RICELAKE survivor PL Low Profile Modular Railroad Track Scale Instruction Manual
- June 3, 2024
- ricelake
Table of Contents
survivor PL Low Profile Modular Railroad Track Scale
Survivor® PL
Low Profile Modular Railroad Track Scale
Installation Manual
October 18, 2022
PN 98740 Rev E
© 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
Revision History
Revision History
This section tracks and describes the current and previous manual revisions for awareness of major updates and when the updates took place.
Revision F
Date
Description
October 18, 2022 Updated graphics representing scale platform
Table i. Revision Letter History
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 Weighing Systems All Rights Reserved
3
Survivor PL – Low Profile Modular Railroad Track Scale
Contents
1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 1
1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 1
2.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 2
2.1 Foundation Installation . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 2 2.2 Scale Installation . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.3
Approach and Dead Space Hardware Installation . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 7 2.4 Rail Installation . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 7 2.5 Grouting . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 7
3.0 Junction Box and Grounding . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Load Cells to Junction Box . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 9 3.2 Junction Box Connections. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.3 Junction Box
to Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 9 3.4 Indicator to Peripherals . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 9 3.5 Single-Point Ground
Conductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 3.6 Electrical Ground Connections . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 9
4.0 Trimming and Calibration . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
4.1 Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 12 4.2 Trim Load Cells . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2.1 Static Testing of a Track Scale . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 13 4.2.2 Strain Test . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 13
5.0 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 14
Rice Lake continually offers web-based video training on a growing selection of product-related topics at no cost. Visit www.ricelake.com/webinars
4
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Introduction
1.0 Introduction
This manual is intended for use by service technicians responsible for
installing and servicing low profile modular railroad track scales.
Manuals and additional resources are available from Rice Lake Weighing Systems
at www.ricelake.com/manuals Warranty information can be found at
www.ricelake.com/warranties NOTE: Use these instructions as general
installation guidelines unless the engineering drawings furnished with the
scale differ from the instructions in this manual. Engineering drawings
furnished with the scale always take priority over the general installation
guidelines.
1.1 Safety
Safety Definitions:
DANGER: Indicates an imminently hazardous situation that, if not avoided, will
result in death or serious injury. Includes hazards that are exposed when
guards are removed. WARNING: Indicates a potentially hazardous situation that,
if not avoided, could result in serious injury or death. Includes hazards that
are exposed when guards are removed.
CAUTION: Indicates a potentially hazardous situation that, if not avoided,
could result in minor or moderate injury.
IMPORTANT: Indicates information about procedures that, if not observed, could
result in damage to equipment or corruption to and loss of data.
General Safety
Do not operate or work on this equipment unless this manual has been read and
all instructions are understood. Failure to follow the instructions or heed
the warnings could result in injury or death. Contact any Rice Lake Weighing
Systems dealer for replacement manuals.
WARNING Failure to heed could result in serious injury or death. Some
procedures described in this manual are potentially dangerous. These
procedures are to be performed by qualified service personnel only Do not
allow children or inexperienced persons to operate this unit. Do not operate
without all shields and guards in place. Do not use for purposes other then
weight taking. Do not place fingers into slots or possible pinch points. 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 remove or obscure warning labels. Keep
hands, feet and loose clothing away from moving parts.
© Rice Lake Weighing Systems All Rights Reserved
5
Survivor PL – Low Profile Modular Railroad Track Scale
2.0 Installation
DANGER: Crush hazard, keep hands, feet and other body parts clear when setting weigh modules in place. Moving parts can crush and cut.
Recommended Tools and Equipment Below is a list of recommended tools and equipment necessary to assemble and install the Survivor PL Rail Scale.
