RICE LAKE RoughDeck CC Caster Cargo Scale with EZ Mount Load Cell Kits and a TuffSeal Junction Box Instruction Manual
- June 5, 2024
- RICE LAKE
Table of Contents
RICE LAKE RoughDeck CC Caster Cargo Scale with EZ Mount Load Cell Kits and a TuffSeal Junction Box Instruction Manual
An ISO 9001 registered company © Rice Lake Weighing Systems. All rights
reserved.
Rice Lake Weighing Systems® is a registered trademark of Rice Lake Weighing
Systems.
All other brand or product names within this publication are trademarks or
registered trademarks of their respective companies.
All information contained within this publication is, to the best of our
knowledge, complete and accurate at the time of publication. Rice Lake
Weighing Systems reserves the right to make
changes to the technology, features, specifications and design of the
equipment without notice.
The most current version of this publication, software, firmware and all other product updates can be found on our website: www.ricelake.com
Technical training seminars are available through Rice Lake Weighing Systems. Course descriptions and dates can be viewed at www.ricelake.com/training or obtained by calling 715-234-9171 and asking for the training department.
Rice Lake continually offers web-based video training on a growing selection of product-related topics at no cost. Visit www.ricelake.com/webinars.
1.0 Introduction
The installation should be planned by a qualified structural engineer. Each
installation is unique, this manual is meant to serve as a general guideline
for installation.
Manuals and additional resources are available from the Rice Lake Weighing
Systems website at www.ricelake.com Warranty
information can be found on the website at
www.ricelake.com/warranties
The RoughDeck CC Caster Cargo Scale has a 20,000 lb capacity with a powder
coat surface for durability. Load and unload the caster deck scale in all
directions with 360 degree swivel casters (108 Kalpar Casters model
DL55014893).
The EZ Mount kits provide an extremely accurate method for weighing medium and
large capacity structures that are subject to large thermal
expansion/contraction or vibration forces. The design uses a double ended
shear beam load cell (700 bridge) and transmits the load with a sliding pin on
the load-bearing groove of the cell. This design is very effective in
providing for thermal expansion/contraction with little friction.
In the majority of applications, the assemblies are self-checking and held captive with no need for check or stay rods, making this mount a good choice for areas with frequent seismic activity. The sliding pin design eases load cell installation and replacement without the need to raise the structure a large amount. The Rough Deck CC uses four stainless steel EZ Mount 1 weigh modules (Section 2.2 on page 4) containing 10,000 lb stainless steel IP67 load cells (RL70000SS). The Rough Deck CC also utilizes a JB4SS TuffSeal NEMA Type 4X stainless steel signal trim junction box. The TuffSeal junction box can be placed in any of the corners of the caster deck (Section 4.2 on page 8) and accessed through any of the 4 removable deck panels along with the load cells and mounts.
1.1 Safety
Safety Signal Definitions:
General Safety
Do not operate or work on this equipment unless this manual has been read and all instructions are understood. Contact any Rice Lake Weighing Systems dealer for replacement manuals.
Failure to heed may result in serious injury or death.
Do not use for purposes other than weight measurement.
Do not use any load-bearing component that is worn beyond 5% of the original
dimension.
Do not use this product if any of the components are cracked.
Do not exceed the rated load limit of the unit.
Do not make alterations or modifications to the unit.
Do not use without the deck completely assembled.
Do not place fingers into slots or possible pinch points.
2.0 Mechanical Installation
This section provides an overview of mechanical installation information.
2.1 General Installation Guidelines
The RoughDeck CC system uses four EZ mounts. EZ mounts come assembled to the mount risers with wooden blocks to keep the load cell from being loaded during shipping.
The mounting surface for the mounts must be level within ±0.5°.
If the mounting surfaces are not level, use shims and/or grout to level the
mount. If possible, check that the mount is level when the structure is fully
loaded because excessive deflections in legs and supporting structures may
cause additional side forces, which affect accuracy. Deflection of the mounts
top or base plate due to loading should not exceed ±0.5°. The load on each
mount assembly should vary by no more than 20%.
Add shims where necessary to achieve correct load distribution.
During installation, avoid overload damage to the load cells.
2.2 Mount Installation
Secure an EZ Mount assembly to the riser mount plate in each corner of the caster deck. The access panel top plate and corner caster plate need to be removed to access the mounting holes to secure the EZ Mount assemblies.
