It is essential that all instructions in this
manual be followed precisely to ensure
proper operation of the equipment.
97-1012-02
Revision G
March 2010
Page 2
NOTICE
The content of this document is the intellectual property of Kistler-Morse® Corporation. Any
reproduction or translation of this document without the written authorization of a Kistler-Morse
corporate ofcer is prohibited.
®
CAUTION
Follow these rules if welding is done on the vessel after installation of the Microcell™ system. The
electrical current of the welder may pass through the Microcell™, causing damage to the sensor and
possibly to the signal processor. To avoid damage, follow these precautions:
1. Disconnect the Microcell™ cables from the signal processor.
2. Ground the welder as close to the welding joint as possible. The welding ground must be between
the Microcell™ and the weld joint to prevent the welding current from going through the Microcell™
to earth ground.
Order Verication ........................................................................................................................................ 2
Microcell™ Order ................................................................................................................................. 2
Drill and Tap .......................................................................................................................................... 8
Mounting the Microcell™ Sets ............................................................................................................. 9
Drill and Tap ........................................................................................................................................ 20
Live Load Calibration ............................................................................................................................... 27
Adding a Known Quantity of Material ................................................................................................. 27
Removing a Known Quantity of Material ............................................................................................ 28
Problem 1. Small Amplitude Changes or Erratic Fluctuations in Display Readings ............................... 29
Problem 2. Repeatable Drift Over a 24-hour Period ............................................................................... 30
Problem 3. Sudden Change in Weight Reading or System Requires Frequent Recalibration ................ 31
APPENDIX A. MICROCELL™ SPECIFICATIONS ................................................................................. 32
APPENDIX B. GLOSSARY ..................................................................................................................... 34
APPENDIX C. ALTERNATE METHOD FOR CHECKING OUTPUT ...................................................... 35
APPENDIX D. SPARE PARTS RECOMMENDATIONS ......................................................................... 36
APPENDIX E. TECHNICAL DRAWINGS ............................................................................................... 37
Page 5
CHAPTER 1. INTRODUCTION
APPLICATIONS
The 3” Microcell™ can be installed on carbon
steel, stainless steel, or aluminum vessel supports.
The 2” Microcell™ can be installed on carbon steel
vessel supports only. Refer to Appendix A
(Microcell™ Specications) for stress limits on
each type of Microcell™.
Microcell™ sets can be installed on leg-supported
and beam-supported vessels. Refer Chapter 3
for installation details on installing Microcell™ on
vertical column legs. Refer to Chaper 4 for
installation details on installing Microcell™ on
horizontal beams.
Figure 1-1. The Kistler-Morse® Microcell™.
EQUIPMENT DESCRIPTION
The Microcell™ (Figure 1-1) is a highly sensitive
bolt-on strain gage sensor used to determine the
weight of material contained in storage vessels.
Microcell™ sets bolt onto a vessel’s metal support
structure. As weight is added to or removed from
the vessel, the vessel support structure
experiences strain changes proportional to the
weight changes. The Microcell™ detects the
strain changes and produces a voltage output
proportional to those changes, thus indicating the
change in weight. Kistler-Morse® signal
processors convert the Microcell™ voltage outputs
to weight or level. Refer to Appendix A for
specications.
The Microcell™ is easy to install. It mounts to the
surface of the structural support and never comes
in contact with the vessel contents. Used in many
different industries, it can weigh any type of
material stored in a vessel with metal support
members. The Microcell™ is rugged, can operate
in industrial environments, and requires no periodic
maintenance. It is immune to electrical noise due
to its high-level output voltage.
Contact Kistler-Morse® for information on
non-standard applications.
Be sure to read the entire installation procedure
pertaining to your application before beginning
installation.
MANUAL CONVENTIONS
Three kinds of special explanations appear
throughout the manual. The format and
signicance of each is dened below:
WARNING
Possible danger to people. Injury may result
if this information is ignored.
CAUTION
Possible risk to the product. The Microcell™
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 Microcell™.
1
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CHAPTER 2. PRE-CHECK PROCEDURES
INTRODUCTION
This chapter describes the pre-check procedures
for Microcell™ sets. Verifying the application and
checking the Microcell™ sets before installation
will ensure installation of properly working
equipment that will provide accurate monitoring
of vessel contents.
APPLICATION VERIFICATION
Prior to ordering Microcell™ sets, be sure to have
read the Microcell™ Selection Guide
(Kistler-Morse® #97-5023) and completed the
appropriate Application Data Form (Kistler-Morse®
#97-5025 for Microcells™ on vertical column legs
or Kistler-Morse® #97-5024 for Microcells™ on
horizontal beams). A copy of the completed form
was returned with both the order acknowledgment
and equipment shipment. If you cannot locate the
form, contact Kistler-Morse® to get another copy
before proceeding. Review the information on the
form now to verify the application details.
Note
If the calculated stress on the Application Data
Form is outside the following ranges, this is a
special application:
3” Microcell™: 2,500 psi - 7,500 psi
(1.8kg/mm2 - 5.3kg/mm2)
2” Microcell™: 3,750 psi - 11,250 psi
(2.6kg/mm2 - 7.9kg/mm2)
ORDER VERIFICATION
Prior to beginning installation, verify the order is
complete and assemble additional equipment
needed for the installation.
MICROCELL™ ORDER
The following are included with the order
(quantities dependent on application):
STANDARD
Microcell™ set, each complete with:
Sensor
Environmental Cover
#8-32 socket head cap screws (2)
#8 hardened at washers (2)
JB1 or JB2 Junction Boxes, each complete with:
Terminal board
Watertight ttings (4)
Watertight plugs (for any cable openings that
will not be used)
Installation Kit, each complete with:
Microcell™ drill template with #8-32 socket
head cap screw
#29 drill bit
#8-32, 2-ute, spiral-point tap
Sikaex 1A polyurethane sealant or Dow
Corning RTV 738 or RTV 739 and Material
Safety Data Sheet (MSDS)
Rust-inhibiting silicone grease
OPTIONAL
Insulation and insulation hardware (if best
performance is required for an outdoor
installation on column legs)
Contact Kistler-Morse® before proceeding further
with a special application.
If any items are missing from the order, contact
Kistler-Morse® before proceeding. Substituting
parts without Kistler-Morse® approval may cause
system problems and will void the warranty.
Note
A signal processor and its manual are required
to calibrate the system. If using an existing
signal processor, this will not be included in
the order.
2
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MICROCELL™ INSTALLATION EQUIPMENT
Tape measure
Marking pen
Kistler-Morse® Test Meter
Kistler-Morse® Microcell™ Sensor Drill Template
Drill motor
Tapping uid
Tap handle
Disk grinder, 4½” (114 mm) or larger, or belt
grinder
Sandpaper (coarse and ne)
Degreaser (isopropyl alcohol or acetone)
Level
Caulking gun
9
/64” hex T-handle driver
Digital Multimeter (DMM)
Tape (electrical or masking)
Note
If the Microcell™ sets will be install by
Kistler-Morse®, the service technician provided
by Kistler-Morse® will bring this equipment on
site with the tool kit. If the Microcell™ sets will
be installed by the customer, the purchase
of a Kistler-Morse® Test Meter is highly
recommended to simplify the installation.
CAUTION
Only use Sikaex 1A polyurethane sealant or
Dow Corning RTV 738 or RTV 739. Other
sealants may contain acetic acid, which is
harmful to sensors and electronics.
CHECKING EQUIPMENT
CAUTION
Handle Microcell™ sets with care. Dropping,
striking, etc. can damage the Microcells™.
VISUAL CHECK
Visually inspect all equipment in the order,
including Microcells™, junction boxes,
Installation Kit, and insulation (if provided), to verify
they were not damaged during shipment. If any
item was damaged, contact Kistler-Morse
immediately for a replacement.
FUNCTIONAL CHECK
Perform a functional check of the Microcells™
before installation to verify they were not damaged
during shipment. Two methods of performing the
check are described below.
®
JUNCTION BOX AND FIELD WIRING
EQUIPMENT
Drill motor
#29 drill bit
#8-32, 2-ute, spiral-point tap
Tap handle
Tapping uid
9/64” Allen wrench
#8-32 socket head cap screws
#8 at washers (3/16” inner diameter, 7/16” outer
diameter)
Belden™ 8791, 18 gauge, 3-conductor shielded
interconnect cable or equivalent (for up to
1,000 ft (305m) length)
Belden™ 8618, 16 gauge, 3-conductor shielded
interconnect cable or equivalent (for 1,000 ft
to 2,000 ft (305m to 610m) length)
Conduit and ttings or cable tray
Caulking gun
Sikaex 1A polyurethane sealant or Dow
Corning RTV 738 or RTV 739
TESTING WITH A KISTLER-MORSE
®
TEST METER
The Kistler-Morse® Test Meter (Figure 2-1) is
designed specically to test Kistler-Morse
®
sensors. If you do not have a test meter,
disregard this section and proceed to TESTING
WITH A DIGITAL MULTIMETER (DMM).