· Two 10 ton bottle jacks, 12 in or shorter · 24 wooden blocks 6 in x 6 in x
24 in oak · 24 wooden blocks 4 in x 4 in x 24 in oak · 24 wooden blocks 2 in x
4 in x 24 in oak · Flat blade screw driver · Small blade screw driver for
adjusting j-box pot. · #2 Phillips screw driver · Transit · Small magnetic
level · Large funnel with 1 in opening in bottom · 24 in plastic pipe to
attach to above funnel for
pouring grout · 1 5/8 in combination wrench · 1 5/8 in socket · 15/16 in
socket · 1 1/4 in socket
· 1 1/4 in combination wrench · 1 1/8 in socket · 2 in combination wrench · 2
in socket · 3/8 in Allen wrench · 7/16 in socket · Multi meter · Pliers ·
Torque wrench capable of torquing up to 250 ft lb for 1
1/4 in socket & 2 in socket · Fish tape for pulling wires · Line up punch for
aligning holes · Large hammer · Latex caulk for sealing grout forms · Caulk
gun for above caulk · 1 in x 4 in wood for building grout forms
2.1 Foundation Installation
For installation, reference the foundation drawings supplied with the scale. ·
Do not start construction of the foundation without having certified prints. ·
Pour the scale slab(s). · Pour the approach slab and, if applicable,
intermediate section over rebar or optional anchor bolts. · Use Handbook 44
and AAR Handbook Guidelines for Legal for Trade
NOTE: Anchor bolts should protrude from the concrete enough for the lower base
plates to be secured onto them.=
IMPORTANT: Failure to heed the following could result in damage to the concrete and equipment.
- The concrete foundation must cure in a moist state for at least seven days (three days for high-early concrete). At seven days, standard concrete is approximately 75% of its maximum strength and can handle moderate loads. Loading of a slab before it reaches 75% of maximum strength may damage the foundation. * Standard concrete does not reach full strength until after a 28-day cure.
6
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2.2 Scale Installation
Use the following steps to install the scale.
Leveling bolts Load cell lower base plate
Figure 2-1. Leveling Bolts Installed into Lower Base Plate 1. Set load cell
lower base plates over the pre-cast anchor bolts. 2. Install leveling bolts
into base plates.
Load cell
Load cell spacer plate
Load cell base plate
Installation Anchor bolts
Figure 2-2. Load Cell, Spacer Block, and Base Plate 3. Install load cell, spacer plate and base plate onto lower base plates.
Load Cell Installed
© Rice Lake Weighing Systems All Rights Reserved
7
Survivor PL – Low Profile Modular Railroad Track Scale Check rod bracket
End rail support plate
Figure 2-3. Install Brackets 4. Set longitudinal check brackets and lateral side check brackets over pre-cast anchor bolts.
D
D
C
C
Check Rod
C Check Rod Bracket
Check Rod
C Check Rod Bracket
Section C-C
Figure 2-4. Check Rod Locations
Section D-D
NOTE: The rods for the checking system, should be placed beneath the scale prior to setting of the modules. Bracket quantity varies depending on number of scale sections.
8
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Installation
Ground Strap Connection
Weigh Module Pocket
Install upper load cell components
When bolts are tight, plates will be movable
Figure 2-5. Upper Load Cell Plate Mounting Procedure
5. Remove steel top plates from weigh module. Mark the plates to identify
their location for re-assembly. 6. Install bearing block, upper mount plate,
spacer tubes, bearing cushions and shim plate in each load cell pocket of the
weigh module.
WARNING: Crush hazard, keep hands, feet and other body parts clear when
setting weigh modules in place. Moving parts can crush and cut.
Wooden setting block
Figure 2-6. Weigh Module on Setting Blocks 7. Set the weigh module on 5 in
setting blocks. Center the module between approaches.
© Rice Lake Weighing Systems All Rights Reserved
9
Survivor PL – Low Profile Modular Railroad Track Scale
Figure 2-7. Module Elevation 8. Using a jack and shims, level the module and
set its elevation between 2 1/8 in and 2 1/4 in above concrete
approaches.
Jack Upper Load Cell Mount Plate
Load Cell Leveling Bolts
Figure 2-8. Load Cell Assembly 9. Using leveling bolts, raise and level the
load cell assemblies to contact the upper mount bearing plates.
Check Rod
Figure 2-9. Check Rod Level with Horizontal Plane
10. Jack the weigh module to allow removal of setting blocks and shims. 11.
Install the lower base plate, washers and nuts.Do not torque nuts until after
plates are grouted and cured. 12. Install check rods and hardware. Ensure
check rods level with a horizontal plane to within +/- 2 degree. 13. Weld
spacer plates (PN 71860) to the weigh module to secure it in place. 14. Repeat
steps 1-13 for the second weigh module.
