) using the supplied 3/4” wedge
anchors.
Up to four (4) ramps can be installed on the
Xtreme-duty Scale
, one on each side.
Aegis
11/08 21 51206 Rev. 1
3.3.2. Pillar Installation Steps
1. To remove the Top Plate, loosen the three (3)
one quarter inch (¼”) Allen Screws.
2. Carefully run the Interface Cable into the bottom Access Hole, up through the Pillar, and then thread it out through the top Access Hole.
Allow extra cable slack to accommodate the
Instrument wiring.
3. Replace the Top Plate, then secure it into position using the one eighth inch (1/8”)
Allen Wrench
4. Install the Instrument Top Bracket, secure it with the supplied hardware
.
Section 4: Servi ce & Maintenance
5. Connect the Interface Cable to the Indicator. Refer to the appropriate instrument service
manual for correct wiring information.
11/08 22 51206 Rev. 1
Section 4: Service & Maintenance
4.1. GENERAL TROUBLESHOOTING
From the following chart, identify the symptom(s) and cause(s) of each malfunctio n, solving each issue with an appropriate solution.
SYMPTOM CAUSE SOLUTION
Displays stay at zero
Erratic Weights
Inaccurate Weights
1. Load Cell connections faulty.
2. Instrument faulty.
3. Faulty/bad Load Cell(s).
1. Foreign object around load cells, ramps, or under platform.
2. Excessive vibration near platform.
3. Instrument faulty.
4. Platform not level wit h in ¼ ” (3 .0°).
5. Surface not smooth enough (within 1/8”).
6. Faulty/bad Load Cell(s).
1. Instrument out of span.
2. Instrument not properly adjusted to zero.
3. Faulty/bad Load Cell(s).
1. Cable replacement.
2. Service Instrument.
3. Test and replace the Load Cell(s) as shown in
1. Clear the area.
2. Remove the vibration source.
3. Service Instrument.
4. Level the platform surfac e.
5. Find a smoother surface for the platform.
6. Test and replace the Load Cell(s) as shown in
1. Check and alter per the Instrument Service Manual.
2. Zero the instrument according to normal operation procedures.
3. Test and replace the Load Cell(s) as shown in
Section 4.2.3.
Section 4.2.3.
Section 4.2.3.
11/08 23 51206 Rev. 1
Section 4: Servi ce & Maintenance
4.2. SCALE PLATFORM TROUBLESHOOTING
Except for severe structural damages, most Platform Assembly problems can be traced to the following causes.
Material under or around the Platform.
Broken Load Cell receiver cups..
Faulty Load Cells.
4.2.1. Scale Platform Testing
1. Inspect the Interface Cable from the Platform to the Instrument f or visible breaks or cracks.
2. ZERO the Instrument Display.
3. Apply a test load of
25% of the Load Cell capacity to one corner.
The Instrument should display a weight reading within 0.1% of the applied
weight, or One Instrument Division, whichever is greater.
4. Repeat Step 3 for all the corners, placing the same Test Load on each corner.
4.2.2. Load Cell Testing
When corners do not match the correct tolerances, unsolder each Load Cell Cable, then test each Load Cell for the settings on the following chart.
TEST READING REMARKS
Green to Black (Input) 1106 Ohms (+5 / -2 Ohms) Input Resistance Red to White (Output) 1000 Ohms (+5 / -2 Ohms) Output / Bridge Resistance Yellow (Shield) to Load Cell Case Input and Output Leads to Shield Input and Output Leads to Case
More than 1,000 megohms Insulation Resistance
.
11/08 24 51206 Rev. 1
Section 4: Servi ce & Maintenance
4.2.3. Load Cell Replacement Steps
1. Cycle-down the power to the indicator, then unplug the unit.
2. Remove the platform and junction box access covers.
3. Loosen the gland bushing, and tie a string or wire to the end of the cable to act as
a pull wire.
4. Place wire markers on the cable ends.
Masking tape is an effective alternative
5. Disconnect the faulty load cells wires from the terminal block.
6. Lift the platform end with a forklift or heavy pry bar, using wood blocks for safety.
7. Remove the load cell, pull i ng the cable through the scale while leaving the pull
string/wire in the scale.
8. Remove the defective load cell from the receiver cups , then install the new load
cell. Use a lubricant on the O-rings.
9. Disconnect the pull string/wire from the defective load cell's cable, then attach to
the replacement load cell's cable end.
10. Pull the cable from the new cell through to the junction box.
11. Lower the scale to the surface removing the saf ety blocks.
12. Distribute the scale’s weight evenly on all four (4) load cells..
13. Connect the load cell wires into the junction box, then tighten the box gland
bushing(s).
14. Replace the platform ac ces s cov er .
11/08 25 51206 Rev. 1
PART No.