Note
The test meter display indicates a low battery or
behaves erratically when the batteries are weak.
When this occurs, replace the batteries before
testing.
1. See Figure 2-1. Connect the Microcell™
red, white, and black wires to the
corresponding test meter terminals. Place
the Microcell™ on a stable surface.
2. Turn on the power to the test meter and set
the Simulate/Test Switch to the Test
position. Verify the no-load output is
between +25mV and -25mV.
3. Repeat Steps 1 and 2 for each Microcell™.
If the no-load output for any Microcell™ is
outside these specications:
3
Page 8
A. Proceed to TESTING WITH A DIGITAL
MULTIMETER (DMM) to determine the
resistance values for that Microcell™, and
B. Contact Kistler-Morse
®
for assistance
after determining the resistance values
and before proceeding with installation.
CAUTION
Replace Micrcells™ in packing tubes until ready
to install.
3. Put one DMM lead on the Microcell™ white
wire and the other lead on the black wire.
Place the Microcell™ on a stable surface.
Verify the resistance is within the following
limits:
3” standardized Microcell™ (light blue cover):
8,300Ω - 8,700Ω
2” standardized Microcell™ (dark blue cover):
1,800Ω - 2,200Ω
4. Repeat Steps 2 and 3 for each Microcell™. If
either reading for any Microcell™ is outside
these specications, contact Kistler-Morse® for
assistance before proceeding with installation.
CAUTION
Replace Micrcells™ in packing tubes until ready
to install.
Figure 2-1. Kistler-Morse® Test Meter.
TESTING WITH A DIGITAL MULTIMETER (DMM)
Follow this procedure to test the Microcell™ sets
®
if you do not have a Kistler-Morse
Test Meter or
the readings using the Test Meter were outside the
specications:
1. Set the DMM resistance scale to
accommodate a measured range up to
20,000Ω.
2. Put one DMM lead on the Microcell™ white
wire and the other lead on the red wire. Place
the Microcell™ on a stable surface. Verify the
resistance is within the following limits:
3” standardized Microcell™ (light blue cover):
8,300Ω - 8,700Ω
2” standardized Microcell™ (dark blue cover):
1,800Ω - 2,200Ω
4
Page 9
CHAPTER 3. MICROCELL™ INSTALLATION
ON VERTICAL COLUMN LEGS
INTRODUCTION
Follow the instructions in this chapter only if
installing Microcells™ on vertical column legs.
This chapter describes the mounting locations,
installation details, and wiring details for
Microcells™ and junction boxes. Follow all
instructions carefully to ensure proper system
operation.
Note
Do not mix different types of Microcells™ on
one vessel. The three types (3” standardized,
3” non-standardized, and 2” standardized) are
not interchangeable.
MOUNTING LOCATIONS
Follow the procedures below to determine and
mark Microcell™ mounting locations prior to
beginning installation. Following these procedures
will ensure optimal system performance. Consult
Kistler-Morse® if special considerations prevent
you from installing Microcells™ at the designated
locations.
MICROCELL™ SETS
BEST PERFORMANCE
See Figure 3-1. For best performance,
Microcells™ are mounted in a rosette array — a
vertical Microcell™ with a horizontal Microcell™
above it in a “T” conguration. A Microcell™ set
consists of two rosette arrays (four Microcells™
total) mounted on opposite sides of a support leg,
at the same elevation.
Note
Best performance cannot be achieved if:
1. The leg is too narrow for the horizontal
Microcell™ and its environmental cover, or
2. Installation is on round legs.
See STANDARD PERFORMANCE.
Figure 3-1. Microcell™ Rosette Array for
Best Performance.
STANDARD PERFORMANCE
For standard performance, Microcells™ are
mounted vertically. A Microcell™ set consists of
two (2) Microcells™ mounted on opposite sides of
a support leg, at the same elevation.
Figure 3-2. Vertical Microcell™ for
Standard Performance.
5
Page 10
HORIZONTAL DISTRIBUTION OF
MICROCELL™ SETS
Microcell™ sets are placed on each support leg.
Refer to Figure 3-3 for the mounting locations for
each shape.
VERTICAL LOCATION OF MICROCELL™
SETS
Note
Microcell™ locations may be adjusted up to
12 in (305mm) vertically to avoid obstacles. If
adjusting locations, maintain the conguration
of the Microcell™ set (i.e., if one Microcell™ in
the set is moved from its ideal location, move
the other(s) as well).
COLUMN LEGS WITHOUT X-BRACES
See Figure 3-4.
If the free leg distance is between 12 in (305mm)
and 11 ft (3.4m), mount the Microcell™ sets at
mid-height of the free leg.
If the free leg distance is more than 11 ft (3.4m),
mount the Microcell™ sets at 5 ft 6 in (1.7m) above
the foundation.
If the free leg distance is less than 12 in (305mm),
this is a special application situation. Consult
Kistler-Morse® before proceeding further.
Figure 3-4. Vertical Location of Microcell™
Sets for Legs Without X-Braces.
COLUMN LEGS WITH X-BRACES
See Figure 3-5.
If the free leg distance is 12 in (305mm) or more, mount
the Microcell™ sets at mid-height of the free leg.
Figure 3-3. Microcell™ Mounting Arrangements on Legs.
Measure the free leg between the bottom of the bottom
X-brace or horizontal brace and the top of the
foundation.
6
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For an alternate location, measure the free leg
between the top of the top X-brace or horizontal
brace and the beam supporting the vessel.
Figure 3-5. Vertical Location of Microcell™
Sets for Legs With Braces and with Free
Leg Greater Than 12 in (305mm).
See Figure 3-6. If the free leg distance is less than
12 in (305mm), mount the Microcell™ sets at the
mid-height between the lowest braces. When
mounting between the braces, insulation around
the adjacent braces is required for best
performance. This insulation will reduce the effect
of sun-induced stresses on the support metal.
Figure 3-6. Vertical Location of Microcell™
Sets for Legs With Braces and with Free
Leg Less Than 12 in (305mm).
7
Page 12
INSTALLING MICROCELL™ SETS
Note
1. Use lubricating uid (Relton RapidTap®
Heavy Duty Cutting Fluid or equivalent)
when drilling and tapping.
2. Drilling and tapping instructions assume
metal thickness greater than ¾” (19mm).
If the thickness is less, drill all the way
through the metal and tap until cutting
complete threads through the other side.
Minimum metal thickness is 0.1875” (5mm),
which provides six thread engagement.
SURFACE PREPARATION
1. See Figure 3-7. At the center of the
vertical Microcell™ mounting location, drill a
¾” (19mm) deep hole with the #29 drill bit.
This produces the template mounting hole.
Repeat for the horizontal Microcell™
(if applicable).
2. See Figure 3-7. Mark the surface preparation
area for the vertical Microcell™ and horizontal
Microcell™ (if applicable).
3. Attach the coarse grit sandpaper to the
grinder. Remove heavy paint and rust with
the grinder until a bare metal surface is
achieved. Due to the use of coarse grit, the
resulting surface is somewhat coarse.
4. Replace the coarse grit sandpaper with the
ne grit sandpaper. Grind until the surface(s) is
completely down to bare metal and smooth to
the touch.
Note
The Microcell™ must be mounted against
smooth, bare metal. Remove all paint and rust
from the area where the Microcell™ is to be
fastened.
DRILL AND TAP
1. Using the #8-32 tap, thread the template
mounting hole for the vertical Microcell™
(drilled during Surface Preparation) to a
minimum
Remove any burrs from the hole.
2. See Figure 3-8. Position the drill template
so the center hole lines up with the template
mounting hole.
3. Fasten the drill template to the template
mounting hole through the center hole, using
the captive #8-32 socket head cap screw. Use
a level to ensure correct orientation.
4. Using the #29 drill bit, drill two ¾” (19mm)
deep holes in the leg through the template drill
guides.
5
/8” (16mm) depth, full threads.
Figure 3-7. Prepared Mounting Surface.
Figure 3-8. Drill and Tap Template.
8
Page 13
5. Loosen the screw securing the template and
rotate the template until the two tap guides line
up with the drilled holes. Push the #8-32 tap
into one of the tap guide holes to align the
template. Retighten the screw securing the
template.
6. Using the #8-32 tap, thread the two holes
through the template tap guides. Tap to a
minimum
5
/8” (16mm) depth, full threads.