10
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Installation
2.3 Approach and Dead Space Hardware Installation
Use these instructions to install the approach and dead space hardware.
Reference drawings are provided for approach and dead space details.
Anchor Bolts Figure 2-10. Approach Plate on Anchor Bolts
1. Install approach plates on the anchor bolts. Ensure they are at the
required elevation by using shims or jam nuts beneath each plate.
2. Install dead space rail plates on the anchor bolts at the required
elevation.
2.4 Rail Installation
The following instructions describe the installation of rail sections on the
scale.
45°
Cut through ball of rail only at 45°
5/8″ Max 1/8″ Min
Figure 2-11. Mitered Rail Head Cut Location
1. Cut A.R.E.A. rail sections using 45° mitered rail head cuts at the weigh
rail and approach rail transitions. 2. Set rail support plates over the pre-
cast anchor bolts on the approach and center section foundations. 3. Set weigh
rails and approach rails onto the rail support plates. 4. Shim and align rails
to match elevation of scale and set the desired grade.
Option: Install jam nuts under approach rail support plates to act as a
leveling device. 5. Install rail clips and secure rails in place. 6. Install
anti-creep rail anchors.
2.5 Grouting
Prior to grouting, re-check all weigh modules and rail alignment, levels and
elevations. 1. Use an epoxy-type 9000 psi grout under the load cell base
plates and center section rail support plates. Do not grout under the
longitudinal check brackets or side check brackets. 2. After the grout has
hardened, tighten/torque nuts on all anchor bolts. 3. The checking system can
now be tightened. Bring the nuts up to snug.
© Rice Lake Weighing Systems All Rights Reserved
11
Survivor PL – Low Profile Modular Railroad Track Scale
3.0 Junction Box and Grounding
Electrical conduit is pre-installed at the factory and only needs to be
connected between the modules and from the modules to the junction box.
Following conduit work, load cell cables are routed through each conduit from
the load cells to the junction box. All load cell cabling used for this
installation comes in the shipping container. The layout pattern for the
electrical conduit on a three module rail scale installation is shown in
Figure 3-1.
Module A
LC1
LC2
Module B LC3
Module C
LC4
LC5
LC10
LC9
LC8
J-Box
Detail A
Load Cell Cable to Connector
+SI – White – SI – Red +EX – Green – EX – Black SHD – Shield
J3
+SI -SI +EX -EX SHD
Load Cell #1
J1
+SI -SI +EX -EX SHD
Load Cell #2
+SI
-SI
+EX
Load Cell #8
-EX
SHD
J4
+SI -SI +EX -EX SHD
J2
Load Cell #7
LC7
LC6
J-Box
Detail B
Expansion/J9
SHD +SI -SI +SEN +EX -SEN -EX
Indicator/J10
SHD +SI -SI +SEN +EX -SEN -EX
Cable to J-Box
SHD – Shield +SI – White – SI – Red +SEN – Blue +EX – Green – SEN – Yellow – EX – Black
Load Cell Cable to Connector
+SI – White – SI – Red +EX – Green – EX – Black SHD – Shield
Detail A
J3
+SI -SI +EX -EX SHD
Load Cell #3
J1
+SI -SI +EX -EX SHD
Load Cell #4
+SI
-SI
+EX
Load Cell #6
-EX
SHD
J4
+SI -SI +EX -EX SHD
J2
Load Cell #5
Expansion/J9
SHD +SI -SI +SEN +EX -SEN -EX
Indicator/J10
SHD +SI -SI +SEN +EX -SEN -EX
Cable to J-Box Cable to Indicator
SHD – Shield +SI – White – SI – Red +SEN – Blue +EX – Green – SEN – Yellow –
EX – Black
SHD – Shield +SI – White – SI – Red +SEN – Blue +EX – Green – SEN – Yellow –
EX – Black
Detail B
Figure 3-1. J-Box Wiring and Conduit
12
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Junction Box and Grounding
3.1 Load Cells to Junction Box
Each load cell is equipped with 30 ft of load cell cable, sufficient to reach
a centrally-located junction box on standard scales. A conduit adapter and a
14 in section of 3/4 in flexible conduit is supplied for both ends of each
load cell cable located at the load cell and at the junction box. The main
conduit that runs between these 14 in flexible end sections are 3/4 in
galvanized metal. The conduit is already installed on the deck.
