Fairbanks Tundra Series Truck Scale User Manual
© 2008-2012 by Fairbanks Scales, Inc.
INSTALLATION MANUAL
Tundra Series
Truck Scale
All rights reserved
51193
Revision 5 12/12
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 2008-2012
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.
12/12 3 51193 Revision 5
AMENDMENT RECORD
Tundra Series Truck Scale
Installation Manual
Document 51193
Manufactured by Fairbanks Scales, Inc.
821 Locust Street
Kansas City, MO 64106
Created 8/2008
Revision 1 11/2008 Documentation Release
Revision 2 03/2010 Updated parts list to include checking
Revision 3 08/2010 Corrected drawing 51193-4 to 51193-4a
Revision 4 04/2012 Updated drawings and images. Added magnet to parts list.
Revision 5 12/2012 Updated parts list; new images, pages 9, 38, 40, and 47.
12/12 4 51193 Revision 5
Table of Contents
SECTION 1: GENERAL INFORMATION .................................................................................................................................. 7
1.1. Scale Descriptions .................................................................................................... 7
1.2. Scale Applications ..................................................................................................... 7
1.3. Component Descriptions .......................................................................................... 8
1.3.1. Weighbridge ......................................................................................................................... 8
1.3.2. Deck ..................................................................................................................................... 8
1.3.3. Scale Pit ............................................................................................................................... 9
1.3.4. Smart Sectional Controllers (SSCs) .................................................................................... 9
1.3.5. Load Cells .......................................................................................................................... 10
1.4. Component Specs ................................................................................................... 11
1.4.1. Load Cell Specifications .................................................................................................... 11
1.4.2. Platform Specifications ...................................................................................................... 11
1.5. Options ..................................................................................................................... 12
1.6. Accessories ............................................................................................................. 12
SECTION 2: COMPANY SERVICE INFORMATION ......................................................................................................... 13
2.1. General Service Policy ............................................................................................ 13
2.1.1. Service Technician’s Responsibiliti es ................................................................................ 14
2.1.2. Users’ Responsibility.......................................................................................................... 14
SECTION 3: PRE-INSTALLATION ....................................................................................................................................... 15
3.1. Conferring with Our Client ...................................................................................... 15
3.2. Pre-Installation Checklist ........................................................................................ 15
3.3. Unpacking ................................................................................................................ 16
3.3.1. Physical Installation Notes ................................................................................................. 17
3.4. Tools, Equipment and Materials............................................................................. 17
3.4.1. Measuring, Testing & Checking Equipm ent ...................................................................... 17
3.4.2. Assembly Tools .................................................................................................................. 18
3.4.3. Materials ............................................................................................................................ 18
3.5. Precautions .............................................................................................................. 20
3.5.1. Welding .............................................................................................................................. 20
3.5.2. Load Cell Installation Precautions ..................................................................................... 21
3.5.3. Load Cell Handling............................................................................................................. 21
3.6. Site Inspection ......................................................................................................... 22
3.6.1. Pit/ Foundation ................................................................................................................... 22
3.6.2. Scale House ....................................................................................................................... 22
SECTION 4: SCALE INSTALLATION ................................................................................................................................... 23
4.1. Standard Installation Steps .................................................................................... 23
4.2. Inspecting the Contractor’s Pit Construction ....................................................... 24
4.3. Weighbridge Section Assembly ............................................................................. 24
4.3.1. Proper Bolt Torque............................................................................................................. 25
4.3.2. Torque Chart ................................................................................................................... 26
4.4. Moving the Assembled Sections............................................................................ 27
4.5. Installing Base Plates, and Locator Tools ............................................................. 28
12/12 5 51193 Revision 5
Table of Contents
SECTION 4: SCALE INSTALLATION, CONTINUED
4.6. Completing Scale Construction ............................................................................. 29
4.7. Concrete Deck Forming and Pouring .................................................................... 32