Remove the template from the leg.
7. If installing a rosette array, repeat Steps 1
through 6 for the horizontal Microcell™.
8. Remove burrs from all the holes created.
MOUNTING MICROCELL™ SETS
CAUTION
Do not install Microcells™ in the rain. Do not
trap moisture under the environmental cover.
1. Wipe down a 5 in by 2¼ in (127mm by 57mm)
surface, centered on the template mounting
hole, with degreaser. This cleans the bare
metal and adjacent mounting surface for the
environmental cover.
2. Apply a thin coat of Kistler-Morse
inhibitor to the bare metal surface for the
vertical Microcell™.
CAUTION
Do not apply rust inhibitor beyond this area, or
the environmental cover will not adhere
properly.
3. Connect the Microcell™ red, black, and white
wires to the corresponding terminals on the
®
Kistler-Morse
Test Meter. Turn on the power
to the Test Meter and set the Simulate/Test
Switch to the Test position.
Note
If a Kistler-Morse® Test Meter is not available,
refer to Appendix C (Alternate Method for
Checking Output) before proceeding.
®
rust
Note
3” Microcells™ for vertical and horizontal
installation are slightly different. 3” Microcells™
for horizontal installation are labeled
“Horizontal.” 3” Microcells™ for vertical
installation are not labeled.
CAUTION
For proper installation, tighten each screw until
the T-handle driver exes in torsion ¼ turn past
the point where the screw stops turning.
Repeat this exing procedure several times to
ensure the screw is tight. When both screws
are tight, the voltage must be in the range
-100mV to +100mV. Follow the procedure in
Steps 5 through 7 to achieve this goal.
5. Using the T-handle driver, slowly tighten the
top screw. While turning the T-handle driver,
monitor the test meter carefully. If the
voltage goes outside the range -100mV to
+100mV while tightening, stop immediately
and evaluate the following:
A. If the voltage jumped outside the range
-100mV to +100mV, it may indicate a burr
or rough surface. Remove the screws
holding the Microcell™ to the leg. Check
for and remove burrs and surface
roughness (refer to SURFACE
PREPARATION for removing surface
roughness). Repeat Steps 1through 5.
B. If the voltage gradually moved outside the
range -100mV to +100mV, slowly loosen
the screw until the voltage is within range
again and proceed to Step 6.
6. Repeat Step 5 for the bottom screw. If the
voltage is outside the range -100mV to
+100mV, attempt to bring the reading within
range by loosening the screw being torqued,
tightening the other screw, or some
combination of loosening and tightening. If
you have difculty staying within the range, try
turning each screw ¼ turn at a time until both
screws are tightened.
4. With the cable end down, align a vertical
Microcell™ with its mounting holes. Fasten the
Microcell™ loosely to the leg using the two
#8-32 x
5
/8” socket head cap screws and
washers. Do not tighten the screws. If the
voltage goes outside the range -100mV to
+100mV, immediately loosen the screw(s).
9
Page 14
Note
If the following occurs while tightening screws,
check Microcell™ resistance using a DMM
(described in Problem 1 in Chapter 6):
A. Voltage does not change or changes less
than 25mV as you turn a screw, or
B. Voltage changes randomly as you turn a
screw (i.e., not in a consistent direction).
7. To complete installation, ensure that both
screws are tightened until the T-handle driver
exes in torsion, ¼ turn past the point where
the screw stops turning, with this exing
procedure repeated several times to ensure the
screw is tight, and the voltage is in the range
-100mV to +100mV.
8. Repeat Steps 1 through 7 for the horizontal
Microcell™ (if applicable).
9. Prior to installing the environmental cover(s),
ensure the mating surface(s) on the leg is free
of dirt and grease. Reclean if necessary, being
careful not to remove the rust inhibitor on the
bare metal.
10. See Figure 3-9. Apply a generous bead of
sealant to the inside ange of the
environmental cover. Add extra sealant to the
cable exit channel.
A. Align the environmental cover over the
installed Microcell™, with the cable through
the cover’s exit channel.
B. Press the cover against the web,
squeezing out the sealant around the
edges. Be careful not to squeeze too
much sealant out.
C. Use your nger to smooth the sealant
around all edges and joints, eliminating
areas where moisture may pool, especially
along the top edge. Verify the sealant
forms a continuous, watertight seal. Ensure
the cable exit channel is completely sealed.
D. Repeat Step 10 for the horizontal
Microcell™ (if applicable).
CAUTION
Only use Sikaex 1A polyurethane sealant or
Dow Corning RTV 738 or RTV 739. Other
sealants may contain acetic acid, which is
harmful to sensors and electronics.
Figure 3-9. Environmental Cover.
11. If you created any holes that go completely
through the support metal, spread sealant
(Sikaex 1A polyrethane sealant or Dow
Corning RTV738 or RTV 739) over the open
holes. Use your nger to press sealant into
each hole.
MOUNTING JUNCTION BOX
MOUNTING LOCATION
Each junction box can be wired to a maximum of
two Microcell™ sets (four Microcells™ total):
1. Microcell™ rosette arrays - the four
Microcells™ on a support leg (two sets, each
cosisting of a vertical and a horizontal
Microcell™) are wired to one junction box.
2. Vertical Microcells™ - one junction box can be
wired to Microcells™ from two support legs
(two Microcells™ on each support leg) if the
legs are sufciently close to each other to allow
the Microcell™ cables to reach.
See Figure 3-10. Locate the junction box on the
support leg web or on a brace. Vertically, locate
junction boxes at a convenient height,
approximately 4 ft (1.2m) from the ground. The
exact location of the junction box is not critical,
but ensure you have sufcient cable length and
that a drip loop will be formed by the Microcell™
cables when wired to the junction box.
10
Page 15
Figure 3-10. Possible Junction Box Mounting Locations.
JUNCTION BOX INSTALLATION
CAUTION
Do not install junction boxes in the rain.
Moisture in the junction box will cause
corrosion and system errors.
Note
Junction box mounting hardware is not
supplied by Kistler-Morse®. Kistler-Morse
recommends #8-32 socket head cap screws
and at washers. The instructions below reect
this recommendation.
1. Remove the junction box cover.
2. See Figure 3-11. Hold the junction box at the
previously marked mounting location. Mark
the mounting holes. Mark the four outside
mounting holes if mounting on a at surface,
such as an I-beam or rectangular tube. Mark
the two center mounting holes if mounting on a
curved surface, such as a pipe or round tube.
3. Drill and tap the mounting holes with a #29 drill
bit and #8-32 tap.
Figure 3-11. Junction Box Mounting.
®
4. Mount the junction box with #8-32 socket head
cap screws and at washers. Tighten the
screws until snug. Replace the junction box
cover and screws if not ready to begin wiring
to ensure that no moisture enters the junction
box.
WIRING MICROCELLS™ TO
JUNCTION BOX
Note
A. There are two versions of the junction box
PCB. One version (63-1135-01) is used for
vertical Microcells™. The other version
(63-1135-03) is used for Microcell™ rosette
arrays. Ensure you have the correct PCB in
the junction box (See Figure 3-13).
B. The four small holes in the bottom of the
junction box are for wiring the Microcells™
to the junction box.
1. Remove the junction box cover.
2. See Figure 3-12. Place a plastic washer on
a watertight tting. Thread the Microcell™
cable through a cap and watertight tting.
Leave an adequate length of cable between
the Microcell™ and tting to provide a drip
loop (See Figure 3-13).
3. Spread a generous bead of sealant around the
sides of the watertight tting.
11
Page 16
CAUTION
Only use Sikaex 1A polyurethane sealant or
Dow Corning RTV 738 or RTV 739. Other
sealants may contain acetic acid, which is
harmful to sensors and electronics.
Figure 3-12. Inserting Microcell™ Cable Through
Watertight Fitting and Cap
Figure 3-13. Wiring Microcells™ to Junction Box.
4. See Figure 3-13. In the bottom of the junction
box, locate one of the four small holes closest
to the terminal being used for that Microcell™.
Screw the watertight tting into the hole.
12
Page 17
Note
TB3 terminal block has 12 terminals to
accommodate up to four Microcells™ (A, B,
C, and D). Locate the terminal labeled for the
Microcell™ you are wiring.
5. Estimate the required length of cable to the
terminal strip, allowing a little extra for strain
relief. Cut the excess cable.
6. Strip back 3 in (76mm) of the cable sheathing
to expose the three wires inside. Strip back
¼” (6mm) of insulation from the end of each of
the wires.
7. Connect the wires from the Microcell™ to the
selected TB3 terminals; black wire to B
terminal, white wire to W terminal, and red wire
to R terminal.