NOTE: Flexible conduit can not come in contact with the ground. Plastic tie
wraps are included in the hardware shipping box and should be used to tie up
the flexible conduit.
If using a single B module, some of the conduit runs are not used. These
conduit runs are used when more than one B modules are installed.
3.2 Junction Box Connections
Each junction box is large enough to hold the summing board, transient
protection devices, packaged desiccant and extra load cell cable coiled inside
the enclosure. An industrial corrosion inhibitor and desiccant such as the
RLWS Industrial Corrosion Inhibitor (PN 16037) should be added to the junction
box enclosure before final closure.
NOTE: Summing card mounted within the junction box is used to make all cable
terminal connections. All terminal pins are clearly marked as to function.
3.3 Junction Box to Indicator
Fifty eight (58) feet of six-wire homerun cable is supplied for wiring the
junction box to the indicator. It is run in 3/4 in galvanized metal conduit
from the junction box to the indicator. Conduit for this purpose is to be
obtained locally. A 30 in flexible conduit section and conduit connector is
provided where this cable exits the junction box. Do not run any other
electrical cables in or near the conduit to the indicator.
3.4 Indicator to Peripherals
All 3/4 in conduit for cabling from the indicator to remote displays and other
peripheral devices is to be obtained locally. Conduit runs may be buried in a
trench or secured above ground. Use separate conduit runs for AC power and DC
data lines to avoid interference. As a general guideline, run AC and DC cables
in separate trenches if possible. If DC data cables must run in the same
trench as AC power lines, separate cables as much as possible (preferably more
than 34 in apart).
3.5 Single-Point Ground Conductor
A bare 10 gauge solid wire is to be run from the scale frame to the grounding
lug on the junction box then underground to the main AC power earth ground. If
the DC transient protection board is installed, the ground conductor should
also be connected to the transient protection board’s ground lug.
3.6 Electrical Ground Connections
IMPORTANT: A single-point grounding system is required. Improper grounding
systems can cause corrupted data from ground loop current flows and costly
lightning damage to electronics.
Always strive for a single-point grounding system. Do not drive ground rods at
the scale location which establishes separate earth grounds for the scale.
These separate earth grounds will not share the same zero reference as the
existing earth ground for the AC power system. This difference in electrical
potential invites ground-loop current flow between the separate grounds, often
corrupting serial data like RS-232, which depends on a stable zero reference.
In addition, a separate earth ground system at the scale can actually invite
lightning or power surge damage:
· A minor power line surge should immediately be shunted to ground. If a
separate ground system exists at the scale with a lower potential than the
main ground, the surge may travel out to the scale ground rod, damaging load
cells on its way.
· A nearby lightning ground strike may instantly raise the zero potential of a
ground rod at the scale location, while leaving the scale house ground rod
unaffected. That lightning surge will now take the easiest path to the lower-
potential ground–through the scale wiring and back to the scale house ground,
possibly damaging the indicator on its way.
Therefore, the best grounding system for the scale is the same grounding
system used for the incoming AC power system. The 120 VAC power source used to
power the indicator will be connected to an existing earth grounded rod system
at the scale house or other building where the indicator is located. This
should consist of a double ground rod system of two 5/8 inx 8 ft copper rods
driven 8 ft deep at the service entrance where the local utility company
brings their lines into the building.
© Rice Lake Weighing Systems All Rights Reserved
13
Survivor PL – Low Profile Modular Railroad Track Scale
The local utility company can test the resistance of the existing ground rods
with a clamp-on megohmeter that measures zero resistance. A reading of 3¾ or
less is acceptable as a ground. If the test determines that the grounding
system is inadequate, the utility company can suggest methods to improve the
system. It’s crucial that the scale owner authorize and make the recommended
improvements to assure an adequate electrical ground. Do not connect the scale
to the AC power supply until the grounding system is adequate.
