It is essential that all instructions in
this manual be followed precisely to
ensure proper operation of the equipment.
LD3 and LD360s are trademarks
of Venture Measurement Company , LLC
97-1137-01
Rev E
Feb 2006
Page 2
NOTICE
The content of this document is the intellectual property of Kistler-Morse. Any reproduction or translation
of this document without the written authorization of a Kistler-Morse officer is prohibited.
CAUTION
Follow these rules if welding is done on the vessel after installation of the Load Disc. The electrical current
of the welder may pass through the Load Disc, causing damage to the transducer and possibly to the signal
processor. To avoid damage, follow these precautions:
1. Disconnect the Load Disc cables from the signal processor.
2. Ground the welder as close to the welding joint as possible. The welding ground must be between the
Load Disc and the weld joint to prevent the welding current from going through the Load Disc to earth
ground.
Note
High temperatures can damage the Load Disc. If you are welding in the vicinity of a Load Disc,
monitor the temperature of the metal adjacent to the Load Disc. If it becomes too hot to touch, stop
welding immediately and remove the Load Disc before continuing. Prior to reinstalling the Load
Disc, verify that no damage has occurred by referring to the measurement procedures in Troubleshooting, Appendix C.
About this manual ............................................................................................................................................ i
Manual Conventions.................................................................................................................................. i
Factors That Affect Performance..................................................................................................................2-3
Chapter 3. Mounting the Load Disc ....................................................... 3-1
General Information......................................................................................................................................3-1
Check Load Disc General Installation ..........................................................................................................3-2
Leveling and Shimming ................................................................................................................................3-5
Leveling/Shimming using Universal Top Adapter Plate (1,000 - 7,500 lbs ONLY) ...............................3-5
Leveling/Shimming using Leveling Top Adapter Plate (1,000 - 7,500 lbs ONLY) .................................3-6
Leveling/Shimming using Leveling Base Adapter Plate.........................................................................3-6
Leveling/Shimming using Anyadapter Plate...........................................................................................3-6
Stainless Steel Junction Box Mounting and Wiring......................................................................................3-7
This chapter describes the organization, manual conventions,
and provides specification information.
Welcome
About this manual
This manual describes the installation of the Load Disc load cell and its
various hardware options. It includes procedures for leveling and shimming
of the vessel if it is neccessary . Instructions for wiring the load cell to the
junction boxes and wiring the junction boxes together and to the signal
processor are also included. Refer to the signal processor manual for specific
information on wiring the junction boxes to the signal processor.
Contact KM at 1-800-426-9010 if you have any questions regarding the
installation. For outside the USA and Canada, call 864-574-2763.
The chapters are organized in the following way:
Chapter 1:Description of the Load Disc
Chapter 2:Preparing the Load Disc for Installation
Chapter 3:Mounting the Load Disc
Appendix A through D include contact info, system calibration, troubleshooting charts and technical drawings (TI’s).
Manual Conventions
Three kinds of special explanations appear throughout the manual —
Warning , Caution and Note. The format and significance of each is
defined below:
WARNING
Possible danger to people. Injury may result if this information is
ignored.
CAUTION
Possible risk to the product. The Load Disc or other equipment may
be damaged if this information is ignored.
Note
Contains additional information about a step or feature critical to the
installation or operation of the Load Disc.
i
Page 6
Introduction
Specifications
LD3 LD360s
Mechanical
Compression4 x Rated Load
Tension1 x Rated Load
Shear0.5 x Rated Load
Functional Integrity2 x Rated Load (compression)
T emperature Range
Standard Temperature Range0° to 100°F (-18° to 38°C) 0° to 100°F (-18° to 38°C)
Mid Temperature Range50° to 150°F (10° to 66°C) 50° to 150°F (10° to 66°C)
Temperature Sensitivity Change±0.015% rated load per degree ±0.015% rated load per degree
Fahrenheit over the Fahrenheit over the compensated
compensated range, 0° to 100°F range, 0° to 100°
Temperature Zero Shift0.006%/°F (0.011%/°C) 0.006%/°F (0.011%/°C)
Humidity100% 100%
Storage Temp Range-Std and Mid-40° to 176° F (-40° to 80°C) -40° to 176°F (-40° to 80°C)
RatingNEMA -6P (include NEMA -4X NEMA -6P (include NEMA -4X
and NEMA -6); hermetically and NEMA -6); hermetically sealed
sealed for high pressure caustic for high pressure caustic washdown
washdown and prolonged and prolonged submergence in water
submergence in water. (Cable (Cable must be installed and
must be installed and tightened tightened to meet rating.)