8. Perform Steps 2 through 7 for each Microcell™
you wire to this junction box (up to four).
9. Spread a generous bead of sealant (Sikaex
1A polyurethane sealant or Dow Corning RTV
738 or RTV 739) around the sides of the plug
for each hole not being used. Screw a plug
into each hole.
10. Replace the junction box cover and screws
if not ready to begin wiring the junction boxes
together to ensure that no moisture enters the
junction box.
WIRING JUNCTION BOXES
TOGETHER AND TO
SIGNAL PROCESSOR
There are two versions of the junction box
enclosure. Both versions have four small holes
for wiring Microcells™ to the junction box, as
described previously. In addition, the junction box
has one or two large holes:
Note
A. The following procedure assumes the
conduit/cable tray has been installed.
B. Seal all conduit ttings against water
entry. Install drain holes at the conduit’s
lowest elevation(s) to allow condensation
to drain.
C. 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 ft
(305m), use 18 gauge Belden™ 8791 cable.
For lengths from 1,000 ft to 2,000 ft (305m
to 610m), use 16 gauge Belden™ 8618
cable.
D. When wiring cable to junction box
terminals, strip back 3 in (76mm) of cable
sheathing to expose the 3-conductor wires
and shield wire inside. Strip ¼” (6mm) of
insulation from the end of each of the
conductor wires.
E. All wiring routed between the junction
boxes and signal processor must be
continuous with no splices.
CAUTION
Only use Sikaex 1A polyurethane sealant or
Dow Corning RTV 738 or RTV 739. Other
sealants may contain acetic acid, which is
harmful to sensors and electronics.
1. Remove the junction box cover.
For a conduited installation, install a conduit
tting in the large hole in the bottom of the
junction box.
For a non-conduited installation, See Figure
3-14. Spread a generous bead of sealant
around the sides of the PG13.5 cable ttings.
Install the ttings in the two large holes in the
bottom of the junction box.
1. One large hole for conduited installation. The
large hole, which accommodates a ¾” conduit
tting, is for wiring the junction box to the other
junction boxes and to the signal processor.
2. Two large holes for non-conduited
installation. The two large holes, which are
equipped with PG13.5 cable ttings, are for
wiring the junction box to the other junction
boxes and to the signal processor.
Kistler-Morse® requires the use of cable
trays for non-conduited installations.
Figure 3-14. Inserting Shielded Interconnect
Cable Through PG13.5 Fitting and Cap.
13
Page 18
2. See Figure 3-15 (for a conduited installation) or
Figure 3-16 (for a non-conduited installation).
Route the 3-conductor cable through the
tting into the junction box farthest from the
signal processor. Connect wires from the
cable to the TB3 terminal in the junction box;
black wire to B terminal, white wire to W
terminal, and red wire to R terminal. Connect
the cable shield wire to the Shield terminal
between TB1 and TB2.
3. Route the cable through conduit/cable tray 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 terminal in the junction box; black wire to
the B terminal, white wire to the W terminal,
and red wire to the R terminal. Connect the
cable shield wire to the the Shield terminal
between TB1 and TB2.
4. Route another 3-conductor cable through the
tting into this junction box, and attach wires
to the TB2 terminal; black wire to B terminal,
white wire to W terminal, and red wire to R
terminal. Connect the cable shield wire to the
Shield terminal between TB1 and TB2.
5. Repeat Steps 3 and 4 until all junction boxes
for the vessel are wired together.
6. Route the cable from the last jucntion box
through conduit/cable tray 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 Microcells™ on the
vessel supports.
Figure 3-15. Wiring Junction Boxes Together - Conduited Installation.
Figure 3-16. Wiring Junction Boxes Together - Non-Conduited Installation.
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Page 19
Note
Ground the cable shield only at the signal
processor.
INSTALLING INSULATION FOR
OUTDOOR VESSELS (OPTIONAL)
The sun affects the performance of an outdoor,
bolt-on sensor system. The sun’s radiation
heats the support metal unevenly, producing
stresses in the supports that are unrelated to the
weight of material in the vessel. The Microcell™
system minimizes errors associate with
sun-induced stressed in several ways.
A. Microcell™ sets and instrumentation of all
support legs allow the system to subtract
bending stresses resulting from uneven heating
of supports.
B. Microcell™ rosette arrays, where
applicable, allow the system to subtract
tensile/compressive stresses resulting from the
heating of supports.
This conguration of the Microcell™ system
minimizes errors associated with sun-induced
stresses. However, if Microcells™ are installed
on the legs between braces (See Figure 3-6),
insulatio on each of the adjacent braces is required
for best performance. This “brace wrap”
insulation increases system accuracy by further
reducing sun-induced stresses.
2. See Figures 3-17 ad 3-18. Lay the wrap on a
at surface. Mark and cut it at the distance
from Step 1.
3. See Figure 3-19. The goal is to cover most
of the brace with wrap. Covering the brace
where it crosses another brace in the middle
is unnecessary. Depanding on the brace lenth,
multiple sections of wrap may be required,
with each section overlapping the one below
it by a minimum of 2 in (51mm). Measure and
record the space available for each section of
wrap. If the space is more than 60 in (1.5m),
skip Step 4 and proceed to Step 5.
Note
If a junction box is mounted within the area to
be covered by wrap, cut the wrap so it does not
cover the junction box.
4. From the top edge, measure and mark the
wrap at the distance from Step 3. Cut the
wrap where marked.
5. Position the wrap, starting at the bottom of the
brace. Wrap it around the brace, overlapping
the ends as shown in Figure 3-17. Fasten the
wrap to the brace with four tie wraps.
6. Repeat Steps 2 through 5 for additional
sections of wrap. Overlap each section of
wrap by a minimum of 2 in (51mm).
INSULATION ORDER AND INSTALLATION
EQUIPMENT
The following are included with the insulation
order (quantities are dependent of the number
of braces):
Brace wrap, 60 in by 85 in (1.5m by 2.2m)
Tie wraps
The following are used for installation:
Flexible tape measure
Heavy-duty knife
INSTALLING BRACE WRAP
1. See Figure 3-17. Using a exible tape
measure, measure and record the wrap width
required. allowing for a minimum 2 in (51mm)
overlap.
Figure 3-17. Wrap on Various Shapes.
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Page 20
Figure 3-18. Cutting Wrap Width.
Figure 3-19. Installing Brace Wrap.
16
Page 21
CHAPTER 4. MICROCELL™ INSTALLATION
ON HORIZONTAL BEAMS
INTRODUCTION
Follow the instructions in this chapter only if
installing Microcells™ on horizontal beams.
This chapter describes the mounting locations,
installation details, and wiring details for
Microcells™ and junction boxes. Follow all
instructions carefully to ensure proper system
operation.
Note
Do not mix different types of Microcells™ on
one vessel. The three types (3” standardized,
3” non-standardized, and 2” standardized) are
not interchangeable.
MOUNTING LOCATIONS
Figure 4-1. Microcell™ Shear Mounting Set.
Follow the procedures below to determine and
mark the Microcell™ mounting locations prior to
beginning installation. Following these procedures
will ensure optimal system performance. Consult
Kistler-Morse® if special considerations prevents
the installation of the Microcells™ at the
designated locations.
MICROCELL™ SETS
See Figure 4-1. Microcells™ are mounted on
beams in a shear mounting set. A Microcell™
is set at a 45° angle to the horizontal with another
Microcell™ set perpendicular to it on the other
side of the support beam. Both Microcells™ are
mounted with the lead wires on the “down” end.
DISTRIBUTION OF MICROCELL™ SETS
The distribution of Microcell™ sets on beams is
dependent on vessel support conguration. Figure
4-2 shows the distribution of sets for eight support
congurations, varying from independent vessels
to multiple vessels with common columns and
beams. Note in all cases with common beams
between multiple vessels, the common beams are
not instrumented with Microcells™.
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Page 22
Figure 4-2. Microcell™ Mounting Locations.
18
Page 23
Figures 4-3, 4-4, and 4-5 show the location of a
Microcell™ set on a beam. The ideal location is
midway between the vessel support bracket and
the support column (or supporting beam). This
places the shear mounting set away from joints
and load points. The minimum distance between
the load point and the support column or beam is
18 in (457mm). If less space is available, this is a
special application. Consult Kistler-Morse
®
before
proceeding further.
The top of Microcell™ A points toward the load
point from the vessel, putting the Microcell™ in
compression when the load is applied. Microcell™
B is mounted on the other side of the web, directly
behind and at a 90° angle to Microcell™ A. The
top of Microcell™ B points away from the load
point, putting the Microcell™ in tension when the
load is applied. There is no physical difference in
Microcells™ A and B; the designations relate to
how to wire the Microcells™ to the junction box.
