Kistler-Morse LD360s User Manual

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TM TM

Load Disc LD3 /LD360s

Installation Manual

CAUTION

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

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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.

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Table of Contents

Introduction ...................................................................................................i

Welcome ...........................................................................................................................................................i

About this manual ............................................................................................................................................ i

Manual Conventions.................................................................................................................................. i

Specifications...................................................................................................................................................ii

Chapter 1. Description of the Load Disc ................................................ 1-1

Introduction ..................................................................................................................................................1-1

General Description of Measurement System ........................................................................................1-1

Applications Description ................................................................................................. .......................1-1

Installation Option Description.....................................................................................................................1-2

Universal T op Adaptor Plate .................................................................................................................1-2

Leveling Top Plate Adapter (1,000 - 7,500 lbs ONLY).........................................................................1-3

Anyadapter Plate (1,000 - 7,500 lbs ONLY) ...................................................................................... ...1-3

Leveling Base Adapter Plate .................................................................................................................1-4

Chapter 2. Preparing for the Load Disc Installation ............................ 2-1

Check Shipment ............................................................................................................................................2-1

Check Load Disc Order Items ................................................................................................................2-1

Visual Check ...........................................................................................................................................2-1

Prepare Installation Equipment.....................................................................................................................2-2

Installation Equipment Needed .............................................................................................................2-2

Vessel Preparation ........................................................................................................................................2-2

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

Appendix A: Contact Information.............................................................................. A-1

Appendix B: System Calibration................................................................................. B-1

Appendix C: Troubleshooting ..................................................................................... C-1

Appendix D: Technical Drawings................................................................................ D-1

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Table of Contents

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Introduction

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.

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Introduction

Specifications

LD3 LD360s

Mechanical Compression 4 x Rated Load

Tension 1 x Rated Load Shear 0.5 x Rated Load Functional Integrity 2 x Rated Load (compression)

Electrical

Excitation Voltage 10-14 VDC 10-14 VDC Impedance 7.5K Ohms±1% 7.5K Ohms±1% Maximum Current 3mA @ 12 VDC excitation 3mA @ 12 VDC excitation

Output (@ 12 VDC excitation Non-Linearity/Hysteresis combined: 0.08% of standardized output 0.08% of standardized output

Return to Zero 0.05% of Rated Output 0.05% of Rated Output Zero Balance 1% Rated Capacity 1% Rated Capacity

Rated Output (12 VDC excitation) 360 mV±1% (30mV/V nominal) 360 mV±1% (30mV/V nominal)

Environmental

T emperature Range Standard Temperature Range 0° to 100°F (-18° to 38°C) 0° to 100°F (-18° to 38°C) Mid Temperature Range 50° 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 Shift 0.006%/°F (0.011%/°C) 0.006%/°F (0.011%/°C) Humidity 100% 100% Storage Temp Range-Std and Mid -40° to 176° F (-40° to 80°C) -40° to 176°F (-40° to 80°C) Rating NEMA -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

Construction 17-4 PH 900 stainless steel 17-4 PH 900 stainless steel Connection Nickel plated brass body with a 6P rated sealed 5-conductor 12mm

Shipping Weight 5.0 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)

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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

Figure 1-2: General installation layout for Load Disc using a junction box.

Load Disc

(x4) junction box

signal processor

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.

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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.

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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)

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Chapter 1: Description of the Load Disc

Leveling Base Adapter Plate

This kit consists of a Leveling Base Adapter Plate and four hex bolts, flat washers, 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.

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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.

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Chapter 2: Preparing for the Load Disc Installation

Prepare Installation Equipment

(Customer Supplied)

The following equipment is needed to install Load Discs:

Lifting equipment Tape measure Level Pry bar Marking pen Wrenches ASTM A-325 bolts (or equivalent strength), lock

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.

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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

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.

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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.

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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

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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 is recommended. (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 Output Output 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

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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.

Calculation Example:

A verage Output Change = (86mV + 83mV + 69mV + 89mV) / 4 = 81.8mV

c. Place the four top bolts (customer supplied)

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 Output Output 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

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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.

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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.

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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

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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.

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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

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Appendix A: Contact Information

Contact Information

Technical Service

You may reach Kistler-Morse headquarters at the following:

Mail: Kistler-Morse

150 Venture Boulevard Spartanburg, SC 29306 USA

Telephone: 1-800-426-9010

(864) 574-2763 Fax: (864) 574-8063 E-mail: sales@kistlermorse.com Website: http://www.kistlermorse.com

A complete, unabridged copy of our product warranty is available upon request from KM. A summary of the warranty, subject to the terms 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

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

TEST METER

OFF

SIMULATE TEST

+EX SIGNAL -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

Problem Problem Details Solution

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

Problem Problem Details Solution

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.

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:

Drawing No. Drawing T itile

TI-LC.LD360s-(revC) Installation Arrangements, 1K-25K, Load Disc 360s (14 Pages)

Installation Instructions Page 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

RF-LC.LD360s-(revA) Retrofit TI-DWG, 1K-25K, Load Disc 360s (1 Page)

LD360s/UA360 Retrofit from LDII/UA1 1

TI-LD360s-01(revB) LD360s Typical Cabling Diagram (1 Page) 1

TI-LD360s-FM-01 FM Approved Installation Drawings (3 Pages) 1-3

TI-LC.LD3-(revA) Installation Arrangements, 1K-25K, LD3 (14 Pages)

Installation Instructions Page 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

RF-LC.LD3-(revA) Retrofit TI-DWG, 1K-25K, LD3 (1 Page) 1

TI-LC.LD3&LD360-01 Load Block to Load Disc Retrofit Installing (1 Page) 1

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