Be certain each load cell grounding strap is securely connected to the top
plate and bottom plate of each load cell mount. There should be metal-to-metal
contact with no presence of paint or grout. This strap is designed to channel
power surges on the deck around–rather than through–the load cell to ground
Grounding Strap
Figure 3-2. Grounding Strap on Load Cell Mount
These, and all, ground connections must be torqued to a specified value and
retorqued at regular service intervals. A thick coating of anti-oxidant grease
should be maintained on all ground connections to prevent corrosion.
A separate grounding system conductor must extend uninterrupted from the main
service panel ground to the scale to protect load cells and scale wiring from
lightning and other transient damage. This ground wire conductor must be an
unsheathed #10 copper wire or larger. Run the bare ground wire conductor
intact from the AC power ground rod to the scale in a separate trench. Bring
the wire up from the trench near the junction box and attach it to the ground
lug of the junction box. A #10 bare ground wire is run from the ground lug of
the junction box to one of the junction box mounting studs on the scale frame,
thus grounding the scale frame to the same single-point ground as the AC power
for the indicator.
RICE LAKE WEIGHING SYSTEMS
1
J3 +SI -SI +EX -EX SHD
TRIM R14
R17 R18 R19
JP6
VR3
1
+SI R21
-SI R22
+EX
R23
-EX
SHD
J4
TRIM
R26
VR1 R25 R24
CELL# SIGNAL
CUT
TO
DISABLE SECT#
VR2 R16 R15
CELL# SIGNAL
J1
+SI
-SI JP7
+EX JP8
-EX
SHD
R20
+SI -SI JP9 +EX JP10 -EX
SHD
J2
1
1
VR6
TRIM
R1
JP2 R4
R5
JP3
R6
TO
DISABLE SECT#
JP1
CUT
R8
R9
JP4
R10 JP5
TRIM
R13
J7
TRIM
R40
1
+SI
1
J5 +SI
VR7 R42 R41
CELL# SIGNAL
-SI
-SI
JP17
+EX
R43
+EX
R44
JP18
-EX
-EX
R45
SHD
SHD
TO
JP16
R46
JP11
TO
TRIM
R27
JP12 R30
R31
JP13
R32
DISABLE SECT#
VR10
DISABLE SECT#
VR9
CUT
CUT
1
1
+SI R47
+SI R34
-SI
-SI
R48
JP19
R35
JP14
+EX
R49
+EX
R36
JP20
JP15
-EX
-EX
R38 R37
VR12
SIGNAL VR8 R51 R50
CELL# SIGNAL
CELL#
SHD
J8 JP
TRIM
R52
CONNECT BOTH SHUNTS
TO APPLY SIGNAL JP
SHD
J6
JP
TRIM
R39
SIGNAL
DISCONNECT BOTH SHUNTS JP TO REMOVE SIGNAL
VR11 R29 R28
CELL# SIGNAL
VR4 R12 R11
CELL# SIGNAL
VR5 R3 R2
CELL# SIGNAL
SIGNAL
L2
R7 L1 L4
Assembly PN Rev.
EXPANSION/J9
SHD +SI -SI +SEN +EX -SEN -EX
L3 R33
INDICATOR/J10
SHD
ARC
+SI
-SI
+SEN
+EX
-SEN
-EX
CUT TRACE TO ISOLATE SENSE LINE
Transient Board Connectors JMP/POS
JMP/NEG
DLD 2005
ARGND
Grounding Lug
Ground Lug
10 ga. bare ground wire to DC protection ground connection
before indicator
Figure 3-3. Junction Box Ground Wire Connections.