Physical
Construction17-4 PH 900 stainless steel 17-4 PH 900 stainless steel
ConnectionNickel plated brass body with a 6P rated sealed 5-conductor 12mm
Shipping Weight5.0 lbs (2.3 kg) 5.0 lbs (2.3 kg)
to meet rating.)
polymide insert and neoprene male receptacle Turck Eurofast
Grommet. 22 AWG 3 conductor compatible
unshielded with PVC sheath
(15’ standard)
4 x Rated Load
1 x Rated Load
0.5 x Rated Load
2 x Rated Load (compression)
ii
Page 7
Chapter 1: Description of the Load Disc
Chapter 1:
Description of the Load Disc
This chapter describes the Load Disc Compression Load Cell
and its installation options.
Introduction
Figure 1-1:
Load Disc Compression Load
Cell with optional NEMA-6P
cable system
weight/4
weight/4
Figure 1-2:
General installation layout for Load Disc
using a junction box.
Load Disc
(x4)
junction box
signal
processor
weight/4
weight/4
Signal
transmission/
Serial Output
Setpoints for
signaling a change
in staus, such as
high and low
alarms
The Load Disc is a low profile load cell that is bolted to both the support
surface and the vessel supports, and is used to measure the weight of materials
in vessels and tanks. The sealed, stainless steel construction–NEMA-6P rated
unit with watertight cable system and cable entry–makes the Load Disc ideal
for use in high-pressure wash down and occasionally submerged environments.
The low-profile design for low clearance installations also keeps the vessel’s
center of gravity low and stable. Vessel tipping, walking or overturning while
agitating is eliminated. Installation and setup is simplified with less hardware.
No external vessel hold-downs are necessary, even in areas of high wind or
seismic activity. There are no moving parts that can wear out or require
replacement. The high output of the semiconductor sensor allows immunity to
industrial electrical noise and longer “load cell to signal processor” runs.
General Description of Measurement System
The deflection of the Load Disc load cell by the vessel weight is measured by
the semiconductor sensor, which is entirely sealed within the watertight cavity
of the transducer. The sensor converts the deflection into an electrical signal
which is directly proportional to the increase or decrease of the vessel
contents. Material movement and changes in material repose will not affect
the accuracy of the system. Accurate weight information is then sent to a
signal processor for display, information transmission and storage (See Figure
1-2).
Applications Description
The watertight design of the Load Disc load cell makes it ideal for measuring
bulk material in the sanitary and clean-in-place environments. It is particularly suitable for use on mixing and blending vessels, surge hoppers, and
agitated vessels. Rugged, solid, bolt-in-place mounting assures vessel
stability in outdoor storage vessels with gussets or legs used in all process
industries.
1-1
Page 8
Chapter 1: Description of the Load Disc
Installation Option Descriptions
This section will briefly describe the following hardware options
for the Load Disc:
Universal Top Plate Adapter, Leveling Top Plate Adapter,
Anyadapter Plate and Leveling Base Adapter Plate.
See Chapter 2 and 3 for more specific installation instructions and
refer to the TI drawings located in Appendix D.
Universal T op Adapter Plate
This option consists of the Universal T op Adapter Plate, spring washer
and a hex head bolt. The adapter plate attaches to the load disc with the bolt
and washer. The adapter plate then bolts to a vessel gusset or a flat plate
welded to the vessel leg, using customer-supplied hardware.
Note: Accomodates up to thr ee
degrees of tilt in the floor or
vessel legs.
1-2
Page 9
Chapter 1: Description of the Load Disc
Leveling T op Plate Adapter
This option consists of the Universal T op Adapter Plate, a hex head bolt,spherical washer set and jam nuts. The adapter plate attaches to the load disc
with the hex bolt and hardware. The adapter plate then bolts to a vessel gusset or
a flat plate welded to the vessel leg, using customer-supplied hardware.
This hardware arrangement allows 360
degree movement of the top plate and
angular misalignment of up to 3 degrees.
Additionally , there is a leveling feature that
allows vertical height adjustments. This
arrangement also incorporates a locking-jam
nut to insure the height remains unchanged.
(1,000 - 7,500 lb capacity ONLY)
Anyadapter Plate
This option consists of the unique Anydapter Plate which
has a universal bolt pattern (to fit a variety of vessel leg
flanges), and a hex head bolt. The plate attaches to the
load disc with the bolt and washers. The Anyadapter plate
then bolts to a vessel gusset or a flat plate welded to the
vessel leg, using customer-supplied hardware.
This hardware arrangement allows 360 degree movement of the top plate and angular misalignment of up to
3 degrees. Additionally, there is a leveling feature that
allows vertical height adjustments. This arrangement
also incorporates a locking-jam nut to insure that the
height remains unchanged.
(1,000 - 7,500 lb capacity ONLY)
1-3
Page 10
Chapter 1: Description of the Load Disc
Leveling Base Adapter Plate
This kit consists of a Leveling Base Adapter Plate and four hex bolts, flatwashers, and lock washers. The Load Disc bolts onto the leveling base adapter
plate. This plate rests on four leveling nuts and washers screwed onto anchor
bolts installed in the foundation. By turning the leveling nuts, the height of the
load discs and thus the vessel, can be adjusted for proper load distribution.
