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4 Disclaimer Every effort has been made to provide complete and accurate information in this manual. However, although this manual may include a specifically identified warranty notice for the product, Fairbanks Scales makes no representations or warranties with respect to the contents of this manual, and reserves the right to make changes to this manual without notice when and as improvements are made. Fairbanks Scales shall not be liable for any loss, damage, cost of repairs, incidental or consequential damages of any kind, whether or not based on express or implied warranty, contract, negligence, or strict liability arising in connection with the design, development, installation, or use of the scale. Copyright This document contains proprietary information protected by copyright. All rights are reserved; no part of this manual may be reproduced, copied, translated or transmitted in any form or by any means without prior written permission of the manufacturer. 11/ Rev. 2

5 Table of Contents Section 1: General Information Introduction Description Certifications Section 2: Company Service Information General Service Policy Overview Physical Installation Notes Conferring with our Client Pre-Installation Checklist Unpacking Equipment Checkout Users Responsibility Installation Considerations Section 3: Scale Installation A. Introduction B. Preparation for installation C. Installation Section 4: Electrical Installation A. Analog Junction box Installation for analog instruments B. Wiring SSCs and PPSs for Intalogix systems Section 5: Maintenance Scale Maintenance Section 6: Parts & Parts Replacement Parts List Replacing an RC load cell Shimming Appendix I: Specifications / Rev. 2

6 Section 1: General Information INTRODUCTION This manual provides general installation and maintenance instructions for the Fairbanks Scales 9120 Series Omnicell. Almost every installation is different, so please adjust the following information, as needed, for your application. Specifications, parameters and application notes are included. This manual is meant to give general instructions for applying the Omnicell considering its inherent capabilities and limitations; it is not meant to be a scale design manual. Questions concerning specific applications should be directed to the appropriate Product manager. For complete 9120 Series installation you will also need to reference the necessary instrumentation manual. DESCRIPTION Fairbanks Scales Omnicells are a combination of two main components: Mounting assembly (captivates the load cell and provides means to fasten to the vessel and flooring). Load cell (the actual weight detecting device). The 9120 Series Omnicells will arrive preassembled, excluding the load cells. This mounting assembly is specifically designed to be installed without the load cell for easy installation. Load cell installation is done quickly, just prior to calibration. The 9120 Series Omnicells are available in standard capacities ranging from 7.5 t to 100 t. (t = metric tonne.) Higher capacities are available, contact the appropriate Product Manager. The load cells are constructed from stainless steel and are a rocker-column design. The mounting assembly is available in either a zinc-plated or cast mild steel or stainless steel construction. These Omnicells can be welded to the load carrier and the foundation. Welding eliminates problems of getting holes on the top and bottom line up. These assemblies are designed for a welded installation, so welding will not cause any service issues (load cell replacement). 11/ Rev. 2

7 Section 1: General Information The 9120 Series can be installed using mechanical fasteners (nuts and bolts). This installation method eliminates the need for onsite welding. It can also be a combination of welding and mechanical fasteners. For example, the top plate can use mechanical fasteners and the base assembly can be welded. Omnicell systems principle causes of problems are because of mechanical restrictions to, and interaction with, the weigh vessel. The cause is invariable excessive vessel or support deflection that needs be identified, if possible, during the design phase. Close attention should be made to ladders, catwalks, piping, and any items that restrict deflection of the vessel. The 9120 Series Omnicells are commercially approved for applications in the U.S., however Fairbanks Scales recommends contacting your local Weight and Measures Office prior to beginning any Omnicell installation that requires commercial approval. CERTIFICATIONS NTEP CC: / Rev. 2