EZ Mount Orientation
Position EZ Mount assemblies so the load cell cables are positioned on the
inside.
Secure the EZ Mount Base Plate
Verify that there is no initial misalignment and that the load cells are in the center of the hole in the top plate loading bracket. Relocate if necessary.
Attach the base plates to the foundation using suitable anchors for concrete or by bolting or welding to a steel structure.
Verify that the base plates are no more than ±0.5° out of level. Shim if necessary and fully tighten mounting bolts.
Verify bolts securing the load cell to the base plate are tight. Only torque load cell bolts to 20 foot-pounds. This allows the double-ended load cell to flex under load.
If surrounding equipment is frequently steam cleaned, or if the load cell is subjected to direct washdown, a protective shroud for the weighing assembly is recommended.
Proper drainage is necessary so the weighing assembly is not standing in water. All support points should be equally stiff so that they deflect by the same amount as the structure is loaded.
3.0 Load Cell Wiring
This section provides an overview of load cell wiring information.
-
Route the load cell cables so they will not be damaged or cut. Cable should not be routed near heat sources greater than 150°F. Do not shorten any load cell cable. The load cell is temperature compensated with the supplied length of cable. Cutting the cable will affect temperature compensation. Coil and protect excess cable so it will not be mechanically damaged or be sitting in water.
-
Provide a drip loop in all cables so that water or other liquids will not run directly down the cables onto either the load cells or the junction box.
If conduit protection is necessary against mechanical or rodent damage to the load cell cables, use flexible conduit and conduit adapters at the load cells. Conduit can also provide protection against moisture ingress into the load cell. -
Connect cables for RL70000SS load cells to the summing board in the junction box according to Table 3-1 and the labels on terminal strips of the junction box.
4.0 TuffSeal Junction Box
The RoughDeck CC comes with the TuffSeal stainless steel junction box. The
TuffSeal JB4SS is a signal trim junction box that can accommodate four load
cells.
Manuals and additional resources are available on the Rice Lake Weighing
website at www.ricelake.com. Refer to the Load Cell
and Weigh Module Handbook (PN 22054) for additional system calibration
details.
The TuffSeal JB4SS has a Prevent® breather vent, which inhibits the build-up of pressure caused by sudden temperature or environmental changes. It must be changed every six months to a year, it does become dirty over time. When correctly installed and torqued to 10 in-lb, all models can withstand 900 PSI water pressure.
All terminals will function properly without modification. However, load cell output can be individually trimmed with potentiometers which is further explained in Section 4.4 on page 11.
4.1 Dimensions
4.2 Mounting Location
The TuffSeal junction box can be mounted in any of the four corners of the caster deck to the top of the riser mount plate. The access panel top plate and corner caster plate need to be removed to mount the junction box (see Figure 2-2 on page 4).The junction box should be mounted in a location that is convenient for servicing.
4.3 Junction Box Wiring
The TuffSeal JB4SS junction box has been designed to connect and trim up to four load cells.
- Determine the wiring pattern to be used.
- Route the load cell cables through the cord grips, do not tighten the grips.
- Strip the wire insulation back 1/4” to expose the wire.
- Push in and hold the quick-connect lever with a small screwdriver.
- Insert the appropriate wire into the exposed wire opening.
- Release the screwdriver to allow the spring-loaded gate to close and lock the wire in place.
The spring-loaded terminals will accommodate 12-28 gauge wire.
4.3.1 Connect Indicator
The indicator terminal strip is used to connect the main cable to an indicator. This equipment was examined and approved for the connection to a single indicator only.
-
Determine the indicator’s load cell input connections from the indicator manual.
-
Run a cable from the indicator terminal into the junction box through the cord grip.
-
Strip the wire insulation back 1/4” to expose the wire.
-
Push in and hold the quick-connect lever with a small screwdriver.
-
Insert the appropriate wire into the exposed wire opening.
-
Release the screwdriver to allow the spring-loaded gate to close and lock the wire in place.
If cables could be exposed to water or other liquids, bend a short downward loop in all cables near the cord grips so any fluids draining down the cables will drip off before reaching the junction box.
4.4 Trimming Procedure
Trimming is a process of equalizing the output from multiple individual load cells. If needed, load cell output can be individually trimmed with potentiometers. If more than 5% of normal output needs to be trimmed to equalize output, check for other possible problems. When all errors except cell mismatch and cable extensions or reductions have been corrected, continue with the trimming.