Note
Microcell™ locations may be adjusted up to 12
in (305mm) in any directon to avoid obstacles.
If adjusting locations, maintain the
conguration of the set (i.e,. if you move one
Microcell™ in the set from its ideal location,
move the other Microcell™ as well).
Figure 4-3. Placement of Microcell™ Set to the Left of Load Point.
See Figure 4-5. If a second Microcell™ set is
placed on a beam (Series 601 and 602), the
Microcells™ are labeled C and D (pointing toward
the load point).
Figure 4-4. Placement of Microcell™ Set to the Right of Load Point.
Figure 4-4. Placement of Two Microcell™ Sets on a Beam (Series 601 and 602).
19
Page 24
INSTALLING MICROCELL™ SETS
Note
1. Procedures below refer to Microcells™ A
and B, but also apply to Microcells™ C and
D (if applicable to installation).
2. Use lubricating uid (Relton RapidTap®
Heavy Duty Cutting Fluid or equivalent)
when drilling and tapping.
3. Drilling and tapping instructions assume
metal thickness greater than ¾” (19mm).
If the thickness is less, drill all the way
through the metal and tap until cutting
complete threads through the other side.
Minimum metal thickness is 0.1875” (5mm),
which provides six thread engagement.
SURFACE PREPARATION
1. See Figure 4-6. At the center of the
Microcell™ mounting location, drill all the way
through the web with the #29 drill bit. This
produces the template mounting hole.
2. See Figure 4-6. Mark the surface preparation
area for Microcell™ A. Repeat for Microcell™
B on the other side of the web.
3. Attach the coarse grit sandpaper to the grinder.
Remove heavy paint and rust with the grinder
until a bare metal surface is achieved for
Microcell™ A. Using this grit of sandpaper will
cause the surface to be somewhat coarse.
Repeat for Microcell™ B.
4. Replace the coarse grit sandpaper with the ne
grit sandpaper. Grind until the surface is
completely down to bare metal and smooth to
the touch for Microcell™ A. Repeat for
Microcell™ B.
2. See Figure 4-7. Starting with the location of
Microcell™ A, fasten the drill template to the
template mounting hole through the center
hole, using the captive #8-32 socket head cap
screw. Use a level to ensure correct
orientation (45° angle to the horizontal).
3. Using the #29 drill bit, drill two ¾” (19mm)
deep holes in the web through the template
drill guides.
4. Loosen the screw securing the template and
rotate the template until the two tap guides line
up with the drilled holes. Push the #8-32 tap
into one of the tap guide holes to align the
template. Retighten the screw securing the
template.
5. Using the #8-32 tap, thread the holes through
the template tap guides. Tap to a minimum
5
/8” (16mm) depth, full threads. Remove the
template from the web.
6. Repeat Steps 2 through 5 for Microcell™ B on
the other side of the web.
7. Remove burrs from all of the holes created.
Note
The Microcell™ must be mounted against
smooth, bare metal. Remove all paint and rust
from the area where the Microcell™ is to be
fastened.
DRILL AND TAP
1. Using the #8-32 top, thread the template
mounting hole (drilled during SURFACE
PREPARATION) until the tap is cutting
complete threads through the other side.
Remove any burrs from the hole.
Figure 4-6. Prepared Mounting Surface.
Figure 4-7. Drill and Tap Template.
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Page 25
MOUNTING MICROCELL™ SETS
CAUTION
Do not install Microcells™ in the rain. Do not
trap moisture under the environmental cover of
the Microcell™.
1. Mark two small pieces of masking tape “A.”
Place one piece of tape on the plastic body
of a Microcell™ and one piece near the end
of the Microcell™ cable. Repeat for the other
Microcell™, labeling it “B.”
2. Wipe down a 5 in x 2¼ in (127mm x 57mm)
surface, centered on the template
mounting hole, with degreaser. This cleans the
bare metal and adjacent mounting surface for
the environmental cover.
3. Apply a thin coat of Kistler-Morse® rust
inhibitor to the bare metal surface for
Microcell™ A.
Note
Do not apply rust inhibitor beyond this area
or the environmental cover will not adhere
properly.
4. Connect the Microcell™ red, black, and white
wires to the corresponding terminals on the
Kistler-Morse® Test Meter. Turn on the power
to the meter and set the Simulate/Test Switch
to the Test position.
Note
If a Kistler-Morse® Test Meter is not available,
refer to Appendix C (Alternate Method for
Checking Output) before proceeding with
Step 5.
CAUTION
For proper installation, tighten each screw until
the T-handle driver exes in torsion ¼ turn past
the point where the screw stops turning.
Repeat this exing procedure several times to
ensure the screw is tight. When both screws
are tight, the voltages must be in the range of
-100mV to +100mV. Follow the procedure in
Steps 6 through 8 to achieve this goal.
6. Using the T-handle driver, slowly tighten the
top screw. While turning the T-handle driver,
monitor the test meter carefully. If the
voltage goes outside the range of -100mV to
+100mV while tightening, stop immediately
and evaluate the following:
A. If the voltage jumped outside the range of
-100mV to +100mV, it may indicate a burr
or rough surface. Remove the screws
holding the Microcell™ to the web. Check
for and remove burrs and surface
roughness (refer to SURFACE
PREPARATION for removing surface
roughness). Repeat Steps 1 through 6.
B. If the voltage gradually moved outside the
range of -100mV to +100mV, slowly loosen
the screw until the voltage is within the
range again and proceed to Step 7.
7. Repeat Step 6 for the bottom screw. If the
voltage is outside the range of -100mV to
+100mV, attempt to bring the reading within
range by loosening the screw being torqued,
tightening the other screw, or some
combination of loosening and tightening. If
you have difculty staying within the range,
try turning each screw ¼ turn at a time until
both screws are tightened.
5. With the cable end down, align
Microcell™ A with the mounting holes,
ensuring that the top of Microcell™ A faces
toward the vessel load point. Fasten the
Microcell™ loosely to the web using the two
#8-32 x 5/8” socket head cap screws and
washers. Do not tighten the screws. If the
voltage goes outside the range of -100mV to
+100mV, immediately loosen the screw(s).
Note
If the following occurs while tightening screws,
check Microcell™ resistance using a DMM
(described in Problem 1 in Chapter 6):
A. Voltage does not change or changes less
than 25mV as you turn a screw, or
B. Voltage changes randomly as you turn a
screw (i.e., not in a consistent direction).
21
Page 26
8. To complete installation, ensure that both
screws are tightened until the T-handle driver
exes in torsion, ¼ turn past the point where
the screw stops turning, with this exing
procedure repeated several times to ensure the
screw is tight, and the voltage is in the range
-100mV to +100mV.
9. Repeat Steps 2 through 8 to install
Microcell™ B on the other side fo the web.
10. Prior to installing the environmental cover,
ensure the mating surface on the web is free
of dirt and grease. Reclean if necessary, being
careful not to remove the rust inhibitor on the
bare metal.
11. See Figure 4-8. Apply a generous bead of
sealant to the inside ange of the
environmental cover. Add extra sealant to the
cable exit channel.
A. Align the environmental cover over the
installed Microcell™ A, with the cable
through the cover’s exit channel.
B. Press the cover against the web, squeezing
out the sealant around the edges. Be
careful not to squeeze too much sealant
out.
C. Use your nger to smooth the sealant
around all edges and joints, eliminating
areas where moisture may pool, especially
along the top edge. Verify the sealant
forms a continuous, watertight seal. Ensure
the cable exit channel is completely sealed.
D. Repeat Step 11 for Microcell™ B.
12.If you created any holes that go completely
through the web, spread sealant (Sikaex 1A
polyrethane sealant or Dow Corning RTV738
or RTV 739) over the open holes. Use your
nger to press sealant into each hole.
MOUNTING JUNCTION BOX
MOUNTING LOCATION
Each junction box can be wired to a maximum of
two Microcell™ sets (four Microcells™ total):
1. One set of Microcells™ on a beam; both
Microcells™ are wired to one junction box.
2. Two sets of Microcells™ on a beam; all four
Microcells™ are wired to one junction box if
the sets are sufciently close to each other to
allow the Microcell™ cables to reach the
junction box.
See Figures 4-9 and 4-19. Locate the junction
box on the instrumented beam or on the
supporting column or horizontal beam. Ensure
you have sufcient cable length and that a drip
loop will be formed by the Microcell™ cables when
wired to the junction box.
CAUTION
Only use Sikaex 1A polyurethane sealant or
Dow Corning RTV 738 or RTV 739. Other
sealants may contain acetic acid, which is
harmful to sensors and electronics.
Figure 4-8. Environmental Cover.