Note:
Adapter plate not shown in
illustration at right.
This kit requires an adapter
plate for proper installation.
1-4
Page 11
Chapter 2: Preparing for the Load Disc Installation
Chapter 2:
Preparing for the Load Disc Installation
This chapter describes the pre-check procedures for the Load Disc.
Checking the Load Discs before installation will ensure properly
working equipment that will provide accurate monitoring of vessel
contents.
Check Shipment
Perform the following prior to installing the Load Disc:
Check Load Disc Order Items
The following items are included with a typical order for each vessel
(quantities dependent on application):
Load Disc Load Cell
Junction Boxes or Molded Junction Boxes
Top or Bottom Hardware
If any items are needed, contact KM before proceeding. Substituting
parts without KM approval may cause system problems and will void
the warranty.
Note:
A KM signal processor or a
KM Test Meter are required
to set up and install the
system.
V isual Check
Visually inspect all equipment in the order — including Load Discs,
junction boxes, and signal processors — to verify they have not been
damaged during shipment. If any item has been damaged, contact KM
for a replacement.
2-1
Page 12
Chapter 2: Preparing for the Load Disc Installation
Prepare Installation
Equipment
(Customer Supplied)
The following equipment is needed to install Load Discs:
washers, and flat washers to secure Load Disc to
vessel support (if applicable)*
ASTM A-325 (or equivalent strength) anchor
bolts, lock washers, flat washers, and nuts to
secure Load Disc to vessel foundation (if
applicable)*
Vessel Preparation
KM Test Meter or signal processor
Shims (if applicable)
Grout (if applicable)
Digital Multimeter (FLUKE™ or equivalent)
optional
* See TI drawings in Appendix D for the appropriate bolt size.
There are two aspects to successful use of Load Discs — properly
functioning Load Discs and appropriate vessel support
characteristics. Review the following list of error sources, and make
the recommended corrections before you install the Load Discs:
•An inadequate vessel foundation can allow excessive
movement. Ensure the foundation is concrete or steel.
•Hidden load-bearing structures, such as discharge chutes
or plumbing supported by the floor, can reduce loads on
the vessel supports. Install flexible couplings to minmize
this problem.
•Cross-connecting structures, such as catwalks and
manifolds, can transfer loads from adjacent vessels.
Install slip joint or flex couplings to minimize this
problem.
•Shock loads can damage the Load Disc. Install protective
barriers or stops to prevent vehicles from hitting the
vessel supports.
2-2
Page 13
Chapter 2: Preparing for the Load Disc Installation
Factors That Affect Performance
An independent, isolated vessel with no connection to any other vessel or adjacent structure provides the most accurate
results for a weight measurement system. Examples of this type of application are floor scales and truck scales. Connections to other vessels or structures affect accuracy because the transducers interpret strain changes caused by the connecting structures as being caused by changes in the material weight.
Some typical causes of error related to connecting structures and, where applicable, methods for reducing the errors
follow:
• Catwalk
• Hidden load bearing members
• Vessel goes through roof
• Tripper conveyors or deck plating
• Rigid piping connection between vessel and
another adjacent structure
• Poor Foundation
• Flexible Structure
• Uneven Loading
No horizontal run
No horizontal run
Flex coupling
Horizontal run too short for crosssectional area of pipe
Horizontal run length is ok for
cross-sectional area of pipe
Flex
2-3
Figure 2-1:
Examples of typical causes of error.
Page 14
Chapter 3: Mounting the Load Disc
Chapter 3: Mounting the Load Disc
This chapter describes installation and wiring of the
Load Disc and junction boxes. Follow all instructions
carefully to ensur e proper operation of the system.
General Information
The Load Disc has a variety of mounting hardware options that
accommodate almost all possible applications. These general requirements apply to all applications:
• Ensure the surfaces where the baseplates bolt down onto are clean,
smooth, flat, and level, with less than 1° of slope in any direction.
• Ensure vessel legs/gussets are clean, smooth, flat, and level, with
less than 1° of slope in any direction.
CAUTION: If you need to
raise the vessel or one
vessel leg after installation,
loosen the bolts on all Load
Discs to prevent overloading.
• Position Load Disc so the cable cannot be snagged or chafed and
can be easily routed to the junction box.
• When raising the vessel for Load Disc installation, use proper support to prevent the vessel from tipping or falling.
• During installation, carefully distribute the load to ALL Load
Discs evenly. PLACING THE LOAD ON ANY ONE LOAD DISC
MA Y CAUSE DAMAGE.
• Hardware and Bolts —
1. All bolts and hardware to attach the Load Disc to the vessel
and to the foundation are customer-supplied, ASTM A-325
or equivalent. (See TI drawings Appendix D)
2. Use specified hardware and bolt sizes. Using other than the
specified hardware can either reduce strength or overstress
the Load Disc during installation, voiding the warranty.