14
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Junction Box and Grounding
186210
Ground Wire
RICE LAKE WEIGHING SYSTEMS
1
J3 +SI -SI +EX -EX SHD
TRIM R14
R17 R18 R19
JP6
VR3
1
+SI R21
-SI R22
+EX
R23
-EX
SHD
J4
TRIM
R26
VR1 R25 R24
CELL# SIGNAL
CUT
TO
DISABLE SECT#
VR2 R16 R15
CELL# SIGNAL
J1
+SI
-SI JP7
+EX JP8
-EX
SHD
R20
+SI -SI JP9 +EX JP10 -EX
SHD
J2
1
1
VR6
TRIM
R1
JP2 R4
R5
JP3
R6
TO
DISABLE SECT#
JP1
CUT
R8
R9
JP4
R10 JP5
TRIM
R13
J7
TRIM
R40
1
+SI
1
J5 +SI
VR7 R42 R41
CELL# SIGNAL
-SI
-SI
JP17
+EX
R43
+EX
R44
JP18
-EX
-EX
R45
SHD
SHD
TO
JP16
R46
JP11
TO
TRIM
R27
JP12 R30
R31
JP13
R32
DISABLE SECT#
VR10
DISABLE SECT#
VR9
CUT
CUT
1
1
+SI R47
+SI R34
-SI
-SI
R48
JP19
R35
JP14
+EX
R49
+EX
R36
JP20
JP15
-EX
-EX
R38 R37
VR12
SIGNAL VR8 R51 R50
CELL# SIGNAL
CELL#
SHD
J8 JP
TRIM
R52
CONNECT BOTH SHUNTS
TO APPLY SIGNAL JP
SHD
J6
JP
TRIM
R39
SIGNAL
DISCONNECT BOTH SHUNTS JP TO REMOVE SIGNAL
VR11 R29 R28
CELL# SIGNAL
VR4 R12 R11
CELL# SIGNAL
VR5 R3 R2
CELL# SIGNAL
SIGNAL
L2
R7 L1 L4
Assembly PN Rev.
EXPANSION/J9
SHD +SI -SI +SEN +EX -SEN -EX
L3 R33
INDICATOR/J10
SHD
ARC
+SI
-SI
+SEN
+EX
-SEN
-EX
CUT TRACE TO ISOLATE SENSE LINE
Transient Board Connectors JMP/POS
JMP/NEG
DLD 2005
ARGND
Grounding Lug
JB8SPT Junction Box
With Transient Protection RLWS PN 91783
RICE LAKE WEIGHING SYSTEMS
1
J3 +SI -SI +EX -EX SHD
TRIM R14
R17 R18 R19
JP6
VR3
1
+SI R21
-SI R22
+EX
R23
-EX
SHD
J4
TRIM
R26
VR1 R25 R24
CELL# SIGNAL
CUT
TO
DISABLE SECT#
VR2 R16 R15
CELL# SIGNAL
J1
+SI
-SI JP7
+EX JP8
-EX
SHD
R20
+SI -SI JP9 +EX JP10 -EX
SHD
J2
1
1
VR6
TRIM
R1
JP2 R4
R5
JP3
R6
TO
DISABLE SECT#
JP1
CUT
R8
R9
JP4
R10 JP5
TRIM
R13
J7
TRIM
R40
1
+SI
1
J5 +SI
VR7 R42 R41
CELL# SIGNAL
-SI
-SI
JP17
+EX
R43
+EX
R44
JP18
-EX
-EX
R45
SHD
SHD
TO
JP16
R46
JP11
TO
TRIM
R27
JP12 R30
R31
JP13
R32
DISABLE SECT#
VR10
DISABLE SECT#
VR9
CUT
CUT
1
1
+SI R47
+SI R34
-SI
-SI
R48
JP19
R35
JP14
+EX
R49
+EX
R36
JP20
JP15
-EX
-EX
R38 R37
VR12
SIGNAL VR8 R51 R50
CELL# SIGNAL
CELL#
SHD
J8 JP
TRIM
R52
CONNECT BOTH SHUNTS
TO APPLY SIGNAL JP
SHD
J6
JP
TRIM
R39
SIGNAL
DISCONNECT BOTH SHUNTS JP TO REMOVE SIGNAL
VR11 R29 R28
CELL# SIGNAL
VR4 R12 R11
CELL# SIGNAL
VR5 R3 R2
CELL# SIGNAL
SIGNAL
L2
R7 L1 L4
Assembly PN Rev.