Figure 4-9. Junction Box Location - Two
Microcells™ Per Junction Box.
Figure 4-9. Junction Box Location - Four
Microcells™ Per Junction Box.
JUNCTION BOX INSTALLATION
CAUTION
Do not install junction boxes in the rain.
Moisture in the junction box will cause
corrosion and system errors.
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Page 27
Note
Junction box mounting hardware is not
supplied by Kistler-Morse®. Kistler-Morse
®
recommends #8-32 socket head cap screws
and at washers. The instructions below reect
this recommendation.
1. Remove the junction box cover.
2. See Figure 4-11. Hold the junction box at the
previously marked mounting location. Mark
the mounting holes.
3. Drill and tap the mounting holes with a #29 drill
bit and #8-32 tap.
4. Mount the junction box with #8-32 socket head
cap screws and at washers. Tighten the
screws until snug. Replace the junction box
cover and screws if not ready to begin wiring
to ensure that no moisture enters the junction
box.
WIRING MICROCELL™ SETS TO
JUNCTION BOX
Note
A. Junction box PCB 63-1135-03 is used for
Microcell™ sets on beams. Ensure you
have this PCB in the junction box
(See Figure 4-13).
B. The four small holes in the bottom of the
junction box are for wiring the Microcells™
to the junction box.
1. Remove the junction box cover.
2. See Figure 4-12. Place a plastic washer on
a watertight tting. Thread the Microcell™
cable through a cap and watertight tting.
Leave an adequate length of cable between
the Microcell™ and tting to provide a drip
loop (See Figure 4-13).
3. Spread a generous bead of sealant around the
sides of the watertight tting.
Figure 4-11. Junction Box Mounting.
Figure 4-12. Inserting Microcell™ Cable Through
Watertight Fitting and Cap.
CAUTION
Only use Sikaex 1A polyurethane sealant or
Dow Corning RTV 738 or RTV 739. Other
sealants may contain acetic acid, which is
harmful to sensors and electronics.
4. See Figure 4-13. In the bottom of the junction
box, locate one of the four small holes closest
to the terminal being used for that Microcell™.
Screw the waterright tting into the hole.
Figure 4-13. Wiring Microcells™ to Junction Box.
23
Page 28
Note
TB3 terminal block has 12 terminals to
accommodate up to four Microcells™ (two
shear sets). Wire Microcell™ A to terminal A
and Microcell™ B to terminal B. If there are
four Microcells™ on one beam, wire Microcell™
C to terminal C and Microcell™ D to terminal D.
2. Two large holes for non-conduited
installation. The two large holes, which are
equipped with PG13.5 cable ttings, are for
wiring the junction box to the other junction
boxes and to the signal processor.
Kistler-Morse
trays for non-conduited installations.
®
requires the use of cable
5. Estimate the required length of cable to the
terminal strip, allowing a little extra for strain
relief. Cut the excess cable.
6. Strip back 3 in (76mm) of the cable sheathing
to expose the three wires inside. Strip back
¼” (6mm) of insulation from the end of each of
the wires.
7. Connect the wires from the Microcell™ to the
selected TB3 terminals; black wire to B
terminal, white wire to W terminal, and red wire
to R terminal.
8. Perform Steps 2 through 7 for each Microcell™
you wire to this junction box (up to four).
9. Spread a generous bead of sealant (Sikaex
1A polyurethane sealant or Dow Corning RTV
738 or RTV 739) around the sides of the plug
for each hole not being used. Screw a plug
into each hole.
10. Replace the junction box cover and screws
if not ready to begin wiring the junction boxes
together to ensure that no moisture enters the
junction box.
Note
A. The following procedure assumes the
conduit/cable tray has been installed.
B. Seal all conduit ttings against water
entry. Install drain holes at the conduit’s
lowest elevation(s) to allow condensation
to drain.
C. 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 ft
(305m), use 18 gauge Belden™ 8791 cable.
For lengths from 1,000 ft to 2,000 ft (305m
to 610m), use 16 gauge Belden™ 8618
cable.
D. When wiring cable to junction box
terminals, strip back 3 in (76mm) of cable
sheathing to expose the 3-conductor wires
and shield wire inside. Strip ¼” (6mm) of
insulation from the end of each of the
conductor wires.
E. All wiring routed between the junction
boxes and signal processor must be
continuous with no splices.
WIRING JUNCTION BOXES
TOGETHER AND TO
SIGNAL PROCESSOR
There are two versions of the junction box
enclosure. Both versions have four small holes
for wiring Microcells™ to the junction box, as
described previously. In addition, the junction box
has one or two large holes:
1. One large hole for conduited installation. The
large hole, which accommodates a ¾” conduit
tting, is for wiring the junction box to the other
junction boxes and to the signal processor.
CAUTION
Only use Sikaex 1A polyurethane sealant or
Dow Corning RTV 738 or RTV 739. Other
sealants may contain acetic acid, which is
harmful to sensors and electronics.
1. Remove the junction box cover.
For a conduited installation, install a conduit
tting in the large hole in the bottom of the
junction box.
For a non-conduited installation, See Figure
4-14. Spread a generous bead of sealant
around the sides of the PG13.5 cable ttings.
Install the ttings in the two large holes in the
bottom of the junction box.
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Page 29
.
Figure 3-14. Inserting Shielded Interconnect
Cable Through PG13.5 Fitting and Cap.
2. See Figure 4-15 (for a conduited installation) or
Figure 4-16 (for a non-conduited installation).
Route the 3-conductor cable through the
tting into the junction box farthest from the
signal processor. Connect wires from the
cable to the TB3 terminal in the junction box;
black wire to B terminal, white wire to W
terminal, and red wire to R terminal. Connect
the cable shield wire to the Shield terminal
between TB1 and TB2.
3. Route the cable through conduit/cable tray
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 terminal in the junction box;
black wire to the B terminal, white wire to the
W terminal, and red wire to the R terminal.
Connect the cable shield wire to the the Shield
terminal between TB1 and TB2.
4. Route another 3-conductor cable through the
tting into this junction box, and attach wires
to the TB2 terminal; black wire to B terminal,
white wire to W terminal, and red wire to R
terminal. Connect the cable shield wire to the
Shield terminal between TB1 and TB2.
5. Repeat Steps 3 and 4 until all junction boxes
for the vessel are wired together.
6. Route the cable from the last jucntion box
through conduit/cable tray 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 Microcells™ on the
vessel supports.
Note
Ground the cable shield only at the signal
processor.
Figure 4-15. Wiring Junction Boxes Together - Conduited Installation.
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Page 30
Figure 4-16. Wiring Junction Boxes Together - Non-Conduited Installation.
26
Page 31
CHAPTER 5. SYSTEM CALIBRATION
INTRODUCTION
This chapter describes general procedures for
calibrating the Microcell™ system. Before
calibrating, you must install a signal processor.
Refer to the signal processor manual for the
procedures to input calibration parameters.
There are two calibration methods:
A. Live Load Calibration — Set LO span and HI
span while moving material into or out of the
vessel. This is the preferred method.
B. Manual Calibration — Set scale factor counts,
scale factor weight, and zero calibration value
without moving material. This method is less
accurate than live load calibration.
A 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 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 Microcells™, 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 sensor sensitivity, vessel
support stress, 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 load 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.
The following sections provide procedures for
performing live load and Manual Calibrations.
LIVE LOAD CALIBRATION
Live load calibration can be performed by
adding or removing a known quantity of material
from the vessel. The quantity of material moved
must be at least 25% of the vessel’s total
capacity. The procedures for both live load
calibration methods follow.
ADDING A KNOWN QUANTITY
OF MATERIAL
See Figure 5-1.
1. Record the current live load.
2. Input LO Span: LO Span = current live load.
3. Add known quantity of material to the vessel.
Ensure all material has stopped moving before
proceeding.
4. Input HI Span: HI Span = LO Span + Added
Weight.
Example
You are using Microcells™ to monitor a vessel. The vessel
contains 50,000 lb of material and can hold a maximum of
200,000 lb. You plan to add 60,000 lb of material (which is
greater than 25% of 200,000 lb).
Following the Live Load Calibration procedure:
1. Current live load = 50,000 lb
2. LO Span = current live load = 50,000 lb
3. Add 60,000 lb of material.
4. HI Span = LO Span + Added Weight
= 50,000 lb + 60,000 lb
= 110,000 lb
Figure 5-1. Live Load Calibration by Adding or Removing a Known Quantity of Material.
27
Page 32
REMOVING A KNOWN QUANTITY
OF MATERIAL
See Figure 5-1.
1. Record the current live load.
2. Input HI Span: HI Span = current live load.
3. Remove known quantity of material to the
vessel. Ensure all material has stopped
moving before proceeding.