3. All bolts are kept loose until shimming and leveling is
complete.
• Securing Load Disc after Leveling/Shimming —
Once the weight distribution criteria has been satisfied
(page 3-4) through leveling and/or shimming, complete the installation by tightening the required bolts for your application.
3-1
Page 15
Chapter 3: Mounting the Load Disc
Load Disc
General Installation
Note: Concrete foundation and grouting shown
for reference only. The
concepts apply to all
foundation types.
Anchor bolts supplied
by customer .
This section describes the Load Disc installation procedures for the
following hardware options:
Universal Top Plate Adapter , Leveling Top Plate Adapter , Anyadapter
Plate, and Leveling Base Adapter Plate.
1.Prior to installing the Load Discs, verify that they are the
correct capacity for your application by reviewing the
information engraved on the Load Disc baseplates.
2.If you have not already done so, connect the Load Disc cable to
the KM Test Meter (See pg. C-1). Measure the Load Disc
voltage output. W ith no-load, the preliminary measurement
should be +5mV and -5mV. (This measurement range is used
only to verify the condition of the Load Disc.) If the reading
is significantly outside of this range, consult the factory
before continuing the installation.
3. Raise the vessel.
4.Remove the cable from the KM Test Meter to the Load Disc.
5.Place bolt through center hole of adapter plate and install
hardware for your application
(See Appendix D:TI Drawings)
a.For Universal Top Plate Adapter, install bolt and
plate to the Load Disc, tightening bolt to 5-10 ft-lbs.
b.For Leveling and Anyadapter, install washers and
nuts to the bolt and plate, making sure the washers/
nuts are loosely tightened against plate. Install the
plate assembly to the Load Disc, tightening bolt to
5-10 ft-lbs.
6.For Leveling and Anyadapter applications, adjust plate to
lowest position by lowering jam nut to top of Load Disc and
tighten. Then lower leveling nut to the jam nut.
Figure 3-1: Angular misalignment
3-2
Page 16
Chapter 3: Mounting the Load Disc
7.Inspect the foundation and vessel mounting surfaces that
will mate to the Load Disc plates.
a.Check the mounting hole locations and size on both
the foundation base and the vessel foot pad. (Refer
to the TIdrawings, Appendix D.)
b.Check the surfaces for flatness and angular
misalignment. A baseplate with leveling nuts isrecommended. (See Figure 3-1 below)
8.Mount the Load Disc assembly to the foundation. (See TI
drawings, Appendix D)
a.Gently lower the Load Disc to the foundation. Take care
to align the mounting holes with the foundation
mounting holes/studs.
b.Install the bolts and nuts as required. DO NOT fully
tighten the bolts at this time. Leave a 1/4-inch gap
between the nut and the washer to allow positioning
of the Load Discs. (See Figure 3-2.)
c.Repeat Steps 8a and 8b for the remaining Load Discs.
Figure 3-2: Leave 1/4-inch gap for positioning
Load Disc # No-Load Output Dead Weight OutputOutput Change (mV)
(mV)(mV)(Dead Weight Output - No-Load Output)
9.Re-install the Load Disc cable and record the voltage output at
“no- load” condition now that it is in position.
a.If not already done, connect the Load Disc cable to
the KM Test Meter as seen in Figure C-1
Troubleshooting.
b.Turn on the power to the KM Test Meter and set the
Simulate/T est switch to the T est position.
c.Record the no-load output into Figure 3-3 below or
create your own similar table. See the example chart in
Figure 3-5.
d.Assign a number (1, 2, 3, etc.) to the Load Disc and note
it.
e.Repeat steps c and d for all the Load Discs.
1
2
3
4
Figure 3-3: W eight Distribution Chart: Record YOUR system’s Load Outputs
3-3
Page 17
Figure 3-4: Lower vessel onto
top plate.
Chapter 3: Mounting the Load Disc
10.Mount the vessel to the Load Disc.
a.Lower the vessel gently onto the Load Discs.
(Alignment pins may be used to help guide and
position the vessel.) (See Figure 3-4)
b.Center the Load Disc top mounting holes with the
vessel mounting holes, using the clearance
available from the bottom mounting holes.
Note: If the vessel hole pattern does NOT match up with
the Load Disc hole pattern, modify the mounting holes on
the vessel. DO NOT hammer or for ce the Load Disc into
position by tightening the mounting bolts. The vessel holes
will need to be resized or relocated.
Note: All output changes should
be positive! If you observe a
negative output change, check
wiring polarity and vessel load
shifting.