4.8. Replacing the Locator Tools with Load Cells ....................................................... 34
4.9. Mounting the Weighbridge Components .............................................................. 35
4.9.1. SSC, PPS, or Balance Box Mounting ................................................................................ 35
SECTION 5: ELECTRICAL INSTALLATION .......................................................................................................................36
5.1. Wiring Information ................................................................................................... 36
5.1.1. Maximum Cable Lengths ................................................................................................... 36
5.2. Electronic Component Care ................................................................................... 36
5.2.1. Protection Against Hostile Environments........................................................................... 37
5.2.2. Tightening O-rings ............................................................................................................. 38
5.3. Load Cell Numbering............................................................................................... 39
5.4. Smart Sectional Controller (SSC) to Load Cell Wiring ......................................... 40
5.4.1. RC Load Cell Wiring .......................................................................................................... 40
5.5. Power Supply Wiring ............................................................................................... 41
5.6. Indicator to Pit Power Supply Cable Connection ................................................. 42
5.7. Grounding the Scale ............................................................................................... 43
5.8. Indicator and Accessories. Test and Calibration ................................................. 44
SECTION 6: SERVICE & MAINTENANCE ......................................................................................................................... 45
6.1. Recommended Preventive Maintenance Schedule .............................................. 45
6.1.1. Performed every month .................................................................................................. 45
6.1.2. Performed every six (6) months ......................................................................................... 45
6.2. Component Replacement Steps............................................................................. 46
6.2.1. Rocker Column Load cell replacement .............................................................................. 46
6.2.2. SSC Board Replacement ................................................................................................... 47
6.2.3. Pit Power Supply PC Board Replacement ........................................................................ 47
SECTION 7: PARTS ................................................................................................................................................................ 48
7.1. Scale Parts List ........................................................................................................ 48
7.2. Load Cells and Hardware ........................................................................................ 48
7.3. O-Rings ..................................................................................................................... 49
APPENDIX I: INTALOGIX WIRING .................................................................................................................................. 50
APPENDIX II: FOUNDATION CHECK LIST ........................................................................................................................ 53
APPENDIX III: PIT DRAWING ............................................................................................................................................. 54
12/12 6 51193 Revision 5
SECTION 1: GENERAL INFORMATION
1.1. SCALE DESCRIPTIONS
The Tundra Truck Scale is a fully electronic Pit Type Truck Scale.
• This field-assembled unit has a pour-in-place concrete deck.
• Concrete approaches are also required according to H44 Standards.
1.2. SCALE APPLICATIONS
• Asphalt & concrete plants • Aggregate yards • Coal mines
• Dairy farms • Farmer’s markets • Grain plants
• High volume applications • Landfills • Ports of entry
• Timber Mills • Transfer stations • Transportation companies
12/12 7 51193 Revision 5
Section 1: General Information
1.3. COMPONENT DESCRIPTIONS
1.3.1. Weighbridge
The weighbridge is constructed of structural steel beams which bolt together. The
weighbridge is supported by the load cells and bearing plates, and includes checking
devices to limit excessive longitudinal and lateral platform movements.
1.3.2. Deck
The platform deck is constructed of reinforced concrete, as detailed on the
Certified Drawing Specifications.
─ The concrete deck is six inches (6”) thick.
─ Concrete is typically poured over corrugated steel, which rests on the
weighbridge and is contained by a steel channel frame.
─ One or more manholes may be provided for access to the scale pit (optional).
12/12 8 51193 Revision 5
Section 1: General Information
1.3. COMPONENT DESCRIPTIONS, CONTINUED
1.3.3. Scale Pit
The scale pit is constructed of reinforced
concrete as detailed on the Certified
Drawing Specifications.
• The Tundra Scale requires a four foot
(4’) or deeper foundation.
─ Some states require a minimum of
four feet (48”) pit depth. Consult
with the local W&M for specifics in
your area.
• The pit includes correctly positioned
piers with level surfaces for RC type
load cell base plates.
• The ground rod(s) should be installed
before the pit floor is poured.
• This System uses Intalogix™
Technology, and requires two (2) pit ground rods.
1.3.4. Smart Sectional Controllers (SSCs)
The Smart Sectional Controllers (SSCs) used on Intalogix™ Applications are mounted
at each section using the supplied self-tapping screws and should be placed on the
cross members at installation.
• Each Sectional Controller has four (4) water-tight gland bushings for cables.
• The Pit Power Supply(ies) are mounted in the same manor.
─ Wiring diagrams for Sectional Controller(s) and Pit Power Supply(ies) are
in Appendix I.
12/12 9 51193 Revision 5
Section 1: General Information
1.3. COMPONENT DESCRIPTIONS, CONTINUED
1.3.5. Load Cells
The load cells directly support the weighbridge. The Tundra Truck Scale uses the
Rocker Column (RC) type Load Cell.
─ The RC cells are 5 1/2” tall.
─ The Load Receiver is free-floating design.
─ The platform is free to move within the clearances provided by adjustable
checking.
─ With weight applied or empty, the platform must stay in, or return to the
original position.