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9 Section 2: Company Service Information OVERVIEW Physical Installation Notes Check all devices for proper operation. If any error messages occur, refer to Troubleshooting or the proper manual of that device. Only those charges which are incurred as a result of the equipment's inability to be adjusted to performance specifications may be charged to warranty. No physical alterations (mounting holes, etc.) are allowed during installation. The installing technician is responsible that all personnel are fully trained and familiar with the equipment's capabilities and limitations before the installation is considered complete. All electrical assemblies must be replaced as assemblies or units. Replacement of individual components is not allowed. These components must be returned intact for replacement credit per normal procedures. All electronic and mechanical adjustments are considered to be part of the installation, and are included in the installation charge(s). Included is any required computer programming or upgrades. Included are any accuracy and/or operational specification changes. The AC receptacle / outlet shall be located near the Instrument and easily accessible. Electrical connections other than those specified may not be performed. Conferring with our Client The technician must be prepared to recommend the arrangement of components which provide the most efficient layout, utilizing the equipment to the best possible advantage. The warranty policy must be explained and reviewed with the customer. 11/ Rev. 2

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12 Section 2: Company Service Information Installation Considerations Thorough application review should be conducted before, during and after installation: Determining Omnicell Capacity - Sizing the Omnicell (general rule) Take the overall live and dead load of the vessel. Multiply by 2, then divide by the number of support points (legs, typically). For example: 4 Legs 26,000 lbs dead load 74,000 lbs live load 26, , ,000 x 2 200, ,000 lb for each Omnicell Loading The vessel will have 3, or more, tank legs. The Omnicells should be level and, under extreme cases, shimmed, so that the load is roughly equal on each Omnicell. Flooring - A thorough inspection of the flooring s deflections must be considered before installing an Omnicell system. Flooring must be rigid enough to handle the total load without deflection. Thermal contraction and expansion Horizontal vessels, in direct sunlight, can create thermal expansion issues. The floating rocker column design of the 9120 Series Omnicell easily handles most thermal expansion/contraction issues. Uplift and lateral constraints In extreme conditions (high winds or seismic activity) uplift and lateral stresses on the Omnicell system are a concern and should be considered when choosing the best Omnicell for the application. The 9120 Series Omnicell provides a degree of built-in uplift and lateral checking, refer to the product QuickFacts for a detailed explanation of the forces. In extreme conditions, additional checking is recommended. Isolate vessel Many external factors affect the accuracy and stability of an Omnicell system. Load cell signals can be affected by EMF sources such as electric forklifts, pumps, motors, etc. A well-isolated tank will provide more reliable results with fewer problems. 11/ Rev. 2

13 Section 2: Company Service Information Eliminate mechanical constraints The vessel should be fully supported on the Omnicells. Reduce or eliminate any mechanical issues which will interfere with the vessel s deflection, such as: rigid vertical or horizontal piping (use flexible piping when connecting to the vessel whenever possible), ladders, catwalks, etc. Orientation Orientation of the 9120 Series Omnicell isn t critical because of the rocker load cell design, however it is recommended positioning the load cell cables away from traffic areas. Heated or chilled vessels Consult with the appropriate Product Manager for any application with vessels that heat or chill the product inside the vessel. In these cases, special consideration may be required to isolate the temperatures. Load cell cabling The load cell cables should be routed away from areas where they could be damaged. Use drip loops at both the load cell and the junction box ends. Hazardous area If the Omnicells will be installed in a Hazardous Area, a document is required from the end user stating the Class, Division, and Group. 11/ Rev. 2