Note: The example below is an
ideal situation (load is centered). Offcenter loads caused
by offset mixers or gear boxes
will place weight on some
supports more than others. Do
not attempt to shim ALL
supports to ten percent of the
average output. Balance the
support weight between each
other making sure all legs carry
a load.
through the vessel and the Load Disc mounting
holes. The bolts must be able to pass freely
through the holes without interference.
d.Tighten the bolts, leaving a 1/4-inch gap for
positioning. (See Figure 3-2)
11.Check dead weight output.
a.Connect the Load Disc cable to the KM Test
Meter, if not already done.
b.Record the dead weight output on your Weight
Distribution Chart that was started on page 3-3.
See the example below in Figure 3-5.
c.Calculate the Output Change. (Change should be
positive.)
d.The output increase from no-load to dead weight
can be within ten percent of the AVERAGE
output increase. In the example below, the average
output change for Load Discs #1, #2 and #4 meet
this condition, while the output from Load Disc
#3 is too low indicating it is carrying less weight.
Allowable range for Output
Change = Average Output
Change ± 10% =
81.8mV ± (.1 x 81.8mV) =
e.Load disc #3 will require a shimming and/or
leveling procedure which will distribute the weight
more evenly over all of the supports. (See
page 3-5, Leveling/Shimming)
73.6 to 90.0 mV
Load Disc # No-Load Output Dead Weight OutputOutput Change (mV)
(mV)(mV)(Dead Weight Output - No Load Output)
1+3+89+86
2+4+87+83
3+2+71+69
4-3+86+89
Figure 3-5: Example of Dead Weight Outputs and Output Change
3-4
Page 18
Chapter 3: Mounting the Load Disc
Leveling and Shimming
Note: For installations where
leveling nuts are not used, load
balancing on the Load Discs
must be achieved by adding or
removing shims. Adjusting the
Load Discs to distribute the
vessel weight evenly may
require adding shims (supplied
by customer) systematically to
all disc locations.
Note: The Universal T op
Plate will accomodate angular
misalignment up to three
degrees maximum (Figure 3-6 ).
Ideally, the load is distributed
evenly across the top plate.
Note: Shimming the plates of
one Load Disc will probably
affect the weight distribution
on the Load Disc located on the
opposite side. Keep this in mind
while shimming.
The main objective of leveling/shimming the vessel is to distribute
the weight evenly on all of the Load Discs. Uneven weight distribution will reduce the accuracy of the weight measurement system as
a whole and in extreme cases may cause Load Disc damage.
Once the general instructions have been completed (page 3-2
through 3-4), begin the leveling and shimming instructions in this
section.
Leveling/Shimming using Universal Top Adapter Plate
(1,000 to 7,000 lb capacity ONLY)
1.Based on the Weight Distribution Chart (Figure 3-3)
and visual inspection, raise the vessel and cut/place
shims as required to adjust the distribution of weight on
the Load Discs. Begin with the “lowest output”
support first!
2.Gently lower the vessel and measure the dead weight
output and the output change of all of the Load Discs
to see how they are affected. Record again into the
Weight Distribution Chart on page 3-3.
3.Repeat Steps 1 and 2 until you have achieved the
desired output change of all of the Load Discs.
Note: Shims are typically
applied between the Load Disc
Top Plate and mating vessel
plate, but the gap condition
may exist at either the top or
bottom plates.
CAUTION: If you need to
raise the vessel or one
vessel leg after installation,
loosen the bolts on all Load
Discs to prevent overloading.
Figure 3-6: Angular misalignment
up to 3 degrees.
3-5
Page 19
Chapter 3: Mounting the Load Disc
Leveling/Shimming using Leveling Top
Adapter Plate, Leveling Base Adapter Plate,
and the Anyadapter Plate
1.Based on the Weight Distribution Chart and visual
inspection, raise the leveling nut to adjust the top plate
until the weight distribution falls within the weight
distribution guidelines (See page 3-4). Check for gaps and
use shims as required.
2.Gently lower the vessel and measure the dead weight
output and the output change of all of the Load Discs
to see how they are affected. (See Weight Distribution
Chart page 3-3.)
3.Repeat Steps 1and 2 until you have achieved the
desired output change of all of the Load Discs.
Note: Shimming the plates of
one Load Disc will probably
affect the weight distribution
on the Load Disc located on
the opposite side. Keep this in
mind while shimming.
CAUTION: If you need to
raise the vessel or one
vessel leg after installation,
loosen the bolts on all Load
Discs to prevent overloading.
3-6
Page 20
Chapter 3: Mounting the Load Disc
Stainless Steel Junction Box Mounting and Wiring
Mounting Junction Box
1.See Figure 3-7. Hold the junction box at the desired
mounting location. Mark the four mounting holes.
2.Mount the junction box with #8-32 socket head cap
screws and flat washers per your application. Tighten the
screws until snug.
Figure 3-7: Plastic and
Stainless Steel Junction Box
Mounting
Wiring Load Discs to Junction Box
See Figure 3-8. The stainless steel junction box accommodates up to
eight Load Discs, with up to two Load Disc wires at each terminal.
Note that the junction box has no pre-cut holes for conduit or fittings.