EXPANSION/J9
SHD +SI -SI +SEN +EX -SEN -EX
L3 R33
INDICATOR/J10
SHD
ARC
+SI
-SI
+SEN
+EX
-SEN
-EX
CUT TRACE TO ISOLATE SENSE LINE
Transient Boa rd Connectors
JMP/POS
JMP/NEG
DLD 2005
ARGND
Grounding Lu g
JB8SPT Junction Box
With Transient Protection RLWS PN 91783
UJB-3T6 DC Transient Protection
RLWS PN 21134
TP-232 DC Transient Protection
RLWS PN 33185
TP-232 DC Transient Protection
RLWS PN 33185
SOLA S1K520 AC Transient Protection
RLWS PN 110812
AC Outlet
AC Outlet
SOLA S1K 520 AC Transient Protection
RLWS PN 110812
Ground Wires
Power Company Ground Rod
*Always verify that installed wiring is properly grounded
Figure 3-4. Single-Point Grounding Diagram
AC Power Supply
10 Copper Ground Wire
Serial Communication
Homerun Cable
Load Cell Cable
© Rice Lake Weighing Systems All Rights Reserved
15
Survivor PL – Low Profile Modular Railroad Track Scale
4.0 Trimming and Calibration
IMPORTANT: See the Association of American Railroads (AAR Scale Handbook) at
http://www.aar.org for specifications on rail testing procedures.
Load cells are trimmed as paired sections, referred to as Section Signal
Trimming, until each sectional output is equal. Adjustments to each section
should be done at least twice.
Trim Section (1, 6; 2, 5; 3, 4)
1
2
3
Weight
Cart
6
5
4
Section 1
1
2
Weight
Cart
4
3
Section 2
Trim Section (1, 4; 2, 3)
Figure 4-1. Load Cell Trimming Diagram
4.1 Equipment Required
This trimming operation can be done using a weight cart parked in various
locations on the scale. Final verification of equal output trimming, however,
will require test weights to be placed on the deck in various locations.
4.2
1. 2. 3. 4.
5.
6.
Trim Load Cells
Connect all load cells to the summing board terminals in the junction box.
Connect the main interface cable from the junction box to the indicator.
Turn on the indicator.
Turn all load cell potentiometers in the junction box clockwise until a
clicking noise is heard when continuing turning. This eliminates any initial
resistance so all signals are at full strength.
Park the loaded weight cart in the middle of the scale, with the wheels
centered over the center line of the two end load cell mounts (Figure 4-2).
Record the indicator reading.
Scale Section 1
1
2
3
Scale Section 2
1
2
6
5
4
3
4
Figure 4-2. Trimming Paired Sections
7. Move the weight cart to the next load cell pair center line and record the
indicator reading. 8. Continue until all pair readings have been recorded. 9.
Choose the lowest reading as the reference section, do not adjust this
reading. 10. Using the section potentiometers, reposition the weight cart on
the other sections and trim the sections to match the
reading of the reference section. 11. Recheck section readings a second time
as the adjustment made may be interactive. 12. Repeat the procedure for the
paired sections on Scale Section 2. 13. Place railroad test car on each
section for final certification.
16
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Trimming and Calibration
4.2.1 Static Testing of a Track Scale A shift test is required to ensure the
scale is preforming within applicable tolerance and to verify a rail car can
be accurately weighed from any direction or at any position on the scale.
Begin the shift test by documenting the current readings for the sections, in
both directions, before any repairs or adjustments are made. After repairs and
adjustments are made, document the readings again. A weight of at least 80,000
lb (36,300 kg) must be used for track scale certification, except for Interim
Approval (returning a scale temporarily to service after repairs, refer to the
AAR Scale Handbook).
Sections of the scale need to be numbered 1, 2, 3 etc., from left to right
when standing at the indicator, facing the scale deck (see Figure 4-1). Normal
sectional placement positions of a scale Test Weight Load, when performing a
shift test, are designated from left to right (view from the indicator) as 1R,
2L, 2, 2R, 3L 3, 3R, etc. The numbers represent the sections, the letters
(when affixed) indicate whether the body of the Test Weight Load lies to the
left or right of the section, with one pair of wheels or jacks directly over
the section.
The following are standard combinations of normal Test Weight Load placement
positions (using a four-section scale as an example).
· 1R, 2, 3, 4L · 1R, 2L, 2R, 3L, 3R, 4L When testing a two-section scale, the
standard combination of normal test car positions is 1R, Center 2L.
When using self-propelled test cars, place the entire car on the left, center
and right end of the scale load receiving element. Test Weight Cars shall be
uncoupled at both ends to avoid coupler error.