14 Section 3: Scale Installation A. Introduction Installation consists of the following: Foundation check, layout, and mounting assembly installation Tools, materials, documentation, and a lifting mechanism (crane or hydraulic jack) Installation of the mounting assemblies Installation of the rocker column load cells B. Preparation for installation 1. Tools, equipment, and materials required: a. Hydraulic jacks -- Use hydraulic jacks that have sufficient capacity plus (+) a safety factor for the size of the vessels you are installing the Omnicells. b. Blocking material to support lifted vessel. c. Determination of how the scale system will be calibrated. Calibration weights (Only application method for NTEP system) i. Get calibration weights on site ii. Dolly, or other method, for moving weights iii. Means for lifting calibration weights (chains, Come-Along winch, etc.) iv. Lifting point on vessel for supporting calibration weights Substitution Product measured by other device (scale, flow meter, etc.) then used as the calibration weight. i. Schedule product to arrive when needed ii. Determine how product will be put into, and removed, from vessel MilliVolt calibration with Intalogix Technology i. Check to make sure the correct equipment was ordered (Q Series instrument and Quad Multiplexer Board or Flash Instrument, Smart Sectional Controller and Pit Power Supply) ii. Load cell calibration sheets d. Determination of how the scale system will be installed. Welded iii. Arc Welding Machine iv. Welding Rod v. Steel Brush vi. Grinder vii. Chipping hammer 11/ Rev. 2

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26 Section 3: Scale Installation Note: It might be necessary, at this stage of the installation, to slightly lift the vessel (using a jack) to install the load cell. 11/ Rev. 2

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42 Section 4: Electrical Installation A. Analog Junction box Installation for analog instruments 1. Introduction The analog j-box should be installed on the vessel, and in an easily accessible location, whenever possible. It is recommended that it be installed in a vertical position. 2. Description The analog j-box has four (5) terminal blocks to connect four (4) load cells and one (1) for a cable that connects to the analog instrument. Load cells are adjusted using adjusting potentiometers. 3. Installation a. Boxes: The box has tabs for bolting to mounting brackets on the side of the vessel. Attach the ground wire lug to one of the mounting bolt studs and tighten securely to provide a good electrical ground. b. Wiring: Cable used in all wiring must be a minimum of 24 AWG. Use cable or equivalent. Load cell wiring color codes LCF-HR4020 Black Green Red White YYeel ll looww (-) Excitation (+) Excitation (-) Signal (+) Signal Shield 11/ Rev. 2

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44 Section 4: Electrical Installation B. Wiring SSCs and PPSs for Intalogix systems 1. Introduction Intalogix systems utilize smart sectional controllers (SSCs) and pit power supplies (PPSes) for load cell excitation and signal processing. 2. Description SSC boxes have four (4) terminals, two (2) for load cells, and two (2) for interconnecting to other SSC boxes or terminating to a pit power supply. Make sure the proper number of SSC boxes are order based on the application requirements. All cell and scale adjustments are made via the Intalogix system instrument. 3. Installation Boxes: The box has tabs for bolting to adapters on the side of the modules. Wiring: Cable used in all wiring must be a minimum of 18 AWG. Use cable or Use appropriate service manual for the instrument being installed. a. Smart Sectional Controller Wire cells into each section s SSC per the appropriate manual. Remember that odd numbered cells go to TB1 location, and even numbered cells go to TB2 location. Load cell drain wires connect to the ground lug on the sectional controller box exterior. b. Grounding SSCs Intalogix systems must have two (2) ground rods in the pit for proper connection. Pit power supplies use a ground separate from the steel and SSC ground rod. c. Instrument-to-PPS cable connection Prepare the cable ends in the standard manner. Use the appropriate manual for wiring instructions of all SSCs and pit power supplies. Connect the instrument interface cable to the instrument in the in the scale house per the instructions in the appropriate indicator service manual. Note: Intalogix installations utilize a different numbering system for load cells because of digital addressing of the SSCs. Number the load cells as follows: With respect to the following starting position, face the vessel from where the instrument is located. The cell at the upper left (far side) of the platform is Cell 1. The cell positions along the far side will be odd cell number, and the near side locations will be even cell numbers. Note: SSCs have connections for two (2) load cells, TB1 and TB2. The oddnumbered cell should go to the TB1 connection, and the even-numbered cell to the TB2 connection. 11/ Rev. 2