Follow this procedure:
1.Prepare junction box —
a.Remove the junction box cover.
b.Remove the terminal board from the junction box.
c.Carefully lay out the conduiting configuration —
the Load Disc cables connect to the terminals on
the left and the signal processor cable connects
on the right. Several Load Disc cables may enter
the box through the same conduit.
d.Cut the required fitting holes in the bottom and/or
sides of the junction box.
e.Install liquid tight fittings.
f.Seal fittings with Sikaflex™ or electrical grade
sealant.
Figure 3-8: Wiring Load Discs to Stainless
Steel Junction Box
3-7
Page 21
Note: Ground the cable
shield only at the signal
processor.
Chapter 3: Mounting the Load Disc
2.Thread the Load Disc cable through the desired conduit
fitting. (See Figure 3-8).
3.Estimate the required length of cable to the terminal strip,
allowing a little extra for strain relief. Cut the excess cable.
4.Strip back 3” (76mm) of the cable sheathing to expose the
three wires inside. Strip back 1/4” (6mm) of insulation from
the end of each of the wires.
5.Connect the Load Disc wires to the selected TB3 terminals
on the left side of the junction box: brown or red wir e
to R, white wire to W, and black wire to B.
6.Perform Steps 2 through 5 for each Load Disc you wire to
this junction box. Up to two Load Discs can be wired to
each terminal.
7.Replace the junction box cover if not ready to begin
wiring the junction boxes together.
Wiring Junction Boxes Together and to Signal Processor
Notes:
1.The procedure below assumes the conduit fitting and
conduit for wiring the junction box to the other junction boxes
and to the signal processor has been installed.
2.Seal all conduit fittings against water entry. Install drain holes
at conduit’s lowest elevation(s) to allow condensation to drain.
3.Use Belden™ 3-conductor shielded interconnect cable or
equivalent to wire junction boxes together and to the signal
processor. For lengths up to 1,000’ (305m) use 18-gage
Belden™ 8791 cable. For lengths from 1,000’ to 2,000’ (305m to
610m) use 16-gage Belden™ 8618 cable.
4.When wiring cable to junction box terminals, strip back 3”
(76mm) of cable sheathing to expose the three conductor wires
and shield wire inside. Strip 1/4” (6mm) of insulation from the
end of each of the conductor wires.
5.All spliced wiring routed between junction boxes and signal
processor must be soldered and encapsulated in waterproof
heatshrink.
1.Remove the junction box cover.
2.See Figure 3-9. Route the 3-conductor cable through the fitting
into the junction box farthest from the signal processor.
Connect wires from the cable to the TB1/TB2 terminal in the
junction box: black wire to B, white wire to W, and
brown or red wire to R.
3.Route the cable through conduit to the next junction box.
Estimate the required length of cable to the terminal strip,
allowing a little extra for strain relief. Cut the excess cable.
Connect wires from the cable to the TB1/TB2 terminal in the
junction box:black wire to B, white wire to W, and
brown or red wire to R.
3-8
Page 22
Chapter 3: Mounting the Load Disc
CAUTION: Only use
Sikaflex™ 1A polyur ethane sealant or Dow
Corning™ RTV 739
or RTV 738. Other
sealants may contain
acetic acid, which is
harmful to sensors
and electronics.
4.Route another 3-conductor cable through the fitting into
this junction box, and attach wires to the TB1 TB2 terminal:
black wire to B, white wire to W, and brown or red wire
to R.
5.Repeat Steps 3 and 4 until all junction boxes on the
vessel are wired together.
6.Route the cable from the last junction box through
conduit to the signal processor. Refer to the signal
processor manual for wiring the junction box to the signal
processor. One vessel takes up one channel in the signal
processor — the channel shows the average value from
all the Load Discs under the vessel.
Figure 3-9: Wiring Stainless Steel Junction Boxes Together and to Signal Processor
3-9
Page 23
Appendix A: Contact Information
Appendix A: Contact Information
Contact Information
Technical Service
You may reach Kistler-Morse headquarters at the
following:
A complete, unabridged copy of our product warranty is available
upon request from KM. A summary of the warranty, subject to theterms and conditions listed fully in the warranty, follows:
KM warrants the equipment to be free from defects in material and
workmanship for two years from date of shipment to original user.
KM will replace or repair, at our option, any part found to be
defective. Buyer must return any part claimed defective to KM,
transportation prepaid.
KM maintains a fully trained staff of field service personnel who
are capable of providing you with complete product assistance.
Phone Consultation
Our Customer Service staff provides the following services by
telephone, via our regular and toll free number (toll free in U.S.A.
and Canada only):
•Technical, application, and troubleshooting assistance
•Spare parts assistance
•Warranty (replacement) assistance
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Appendix A: Contact Information
On-Site Consultation
KM’s Field Service staf f can provide additional services at your request.