4. Input LO Span: LO Span = HI Span - Removed Weight.
Example
You are using Microcells™ to monitor a vessel. The vessel
contains 110,000 lb of material and can hold a maximum of
200,000 lb. You plan to remove 60,000 lb of material (which is
greater than 25% of 200,000 lb).
Following the Live Load Calibration procedure:
1. Current live load = 110,000 lb
2. HI Span = current live load = 110,000 lb
3. Remove 60,000 lb of material.
4. LO Span = HI Span - Removed Weight
= 110,000 lb - 60,000 lb
= 50,000 lb
5. Calculate the Manual Calibration values:
Scale Factor Weight = maximum live load
Scale Factor Counts = S * Counts/mV * Stress
Zero_Cal = current live load
6. Refer to the signal processor manual to input
the calibration values.
Example 1. Microcells™ on Vertical Legs.
You are using 3” Microcells™ in rosette arrays on vertical
column legs. The vessel has four W10x39 carbon steel legs
and no braces. The vessel currently contains 50,000 lb of
material and can hold a maximum of 200,000 lb.
Following the procedure:
1. Counts/mV = 699.05 (from signal processor)
2. S = 0.045 mV/psi (From Table 5-1, for legs with rosette
array)
3. From the Application Data Form, the maximum live load
is 200,000 lb. The stress is 4348 psi.
4. Current live load = 50,000 lb
5. Calculate the values for the calibration:
Scale Factor Weight = Maximum live load = 200,000 lb
Scale Factor Counts = S * Counts/mV * Stress
= 136,776 Counts
Zero_Cal = current live load = 50,000 lb
= 0.045 mV/psi * 699.05 Counts/mV * 4348 psi
MANUAL CALIBRATION
Note
The Kistler-Morse® SVS-2000™ signal
processor performs a manual calibration
automatically with Quick Cong.
See Figure 5-2.
1. Refer to the signal processor manual to
determine how to obtain the A/D converter
sensitivity, expressed in Counts/mV. Record
this value.
2. Record the Microcell™ sensitivity (S).
Sensitivity for Microcells™ on legs and beams
are shown in Table 5-1.
3. Refer to the Application Data Form for the
vessel (contact Kistler-Morse® for an additional
copy if needed). Record the maximum live
load and the stress.
4. Record the current live load in the vessel.
Example 2. Microcells™ on Beams.
You are using 3” Microcells™ on beams. The vessel has four
W10x39 carbon steel horizontal beams and four W10 x 39
carbon steel diagonal beams. The Microcells™ are on the
horizontal beams only. The vessel currently contains
50,000 lb of material and can hold a maximum of 150,000 lb.
Following the procedure:
1. Counts/mV = 699.05 (from signal processor)
2. S = 0.070 mV/psi (From Table 5-1, for beams)
3. From the Application Data Form, the maximum live load
is 150,000 lb. The stress is 5929 psi.
4. Current live load = 50,000 lb
5. Calculate the values for the calibration:
Scale Factor Weight = Maximum live load = 150,000 lb
Scale Factor Counts = S * Counts/mV * Stress
= 0.070 mV/psi * 699.05 Counts/mV * 5929 psi
= 290,127 Counts
Zero_Cal = current live load = 50,000 lb
Figure 5-2. Manual Calibration Line.
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CHAPTER 6. TROUBLESHOOTING
This chapter describes some common problems
you may encounter while using Microcells™. For
each problem, one or more possible explanations
are listed. An indication of when the problem is
likely to be noticed and suggested solutions are
provided for each explanation.
PROBLEM 1. SMALL AMPLITUDE
CHANGES OR ERRATIC
FLUCTUATIONS IN DISPLAY
READINGS.
EXPLANATION
Small amplitude drift or oscillation, with
peak-to-peak disturbance of 0.1% to 0.3% of full
scale, is normal.
Problem Likely to be Noticed
Shortly after initial installation.
Solution
Reduce or eliminate drift or oscillation by
setting “count by” and “averaging”
appropriately on signal processor (refer to
signal processor manual).
EXPLANATION
Fluctuations can be caused by moisture in cable
conduit, junction boxes, or printed circuit boards
(PCBs).
Problem Likely to be Noticed
On system that previously functioned correctly.
Solution
Check conduit, junction boxes, and PCBs for
water contamination. Find water entry source
and correct problem. Dry with a hair dryer.
Remove/replace corroded parts and materials.
CAUTION
If using a sealant to eliminate water entry,
use Sikaex 1A polyurethane sealant or Dow
Corning RTV 738 or RTV 739. Other sealants
may contain acetic acid, which is harmful to
sensors and electronics.
EXPLANATION
Fluctuations can be caused by a damaged
Microcell™.
Problem Likely to be Noticed
Shortly after initial installation or on system that
previously functioned correctly.
Solution
Using Digital Multimeter (DMM) or ohmmeter,
check resistance for individual Microcells™:
1. Set meter resistance scale to accommodate
measured range up to 20,000Ω.
2. Remove one Microcell™ wire from junction
box terminal TB3.
3. Put one DMM lead on the white wire of the
Microcell™ and other DMM lead on the red
wire of the Microcell™. Record resistance
and verify it is within following limits:
A. 3” standardized Microcell™ (light blue
cover) - between 8,300Ω and 8,700Ω
B. 2” Microcell™ and 3” non-standardized
Microcell™ (dark blue cover) - between
1,800Ω and 2,200Ω
If reading is outside this range, the
Microcell™ is damaged and must be
replaced.
4. Put one DMM lead on the white wire of
the Microcell™ and other DMM lead on the
black wire of the Microcell™. Record
resistance and verify it is within following
limits:
A. 3” standardized Microcell™ (light blue
cover) - between 8,300Ω and 8,700Ω
B. 2” Microcell™ and 3” non-standardized
Microcell™ (dark blue cover) - between
1,800Ω and 2,200Ω
If reading is outside this range, the
Microcell™ is damaged and must be
replaced.
5. Verify readings from Steps 3 and 4 are within
140Ω of each other. If not, the Microcell™ is
damaged and must be replaced.
6. Repeat Steps 2 through 5 for each suspect
Microcell™, until damaged Microcell™ is
located.
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EXPLANATION
Fluctuations in readings can be caused by short to
ground.
Problem Likely to be Noticed
Shortly after initial installation or on system that
previously functioned correctly.
Solution
Using a Digital Multimeter (DMM) or ohmmeter,
check for shorts to ground:
1. Set meter resistance scale to
accommodate maximum measured range.
2. Disconnect junction box wires from
signal processor.
3. With one lead to earth ground and other
lead to white wire, check resistance on
disconnected junction box wires:
A. If reading is less than innite
(i.e., there is resistance), a short is
indicated; proceed to Step 4 to identify
location.
B. If no short is indicated, investigate
other explanations for problem.
4. Starting with junction box closest to
signal processor in daisy chain, disconnect
wires connecting junction box to the other
junction boxes. With one lead to earth
ground and other lead to white wire,
check resistance on wires leading from
junction box:
A. If reading is less than innite (i.e., there
is resistance), short is indicated;
proceed to Step 5 to further identify
location.
B. If no short is indicated, proceed to next
junction box in daisy chain. Disconnect
wires connecting it to other junction
boxes and check resistances. Repeat
for each junction box down chain until
short is located; proceed to Step 5.
5. Disconnect Microcell™ wires for one
Microcell™ from above-identied junction
box. With one lead to earth ground and
other lead to white wire, check resistance
on disconnected Microcell™ wires:
A. If reading is less than innite (i.e.,
there is resistance), short is indicated.
Replace shorted Microcell™.
B. If no short is indicated, disconnect next
Microcell™ wires from junction box and
check resistances. Repeat for each
Microcell™ wired to junction box until
short is located. Replace the shorted
Microcell™.
EXPLANATION
Fluctuations in readings can be caused by
problems with signal processor.
Problem Likely to be Noticed
Shortly after initial installation or on system that
previously functioned correctly.
Solution
Check signal processor excitation voltage and
incoming AC voltage for accuracy and stability
(refer to signal processor manual).
PROBLEM 2. REPEATABLE DRIFT
OVER A 24-HOUR PERIOD.
EXPLANATION
Periodic drift is most likely caused by thermal
expansion of vessel or vessel’s supports due to
the sun’s radiation or a vessel’s response to its
own heating cycles.
Problem Likely to be Noticed
Shortly after initial installation or on system that
previously functioned correctly in cool or
overcast weather.
Solution
1. If periodic drift is outside specications
(Appendix A), contact Kistler-Morse®.
2. For Microcells™ installed on vertical
column legs, if drift is within specications
but you want to reduce it further, install
Kistler-Morse® insulation. Contact
Kistler-Morse® to order insulation.