1 1 107972
PLATFORM WELDMENT, X-TREME
2 1 107978
FRAME WELDMENT
3 2 107701
BASE PLATE W/LOWER CUP
4 2 107702
BASE PLATE W/LOWER CUP
5 4 105718
UPPER CUP W/O ANTI-ROTATION
6 1 67171M
J- BOX ASSY. SS
7 4 108120
3 ½” RC L/C /, 15k
8
12
61743
CLAMP BAR
9 4 54555
¾”–10 x 3 ½” HEX HEAD CAP SCREW
10
16
54264
¾” HEX NUT
11 1 83861
WEDGE ANCHOR BOX
12
STICKER, FAIRBANKS SCALES
13
13
54406
½”-13 x ¾” LG FLAT HEAD SOCKET
14 4 54233
¾” FLAT WASHER
15 4 107797
SHIM, .01 x 1 ½” ID x 2 1/8” OD
16 4 107798
SHIM, .03 x 1 ½” ID x 2 1/8” OD
17 4 72967
FULL THD BOLT, ¾”- 10 x 5” LG
18 4 54218
FULL THD BOLT, ¾”- 10 x 3” LG
PART No.
1 1 106975
PLATFORM WELDMENT, X-TREME
2 1 107976
FRAME WELDMENT
3 2 107701
BASE PLATE W/LOWER CUP
4 2 107702
BASE PLATE W/LOWER CUP
5 4 105718
UPPER CUP W/O ANTI-ROTATION
6 1 67171M
J- BOX ASSY. SS
7 4 108121
3 ½” RC L/C /, 30k
8
12
61743
CLAMP BAR
9 4 54555
¾”–10 x 3 ½” HEX HEAD CAP SCREW
10
16
54264
¾” HEX NUT
11 1 83861
WEDGE ANCHOR BOX
12
STICKER, FAIRBANKS SCALES
13
13
66979
½”-13 x 1” LG FLAT HEAD SOCKET
14 4 54233
¾” FLAT WASHER
15 4 107797
SHIM, .01 x 1 ½” ID x 2 1/8” OD
16 4 107798
SHIM, .03 x 1 ½” ID x 2 1/8” OD
17 4 72967
FULL THD BOLT, ¾”- 10 x 5” LG
18 4 54218
FULL THD BOLT, ¾”- 10 x 3” LG
Section 5: Parts
5.1. PARTS LISTS #107979 – 5’ X 5’ X 8”, 20 K
ITEM QTY
DESCRIPTION
5.2. PARTS LIST #106966 – 6’ X 8’ X 8”, 40K
ITEM QTY
DESCRIPTION
11/08 26 51206 Rev. 1
5.4. PARTS DIAGRAM
Section 5: Parts
11/08 27 51206 Rev. 1
108440
Aegis Xtreme-Duty Pit Frame, 4’ x 4’
108441
Aegis Xtreme-Duty Pit Frame, 4’ x 8’
108442
Aegis Xtreme-Duty Pit Frame, 5’ x 5’
108443
Aegis Xtreme-Duty Pit Frame, 6’ x 6’
108444
Aegis Xtreme-Duty Pit Frame, 6’ x 8’
5.5. ACCESSORY PART NUMBERS
5.5.1. Aegis Xtreme-Duty Ramp Assembly
Part No. Description
108413 Aegis Xtreme-Duty Ramp Assembly, 4’ ramp 107988 Aegis Xtreme-Duty Ramp Assembly, 5’ ramp 107307 Aegis Xtreme-Duty Ramp Assembly, 6’ ramp 108415 Aegis Xtreme-Duty Ramp Assembly, 8’ ramp
5.5.2. Aegis Xtreme-Duty Pit Frame Assembly
Part No. Description
Section 5: Parts
5.5.3. Mild Steel Stand-alone Instrument Pillar
Part No. Description
28396 Stand-alone Pillar Assembly, Mild Steel
28392 MS Base Plate 28561 MS Base Plate Su ppor t 28760 MS Top Plate As sy 27787 MS Pillar Weldment 12777 Foot
11/08 28 51206 Rev. 1
108400
4’ x 4’
108401
4’ x 8’
107979
5’ x 5’
20,000 lbs
108402
6’ x 6’
108403
6’ x 8’
108404
6’ x 6’
40,000 lbs
106966
6’ x 8’
108409
6’ x 6’
5.3. Platform Model Matrix
PRODUCT NO. SIZE CAPACITY
20,000 lbs 20,000 lbs
20,000 lbs 20,000 lbs
40,000 lbs 60,000 lbs
108410 6’ x 8’
60,000 lbs
11/08 29 51206 Rev. 1
Manufactured by Fairbanks Scales, Inc.
Aegis Xtreme-Duty Floor Scale
821 Locust Kansas City, MO 64106
www.fairbanks.com
INSTALLATION MANUAL
DOCUMENT 51206
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