4.4.1 Signal Board Trimming Procedure
Use the following steps to properly trim the TuffSeal JB4SS junction box.
- Determine the number of load cells needed.
- Ensure jumpers are in place to enable trimming the load cells. Remove jumpers for unused cells.
- Set all potentiometers fully clockwise to give maximum signal output from each cell.
-
Zero the indicator.
-
Place calibrated test weights over each load cell in turn. The amount of test weights to be used will depend on the scale configuration.
Refer to Handbook 44 Field Manual, published by NIST (National Institute of Standards and Technology, for weight recommendations. For a four cell platform, it’s 25% of scale capacity is recommended. -
Record the value displayed on the indicator once test weight is placed on each corner, directly over the load cell. Do not allow weight to overhang the sides.
-
Allow scale to return to zero each time to check for friction or other mechanical problems.
-
Select the load cell which has the lowest value as the reference point. This cell will not be trimmed.
-
Place the same test load over one of the other load cells.
-
Use the corresponding potentiometer to trim the load cell equal to the reference load cell.
-
Repeat Steps 9 and 10 until all remaining load cells have been trimmed.
-
Once trimming is complete, check all loads cells again for repeatability. If necessary, repeat Steps 4 through 11.
-
Pull excess cable out of the enclosure.
-
Tighten the cord grip assemblies with a wrench. To be watertight, each cord grip must be tightened so the rubber sleeve begins to protrude from the hub.
-
Plug unused hubs to prevent moisture entry.
-
Place the supplied desiccant filter it in the junction box.
-
Replace the cover and tighten the screws in an alternating pattern to be certain the gasket is compressed equally in all locations.
IMPORTANT See the Electronic Replacement Parts and Components catalog to
order extra hole plugs if needed for Step 15.
Inspect the desiccant during normal service and change the desiccant as
needed.
5.0 Calibration
Calibration of the load cells in the EZ Mounts should be performed by a
service technician. Please contact a local scale dealer for assistance with
calibration. Use certified test weights to calibrate the scale after the EZ
Mount assemblies are installed under the RoughDeck CC scale deck (Section 2.2
on page 4) and the junction box corner trimming procedure has been performed
(Section 4.4 on page 11). Rice Lake Weighing Systems recommends using weights
greater than 20% of the scale’s rated capacity and that the weights be evenly
distributed when calibration is performed.
The greater the weight used to perform calibration the more linear the scale
will be.
6.0 Troubleshooting
This section provides an overview of troubleshooting information.
Issues associated with load cells are often non-load cell related. Ensure all
parts of the device are properly connected and secured prior to
troubleshooting:
- Check load cell mount for debris restricting load cell movement or debris between scale and structure.
- Check that the structure and mounts are plumb, level, and square at critical areas.
- Check the load cell cables for damage.
- Check all electrical connections.
If the system can be calibrated but does not return to zero, loses calibration, or demonstrates non-linearity or non-repeatability, see Table 6-1 for troubleshooting information.
If issues persist:
- Check possible indicator malfunction by using a load cell simulator to input a known good signal into the indicator.
- Disconnect each load cell’s signal leads at the junction box and check individual load cell outputs with a Multimeter then check input/output impedances for comparison with load cell manufacturer’s specifications.
If previous troubleshooting does not resolve the issue, see the following procedure:
- Reconnect all but one load cell.
- Replace the load cell with a load cell simulator. Alternate so that each load cell is individually disconnected and replaced with a simulator.
If there is a problem with a particular load cell, the symptom should disappear when that load cell is disconnected and replaced with simulator.
7.0 Replacement Parts
7.1 EZ Mount 1 Weigh Modules
7.2 TuffSeal JB4SS Junction Box
- PG11 Cord Grip Nuts to be tightened to 33 in-lb
- PG7 Cord Grip Nuts to be tightened to 22 in-lb
- Breather Vent Nut to be tightened to 10 in-lb
© Rice Lake Weighing Systems Specifications subject to change without notice.
Rice Lake Weighing Systems is an ISO 9001 registered company.
230 W. Coleman St. · Rice Lake, WI 54868 · USA U.S.
800-472-6703 · Canada/Mexico
800-321-6703 · International
715-234-9171 · Europe +31 (0)26 472
1319
September 20, 2021 www.ricelake.com PN 203881 Rev B
References
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