Installation details are included in
Chapter 3 (Microcell™ Installation on
Vertical Column Legs).
3. If keeping long-term records, take readings
at the same time each day to minimize
error.
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PROBLEM 3. SUDDEN CHANGE
IN DISPLAY READING OR SYSTEM
REQUIRES FREQUENT
CALIBRATION.
CAUTION
Only use Sikaex 1A polyurethane sealant
or Dow Corning RTV 738 or RTV 739. Other
sealants may contain acetic acid, which is
harmful to sensors and electronics.
EXPLANATION
A single broken Microcell™ can cause indicated
weight to shift up or down by a large amount,
up to 100% of full-scale live load.
Problem Likely to be Noticed
On system that previously functioned
correctly.
Solution
Check voltage outputs of individual
Microcells™ (see TESTING WITH A
KISTLER-MORSE® TEST METER in Chapter 2).
Voltage should be between -500mV and
+500 mV on installed Microcells™. If not,
check Microcell™ resistance as described in
Problem 1.
EXPLANATION
Slipping of Microcell™ can cause indicated weight
to shift suddenly.
EXPLANATION
Sudden change in weight reading can be caused
by problems with signal processor.
Problem Likely to be Noticed
Shortly after initial installation or on system that
previously functioned correctly.
Solution
Check signal processor excitation voltage and
incoming AC voltage for accuracy and stability
(refer to signal processor manual).
Problem Likely to be Noticed
Shortly after initial installation.
Solution
If broken Microcell™ is not indicated, perform
the following procedure:
1. Carefully remove environmental cover from
Microcell™.
2. Tighten Microcell™ #8-32 socket head
cap screws, following procedure in
appropriate Microcell™ Installation
Chapter (Chapter 3 for vertical column legs
or Chapter 4 for horizontal beams).
3. Replace environmental cover on
Microcell™. Follow procedure in
appropriate chapter on installation.
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APPENDIX A. MICROCELL™ SPECIFICATIONS.
MECHANICAL
Stress Level
3” Microcell™ Maximum 10,000 psi (7.0kg/mm2)
Recommended* 5,000 psi ± 2,500 psi (3.5kg/mm2 ± 1.75kg/mm2)
2” Microcell™ Maximum 15,000 psi (10.5kg/mm2)
Recommended* 7,500 psi ± 3,750 psi (5.3kg/mm2 ± 2.6kg/mm2)
Fatigue Life > 20 million cycles; load and unload at 0 to 5,000 psi
(0kg/mm2 to 3.5kg/mm2)
*Consult factory for application assistance for stress levels outside the recommended range.
ELECTRICAL
Excitation Voltage Standard 12VDC, ±5%; maximum 30VDC
Excitation Current at 12V 4.0mA at 0° F (-18° C) to 2.7mA at 100° F (+38° C)
Insulation Resistance 2kΩ
Strain Gage to Sensor Frame
Breakdown Voltage > 500VDC
Red-to-White and Black-to-White Resistance
3” Microcell™ Standardized: 8.50kΩ ± 200Ω at 70° F (21° C)
Non-Standardized: 2.0kΩ ± 200Ω at 70° F (21° C)
2” Microcell™ 2.0kΩ ± 200Ω at 70° F (21° C)
OUTPUT FOR 12V EXCITATION
Sensitivity
3” Microcell™ 70mV ± 1%/1,000 psi (70mV ± 1%/0.7kg/mm2)
2” Microcell™ 56mV ± 1%/1,000 psi (56mV ± 1%/0.7kg/mm2)
Zero-Strain Output 0mV ± 25mV
Non-linearity ±0.1% of full-scale output
Repeatability and Hysteresis 0.05% of full-scale output
Output Impedance
3” Microcell™ Standardized: 7.5kΩ ± 75Ω at 70° F (21° C)
Non-Standardized: 1.0kΩ ± 100Ω at 70° F (21° C)
2” Microcell™ 1kΩ ± 100Ω at 70° F (21° C)
ENVIRONMENTAL
Rating Designed for rugged, outdoor applications
Temperature Range
Operational -30° F to +150° F (-34° C to +66° C)
Storage -30° F to +150° F (-34° C to +66° C)
Compensated Standard: 0° F to +100° F (-18° C to +38° C)
Mid: +50° F to +150° F (+10° C to +66° C)
Temperature Effects
Sensitivity Change 0.02%/° F (0.036%/° C), in compensated temperature range
Zero Shift ±5mV/100° F (±5mV/56° C), in compensated temperature range
PHYSICAL
Weight 3 oz (90g)
Cable 3-conductor, 22 gauge, unshielded
Steel Base AISI 1018 carbon steel matched to A36
Aluminum Base Custom — consult factory
Stainless Steel Base Custom — consult factory
Cable Length 5.5 ft (1.7m)
Size See Reference Dimensions
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APPENDIX B. GLOSSARY
CALIBRATION CURVE
A graph of load versus output. Typically, it is a
straight line and relates live load to a voltage or
digital count output.
LIVE LOAD
The weight of the material to be measured;
in other words, the weight of the contents of the
vessel.
HYSTERESIS
The maximum difference between sensor
readings for the same applied load, with one
reading obtained by increasing the load from zero
and the other reading obtained by decreasing the
load from the rated load. It is usually expressed
as a percentage of the rated load.
NON-LINEARITY
The maximum deviation of the sensor calibration
curve from a straight line between zero load and
the rated load.
6. Some type of indicator or display, such as
numerals, needle movement, discrete LED
array, etc.
REPEATABILITY
The maximum difference between sensor readings
for repeated loadings under identical loading and
environmental conditions.
SENSITIVITY
The ratio of the change in electrical output to the
change in load or stress.
SIGNAL PROCESSOR
The electronic rmware and software box
connected to a sensor (such as a Microcell™) or
transducer array. If it is augmented with software,
the rst stage of the signal processor is an A/D
converter. A signal processor generally has
provisions for most, if not all, of the following:
1. Excitation voltage applies to each of the
sensors/transducers in the network.
2. Adjustable zero calibration.
3. Adjustable scale factor.
4. Long-distance signal transmission options,
such as 4-20mA or serial transmission.
5. Set Point (commonly referred to as a contact
closure) to provide a discrete indication that a
specic point has been reached.
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APPENDIX C. ALTERNATE METHOD FOR
CHECKING OUTPUT
If you do not have a Kistler-Morse® Test Meter, use
a Digital Multimeter (DMM) to monitor the voltage
output of each Microcell™ during installation. Set
up the DMM as described below and then follow
the installation procedure for mounting the
Microcell™.
Note
The junction box must be mounted and wired to
the signal processor and powered up before
proceeding with the following procedure. See
previous sections about Mounting Junction
Box, Wiring Microcells™ to Junction Box, and
Wiring Junction Boxes Together and to Signal
Processor before continuing.
1. See Figure C-1. Connect the red wire from
the Microcell™ cable to the R terminal on
terminal block TB3 in the junction box.
Connect the black wire to the B terminal
on TB3.
2. Connect the signal (+) probe of the DMM to the
white wire from the Microcell™ cable. DO NOT
connect the white wire to the terminal block.
3. Connect the common (-) probe of the DMM
to TP1 on the junction box circuit board. If
a test point is not present, connect the
common probe to the lead of either R1 or R2
nearest the TB2 terminal strip.
4. Set a voltage range on the DMM that will
accommodate a measured range of ±1V.
5. Complete installation of the Microcell™,
using the DMM to monitor the voltage output
as you tighten the screws. See Mounting the
Microcell™ for your installation.
Figure C-1. Using DMM to Monitor Voltage Output.
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APPENDIX D. SPARE PARTS RECOMMENDATIONS
Kistler-Morse® recommends the purchase and
maintainance of the following minimum number of
spare parts/tools for the Microcell™ system:
1 Extra per Vessel
Microcell™ Sensor, each complete with:
Sensor
Environmental Cover
#8-32 socket head cap screws (2)
#8 hardened at washers (2)
1 Extra per Plant
T-handle driver
Sikaex 1A polyurethane sealant or Dow
Corning RTV 738 or RTV 739
Kistler-Morse
CAUTION
Only use Sikaex 1A polyurethane sealant
or Dow Corning RTV 738 or RTV 739. Other
sealants may contain acetic acid, which is
harmful to sensors and electronics.
®
Test Meter
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APPENDIX E. TECHNICAL DRAWINGS
This appendix contains the following technical drawing(s):
DRAWING NUMBER DRAWING TITLE
TI-MC.FM-01 FM Approved Intrinsically Safe Interconnect Diagram, Microcell™ Sensor