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46 Section 5: Maintenance Scale Maintenance 1. Check for accumulations of solid material under the Omnicells that may affect the accuracy (ice, frozen mud, debris). 2. Check to see that the customer is doing routine cleaning around the vessel. 3. Inspect load cells for damage to the ends/cables; check cups and O rings for damage. 4. The load cell bearing cups should be inspected, cleaned, and greased annually. 5. Inspect and adjust all check bolts (if applicable) using anti-seize on the threads. 6. Check for all clearances around the scale for any obstructions or interference with the free movement of the platform. 7. Check all check bolt clearances both with and without a concentrated load over each leg (support point), one at a time. 8. Check all load cells for plumb and level. 9. Inspect the boxes for leaks; the interior should be clean and dry. If there is moisture inside, clean and dry it thoroughly. Check all connections at the terminal blocks to ensure they are tight. 11/ Rev. 2

47 Section 6: Parts & Parts Replacement 9120 Series Omnicell Complete Assembly Series, 7.5t, Zinc plated mount, Stainless Rocker Load Cell Series, 7.5t, Stainless mount, Stainless Rocker Load Cell Series, 15t, Zinc plated mount, Stainless Rocker Load Cell Series, 15t, Stainless mount, Stainless Rocker Load Cell Series, 22.5t, Zinc plated mount, Stainless Rocker Load Cell Series, 22.5t, Stainless mount, Stainless Rocker Load Cell Series, 30t, Zinc plated mount, Stainless Rocker Load Cell Series, 30t, Stainless mount, Stainless Rocker Load Cell Series, 40t, Zinc plated mount, Stainless Rocker Load Cell Series, 40t, Stainless mount, Stainless Rocker Load Cell Series, 50t, cast mount, Stainless Rocker Load Cell Series, 50t, Stainless mount, Stainless Rocker Load Cell Series, 100t, cast mount, Stainless Rocker Load Cell Series, 100t, Stainless mount, Stainless Rocker Load Cell Series, 150t, cast mount, Stainless Rocker Load Cell Series, 150t, Stainless mount, Stainless Rocker Load Cell Series, 300t, cast mount, Stainless Rocker Load Cell Series, 300t, Stainless mount, Stainless Rocker Load Cell 11/ Rev. 2

48 Section 6: Parts Parts lists, continued 9120 Series Mounting Assembly Series, 7.5t, Zinc plated mounting assembly Series, 7.5t, Stainless mounting assembly Series, 15t, Zinc plated mounting assembly Series, 15t, Stainless mounting assembly Series, 22.5t, Zinc plated mounting assembly Series, 22.5t, Stainless mounting assembly Series, 30t, Zinc plated mounting assembly Series, 30t, Stainless mounting assembly Series, 40t, Zinc plated mounting assembly Series, 40t, Stainless mounting assembly Series, 50t, Zinc plated mounting assembly Series, 50t, Stainless mounting assembly Series, 100t, Zinc plated mounting assembly Series, 100t, Stainless mounting assembly Series, 150t, Zinc plated mounting assembly Series, 150t, Stainless mounting assembly Series, 300t, Zinc plated mounting assembly Series, 300t, Stainless mounting assembly 9120 Series Load Cells - Replacement Rocker Column, 3.5" tall, 7.5t Capacity, Stainless Steel, 40' Cable Rocker Column, 3.5" tall, 15t Capacity, Stainless Steel, 40' Cable Rocker Column, 3.5" tall, 22.5t Capacity, Stainless Steel, 40' Cable Rocker Column, 5.5" tall, 30t Capacity, Stainless Steel, 60' Cable Rocker Column, 6.0" tall, 40t Capacity, Stainless Steel, 60' Cable Rocker Column, 7.0" tall, 50t Capacity, Stainless Steel, 60' Cable Rocker Column, 7.0" tall, 100t Capacity, Stainless Steel, 60' Cable Rocker Column, 8.3" tall, 150t Capacity, Stainless Steel, 60' Cable Rocker Column, 11.0" tall, 300t Capacity, Stainless Steel, 60' Cable 11/ Rev. 2