Contact KM for rate and scheduling information for the following
services:
•Technical, application, startup, and troubleshooting assistance
on-site
•Training on-site or at our production facility
•Service calls
•Equipment updates to our latest configuration
Note: Load Disc installation, field
wiring, conduit installation, and
junction box and signal processor
mounting must be performed by the
customer. The AC power must be
connected to the signal processor,
but not energized, prior to KM
beginning work.
General descriptions of some of these standard services follow. Of
course, if your service needs vary from those described, we are
available to discuss them with you.
Installation, Startup Assistance, and On-Site Training
The system will be powered up and checked for proper electrical
operation. For best results, KM requires moving a known amount of
material, such as a truckload, for Live Load calibration. Live Load
calibration will be performed if actual material or weight devices can be
moved. If it is not possible to move material, a Manual calibration will
be performed. Recommendations for the optimal performance of the
system will be provided.
On-site training will include simulation of the Live Load calibration
process (if Live Load calibration can not be performed while KM is on
site) and instruction covering operation and maintenance of the system.
Troubleshooting
KM will troubleshoot systems for mechanical, electrical, calibration,
and wiring errors. Normal component repairs will be made and wiring
errors will be corrected, including replacement of non-repairable
printed circuit boards. (To troubleshoot your own equipment, see
Appendix C for Equipment Troubleshooting charts)
Service Calls
KM will perform on-site repair/replacement services.
Return Material Authorization
If a part needs to be sent to the factory for repair, contact KM and
request a Return Material Authorization (RA) number. The RA number
identifies the part and the owner and must be included with the part
when it is shipped to the factory.
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Appendix B: System Calibration for the Load Disc
Appendix B: System Calibration for the
Load Disc
This chapter describes general procedur es
for calibrating the Load Disc system.
Calibration Methods
Before calibrating, install a signal processor. Refer to the signal
processor manual for the procedures to input calibration parameters.
There are two calibration methods:
• Live Load calibration — set lo span and hi span while moving
material into or out of the vessel. This is the preferred method.
• Manual calibration — set scale factor counts, scale factor weight,
and zero calibration value without moving material.
Live Load calibration requires you to move a known quantity of
material into or out of the vessel while performing the procedure. The
quantity of material moved must be at least 25% of the vessel’s total
capacity to provide the best accuracy . Live Load calibration is also
based on the material weight currently in the vessel.
Manual calibration allows you to start using the system as soon as the
Load Discs, junction boxes, and signal processor are installed and
wired, even if you cannot move any (or enough) material now. Manual
calibration values are based on system parameters, including rated load,
and signal processor A/D converter sensitivity. These values are known,
can be calculated, or can be obtained from the signal processor. Manual
calibration is also based on the material weight currently in the vessel.
Note that Manual calibration does not take into account the actual
response to changes in weight. Theoretically , a change in weight results
in a proportional change in digital counts. However, the structure’s
actual response to weight and interaction with piping, catwalks, roof,
discharge chutes, etc. prevents the system from achieving theoretical
values. Manual calibration is a good start, but to obtain the highest
accuracy, perform a Live Load calibration when scheduling permits you
to move material into or out of the vessel.
Refer to the indicator manual(s) for detailed calibration instructions.
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Appendix C: Troubleshooting the Load Disc System
Appendix C: Troubleshooting the
Load Disc System
This section describes an output check and some common
problems. For each problem, one or more possible explanations are listed. For each explanation, suggested solutions
are provided.
Functional Check: Measuring Output
Note: The “no-load”
condition is when the
Load Disc stands
alone without any
weight applied.
SENSOR
ON
TEST
METER
OFF
SIMULATETEST
+EXSIGNAL-EX
Red White Black
Brown White Black
or
Red
ADJUST
Load Disc
Figure C-1: Load Disc
connection to the KM
Test Meter.
1.Connect the brown or red, white and black wires of the Load
Disc to the corresponding T est Meter terminals, as shown in
Figure C-1. Place the Load Disc on a stable surface.
2.Turn on the power to the Test Meter and set the
Simulate/T est switch to the Test position.
3.Verify the no-load output is between + 5mV and -5mV.
(This preliminary measurement specification simply
determines the condition of the Load Disc. If the output
reading is outside +/- 5mV, consult KM.)
4.Repeat Steps 2 and 3 for each Load Disc.
Functional Check:Measuring Resistance
Follow this procedure to test the Load Discs if you do not have a KM
Test Meter or if the no-load output using the Test Meter was out of
range for a Load Disc.
1.Set the ohmmeter resistance scale to accommodate a measured
range up to 20K ohms.
2.Put one DMM lead on the Load Disc’s black wire and the
other lead on the brown wire. Verify the brown-to-black
resistance is between 4.0K ohms and 6.0K ohms.
3.Place the Load Disc on a stable surface. Put one DMM lead
on the Load Disc’s white wire and the other lead on the brown
wire. Verify the brown-to-white resistance is between 8.5K
ohms and 9.0K ohms.