─ The load cells are calibrated with the cable attached, and therefore the cable
should NOT be cut.
─ Load cells and sections are adjusted within the Intalogix™ Equipment
Indicator.
12/12 10 51193 Revision 5
Section 1: General Information
66,000 lbs.
Rocker Column (RC Cells)
water-tight gland bushings
17-4 PH (1.3448)
NEMA 6P (IP68)
≤0.02%
1.0%
5 to 15 VDC
300%
15’
Factory Mutual (FM) Approved
Custom sizes also available.
45 tons to 135 tons
60,000 and 90,000 CLC
66,000 lbs
Field Pour Concrete
Structural Steel
6” thick
NTEP CC #06-112
1.4. COMPONENT SPECS
1.4.1. Load Cell Specifications
Capacity
Type
Sealing
Material
Rating
Resistance
Operating Temperature
Output
Combined Error
Zero Balance (FSO)
Excitation
Ultimate Overload
Cable Length
Cable Protection
Approvals
5.5” Electrochemically Polished Stainless Steel
Glass-to-Metal Connection Points, complete
hermetic sealing; cable entry sealed by four (4)
Stainless Steel
1,000 Ohms
-10 to +40°C (-14 to 104°F)
2.0 mv/v
Stainless Steel Sheathing
NTEP CC# 97-078
1.4.2. Platform Specifications
Deck Dimensions
Scale Capacity
CLC
Load Cell Capacity
Sections
Deck Construction
Module Construction
Deck Thickness
Approval
Widths: 10’, 11’ and 12’ Standard
Lengths: 10’ to 120’ Standard
─
2 thru 7
12/12 11 51193 Revision 5
Section 1: General Information
1.5. OPTIONS
• Dump through deck • CLC up to 100,000
• Factory assembled with factory
poured concrete deck
• Steel deck • Galvanized weighbridge
• Structural grating
• Custom design to fit existing
foundations
1.6. ACCESSORIES
• Remote weight displays • Instrumentation
• Intrinsically safe electronics • Remote terminal
• Ticket printers • Traffic signals
• Manholes
12/12 12 51193 Revision 5
Absolutely NO physical, electrical or program modifications other
SECTION 2: COMPANY SERVICE INFORMATION
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 parameters
of the equipment's specifications and protected from accidental 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 Distributor Personnel ONLY!
WARNING!
warranties
12/12 13 51193 Revision 5
Failure to comply with this policy voids all implied and/or written
Section 2: Company Service Information
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 inability to
be adjusted or calibrated to performance specifications 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
modifications other than
selection of standard options
and accessories are to be
made to this equipment.
12/12 14 51193 Revision 5
SECTION 3: PRE-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, and to meet all
State and Local Weights and Measures Regulations.
─ Smooth and level approaches are required at each end of the platform to
reduce loading shock, and to facilitate testing of the scale.
─ 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.
─ In the absence of such laws, the approaches must conform to paragraph
UR.2.6 of the National Institute of Standards and Technology Handbook
44, which states that the first 10 feet must be level and on the same plane as
the scale platform.
• The platform should be visible from the instrument location.
─ Surface water must drain easily, and not collect, under the scale.
• Explain and review the warranty policy with the customer.
3.2. 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.
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.
NOTE: Always… “CALL BEFORE YOU DIG”. 1-888-258-0808
12/12 15 51193 Revision 5
Section 3: Pre-Installation
All beams and channels come in banded bundles.
3.3. 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.
▪ 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 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.
Do not load the platform if there is any evidence of damage to the platform or
supporting structure.
12/12 16 51193 Revision 5
Section 3: Pre-Installation
3.3.1. Physical Installation Notes
• Before installation, check that all components are in good condition.
─ If damage occurs due to shipping, order the new part or component
immediately.
• 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.
IMPORTANT NOTE: The installing technician is responsible that all personnel
are fully trained and familiar with the equipment's capabilities and limitations bef or e
the installation is considered complete.
3.4. TOOLS, EQUIPMENT AND MATERIALS
The following tools, equipment and materials are suggested to be on hand
before the installation begins.
Certified Project Drawing Specifications
3.4.1. Measuring, Testing & Checking
Equipment
• Surveyor's Transit and Rod
• Plumb Bob
• Stringline and a chalkline
• 50 to100' steel tape measure.
• Machinist’s Levels (Starrett #134 & 132-6)
• Carpenter's Level
• Multimeter
12/12 17 51193 Revision 5
Loading...