49 Section 6: Parts Parts lists, continued Part Number Part Description Saddle, 7.5t to 22.5t capacity, zinc-plated mild steel Saddle, 30t to 40t capacity, zinc-plated mild steel Saddle, 50t to 100t capacity, zinc-plated mild steel Saddle, 7.5 to 22.5t capacity, stainless steel Saddle, 30 to 40t capacity, stainless steel Saddle, 50 to 100t capacity, stainless steel Shipping Spacer, 7.5 to 22.5t capacity, zinc-plated mild steel Shipping Spacer, 30 to 40t capacity, zinc-plated mild steel Shipping Spacer, 50 to 100t capacity, zinc-plated mild steel Lift off bolt washer, 7.5 to 22.5t capacity, zinc-plated mild steel Lift off bolt washer, 30 to 40t capacity, zinc-plated mild steel Lift off bolt washer, 50 to 100t capacity, zinc-plated mild steel Lift off bolt washer, 7.5 to 22.5t capacity, stainless steel Lift off bolt washer, 30 to 40t capacity, stainless steel Lift off bolt washer, 50 to 100t capacity, stainless steel K L M N Grounding Cable, 7.5 to 40t capacity Grounding Cable, 50 to 100t Capacity Grounding Cable, 150t capacity Grounding Cable, 300t capacity Loading cup, anti-rotation, 7.5 to 22.5k capacity, mild steel Loading cup, anti-rotation, 30t capacity, mild steel Loading cup, anti-rotation, 40t capacity, mild steel Loading cup, anti-rotation, 50t capacity, mild steel Loading cup, anti-rotation, 100t capacity, mild steel Loading cup, anti-rotation, 7.5 to 22.5t capacity, stainless steel Loading cup, anti-rotation, 30t capacity, stainless steel Loading cup, anti-rotation, 40t capacity, stainless steel Loading cup, anti-rotation, 50t capacity, stainless steel Loading cup, anti-rotation, 100t capacity, stainless steel Loading cup, 7.5 to 22.5t capacity, mild steel Loading cup, 30 to 40t capacity, mild steel Loading cup, 50t capacity, mild steel Loading cup, 100t capacity, mild steel Loading cup, 7.5 to 22.5t capacity, stainless steel Loading cup, 30 to 40t capacity, stainless steel Loading cup, 50t capacity, stainless steel Loading cup, 100t capacity, stainless steel Series Top Plate, 7.5 to 22.5t capacity, zinc-plated Series Top Plate, 30 to 40t capacity, zinc-plated Series Top Plate, 50 to 100t capacity, cast mild steel Series Top Plate, 7.5 to 22.5t capacity, stainless Series Top Plate, 30 to 40t capacity, stainless Series Top Plate, 50 to 100t capacity, stainless 11/ Rev. 2