NOTE: Refer to the AAR Scale Handbook for more information.
4.2.2 Strain Test In addition to the standard test, the scale should be strain
tested by using a load and a scale Test Weight Load or known test weight.
1. Place the load on the scale and record its weight.
2. Add the Test Weight Load or test weight to the scale.
3. Record the combined weight and subtract the load weight from the combined
weight of the load and the test weight. The difference between the value of
the load and the load plus the test weight should be equal to the test weight.
If not, the difference must not exceed the applicable tolerance as applied to
the test weight.
NOTE: One half of the rail car can be used as a load if the scale is too short
to accommodate an entire rail car plus the test weight load or test weight.
Refer to the AAR Scale Handbook for more information.
© Rice Lake Weighing Systems All Rights Reserved
17
Survivor PL – Low Profile Modular Railroad Track Scale
5.0 Specifications
Gross capacity 85 tons to 170 tons
Sectional capacity 85 tons
Module sizes 12 ft 6 in, 15 ft, 18 ft, 25 ft available
Platform width 7 ft 8 in, 8 ft 7 in low profile design
Top Plate Bolted, Checkered Steel
Rail Size Designed for 115 lb, 132 lb, and rail
Checking Assemblies Longitudinal and lateral checking assemblies with top
access
Load Cells 100K CSP1-100K Accessible from sides of scale
Configuration Single, Single/Single, Single/Double, Double, Double/Double
Accuracy 0.1% in accordance with NIST, AAR, and AREMA requirements. Based on
rail cars uncoupled at both ends
Standard Features Lightning and surge suppression kit Rail clips for deck
Anti-creep angles Low profile above-grade installation Copper transient bypass
cables In-bridge conduit runs
Options Approach rail base plates, rail clips, nuts and washers Anchor bolts
for approach rail plates Custom sizes available Hardware for intermediate
section Anchor bolts for load cell and check stands
Certifications · NTEP Certified, CC#02-087, 98-009 · Measurement Canada
AM-5850 · Meets Cooper E-80 design specifications · Meets AAR and AREMA
specifications
18
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Configuration
Specifications
Model
PL-12-85 PL-15-85 PL-18-85 PL-25-85 PL-12-12-170 PL-12-15-170 PL-12-18-170
PL-12-25-170 PL-15-15-170 PL-15-18-170 PL-15-25-170 PL-18-18-170 PL-18-25-170
PL-25-25-170
Configuration
Platform Size Capacity Weight (lb)
Single Single Single Double Single/Single Single/Single Single/Single Single/Double Single/Single Single/Single Single/Double Single/Single Single/Double Double/Double
12 ft 6 in 15 ft 18 ft 25 ft 12 ft 6 in + 12 ft 6 in 12 ft 6 in + 15 ft 12 ft 6 in + 18 ft 12 ft 6 in + 25 ft 15 ft + 15 ft 15 ft + 18 ft 15 ft + 25 ft 18 ft + 18 ft 18 ft + 25 ft 25 ft + 25 ft
85 tons 85 tons 85 tons 175 tons 170 tons 170 tons 170 tons 175 tons 170 tons 170 tons 175 tons 170 tons 175 tons 175 tons
8500 lb 11250 lb 16240 lb 16380 lb 17000 lb 19750 lb 24740 lb 24880 lb 22500 lb 27490 lb 27630 lb 32480 lb 32620 lb 32760 lb
Table 5-1. Survivor PL Series Platform Sizes
© Rice Lake Weighing Systems All Rights Reserved
19
Survivor PL – Low Profile Modular Railroad Track Scale
20
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© Rice Lake Weighing Systems Specifications subject to change without notice.
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
October 18, 2022
www.ricelake.com
PN 98740 Rev E
References
- The Association of American Railroads (AAR)
- Rice Lake Weighing Systems
- Manuals | Rice Lake Weighing Systems
- Training | Rice Lake Weighing Systems
- Warranties
- Videos and Webinars | Rice Lake Weighing Systems
- Rice Lake Weighing Systems
- Rice Lake Weighing Systems
- Rice Lake Weighing Systems
- Manuals | Rice Lake Weighing Systems