4.Put one DMM lead on the Load Disc’s white wire and the
other lead on the black wire. Verify the black-to-white
resistance is between 8.5K ohms and 9.0K ohms and within
40 ohms of the brown-to-white reading from Step 3.
5.Repeat Steps 2 through 4 for each Load Disc. If any reading is
outside the above ranges, contact KM for assistance before
proceeding with installation.
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Appendix C: Troubleshooting the Load Disc System
ProblemProblem DetailsSolution
Small Amplitude
Changes or Erratic
Fluctuations in display
readings
Fluctuations can be caused
by moisture in cable conduit,
junction boxes, or PCBs.
Fluctuations can be caused
by damaged Load Disc.
Check conduit, junction boxes, and PCBs for
water contamination. Find water entry source
and correct problem. Dry with a hair drier.
Remove/replace corroded parts and materials.
CAUTION
If using sealant to eliminate water entry, use
Sikaflex ™ 1A polyurethane sealant or Dow
Corning™ RTV 739 or RTV 738. Other
sealants may contain acetic acid, which is
harmful to electronics.
Using Digital Multimeter (DMM), check
resistance for individual Load Discs:
1. Set meter resistance scale to accommodate measured range up to 20,000 ohms.
2. Remove one Load Disc’s wires from
junction box terminal.
3. Put one DMM lead on Load Disc’s white
wire and other lead on brown wire.
Record resistance reading, and verify it is
8,750 ± 250 ohms and stable. If reading is
outside this range, Load Disc is damaged
and must be replaced.
4. Put one DMM lead on Load Disc’s white
wire and other lead on black wire. Record
resistance reading, and verify it is 8,750 ±250 ohms and stable. If reading is outside
this range, Load Disc is damaged and
must be replaced.
5. V erify readings from Steps 3 and 4 are
within 400 ohms of each other . If not,
Load Disc is damaged and must
be replaced.
6. Repeat Steps 2 through 5 for each suspect
Load Disc, until damaged Load Disc is
located.
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Appendix C: Troubleshooting the Load Disc System
ProblemProblem DetailsSolution
Small Amplitude
Changes or Erratic
Fluctuations in
display readings
Sudden Change in
Weight Reading or
System Requires
Frequent
Recalibration
Fluctuations can be caused
by problems with signal
processor.
One broken Load Disc can
cause indicated weight to
shift up or down by large
amount, up to 100% of fullscale live load.
Check signal processor excitation voltage
and incoming AC voltage for accuracy and
stability (refer to signal processor manual).
Using Digital Multimeter (DMM), check
resistance for individual Load Discs:
1. Set meter resistance scale to accommodate
measured range up to 20,000 ohms.
2. Remove one Load Disc’s wires from
junction box terminal.
3. Put one DMM lead on Load Disc’s white
wire and other lead on brown wire. Record
resistance reading, and verify it is 8,750± 250 ohms and stable. If reading is outside
this range, Load Disc is damaged and must
be replaced.
4. Put one DMM lead on Load Disc’s white
wire and other lead on black wire. Record
resistance reading, and verify it is 8,750± 250 ohms and stable. If reading is outside
this range, Load Disc is damaged and must
be replaced.
5. V erify readings from Steps 3 and 4 are
within 400 ohms of each other. If not, Load
Disc is damaged and must be replaced.
6. Repeat Steps 2 through 5 for each suspect
Load Disc, until damaged Load Disc is
located.
Sudden change in weight
reading can be caused by
problems with signal processor.
Check signal processor excitation voltage
and incoming AC voltage for accuracy and
stability (refer to signal processor manual).
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Appendix D: Technical Drawings
Appendix D. Technical Drawings (TI)
This appendix contains the following technical drawings for the Load Disc:
Installation InstructionsPage 1-4
LD360s with Leveling Top Universal Adapter Plate 5
LD360s with Universal Top Adapter Plate 6
LD360s with Anyadapter Plate 7
Mounting hole patterns for Anyadapter 8
LD360s with Leveling Base Adapter Plate 9
LD360s Mounting Dimensions 10
LD360s Mounting to Floor and I-beam 11
LD360s with Gusset Leg Attachment on I-Beam 12
LD360s Cabling using Molded Junction Conn, J-Box 13
LD360s Conduit/Non-conduit Cable Layout 14
Installation InstructionsPage 1-4
LD3 with Leveling Top Universal Adapter Plate 5
LD3 with Universal Top Adapter Plate 6
LD3 with Anyadapter Plate 7
Mounting hole patterns for Anyadapter 8
LD3 with Leveling Base Adapter Plate 9
LD3 Mounting Dimensions 10
LD3 Mounting to Floor and I-beam 11
LD3 with Gusset Leg Attachment on I-Beam 12
LD3 Cabling using Molded Junction Conn, J-Box 13
LD3 Conduit/Non-conduit Cable Layout 14