50 Section 6: Parts A A A B B B 9120 Series Base Assembly, 7.5 to 22.5t capacity, zinc-plated 9120 Series Base Assembly, 30 to 40t capacity, zinc-plated 9120 Series Base Assembly, 50 to 100t capacity, cast mild steel 9120 Series Base Assembly, 7.5 to 22.5t capacity, stainless 9120 Series Base Assembly, 30 to 40t capacity, stainless 9120 Series Base Assembly, 50 to 100t capacity, stainless 79-O O-ring, load cell cup, 7.5 to 22.5t capacity, x O O-ring, load cell cup, 30 to 40t capacity, 39,96 x O O-ring, load cell cup, 50t capacity, x O O-ring, load cell cup, 50t capacity, x Shipping bolts, 7.5 to 22.5t capacity, M16x40-8.8, galvanized Shipping bolts, 30 to 40t capacity, M20x60x8.8, galvanized Shipping bolts, 50 to 100t capacity, M24x80-8.8, galvanized Shipping bolts, 7.5 to 22.5t capacity, M16x40-8.8, stainless Shipping bolts, 30 to 40t capacity, M20x60x8.8, stainless Shipping bolts, 50 to 100t capacity, M24x80-8.8, stainless Uplift bolt set screw, 7.5 to 22.5t capacity, M8x65-8.8, galvanized Uplift bolt set screw, 30 to 40t capacity, M10x90-8.8, galvanized Uplift bolt set screw, 50 to 100t capacity, M10x , galvanized Uplift bolt set screw, 7.5 to 22.5t capacity, M8x65-8.8, stainless Uplift bolt set screw, 30 to 40t capacity, M10x90-8.8, stainless Uplift bolt set screw, 50 to 100t capacity, M10x , stainless Uplift Bolt, 7.5 to 22.5t capacity, M24x65-8.8, galvanized Uplift bolt, 30 to 40t capacity, M30x90-8.8, galvanized Uplift bolt, 50 to 100t capacity, M36x , galvanized Uplift bolt, 7.5 to 22.5t capacity, M24x65-8.8, stainless Uplift bolt, 30 to 40t capacity, M30x90-8.8, stainless Uplift bolt, 50 to 100t capacity, M36x , stainless Hex head screw ground strap, 7.5 to 22.5t capacity, M8x12-8.8, galvanized Hex head screw ground strap, 30 to 40t capacity, M8x12-8.8, galvanized Hex head screw ground strap, 50 to 100t capacity, M8x12-8.8, galvanized Hex head screw ground strap, 7.5 to 22.5t capacity, M8 x , stainless Hex head screw ground strap, 30 to 40t capacity, stainless Hex head screw ground strap, 50 to 100t capacity, stainless Hex head screw Saddle, 7.5 to 22.5t capacity, M8x60-8.8, galvanized Hex head screw Saddle, 30 to 40t capacity, M10x65-8.8, galvanized Hex head screw Saddle, 50 to 100t capacity, M12x90-8.8, galvanized Hex head screw Saddle, 7.5 to 22.5t capacity, M8x60-8.8, stainless Hex head screw Saddle, 30 to 40t capacity, stainless Hex head screw Saddle, 50 to 100t capacity, stainless 11/ Rev. 2

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54 Section 6: Parts Replacing an RC load cell 1. Remove power from the instrument. 2. Lift the scale using a proper size and rated hydraulic jack (or jacks) at the corners closest to the defective load cell location. 3. Check upper and lower receiving cups and O rings for damage. Replace as necessary and reapply grease. 4. Insert the new cell into the upper receiving cup. 5. Carefully lower the hydraulic jack until the cell is set into the lower cup. 6. Remove the cover of the J-box, then loosen the gland bushing to free the cable. Remove the old cell wires and connect new cell wires in the balance box/ssc. Secure the cover. 7. Test and adjust the scale as necessary. 11/ Rev. 2

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56 Appendix I: Specifications Capacities Mount construction 7.5 t to 100 t Zinc-plated mild steel/cast mild steel (50 t & 100 t); stainless steel Load cell: Full scale output (FS) 2.0 mv/v/ohm ± 0.1% Combined error Non-linearity Creep error (20 min.) Compensated temperature Excitation voltage 0.02% FS 0.05% FS 0.03% FS 14 F to 104 F (-10 C to 40 C) 5-15 VDC Overload Safe = 150%; Ultimate = 300% Sideload Uplift Bridge resistance Construction Cable Approvals 25% (min) on 50 t capacity ; 15% (min) on 100 t capacity 50% (min) on 50 t capacity ; 30% (min) on 100 t capacity 1000 ohms nominal Stainless steel 17-4 PH Polyurethane: 40 ft. on capacities 22.5 t; 60 ft. on capacities 30 t NTEP #97-078, Factory Mutual 11/ Rev. 2

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58 9120 Series Omnicell Manufactured by Fairbanks Scales, Inc. 821 Locust St. Kansas City, MO INSTALLATION MANUAL DOCUMENT 51267