RICELAKE survivor PL Low Profile Modular Railroad Track Scale Instruction Manual

Table of Contents

survivor PL Low Profile Modular Railroad Track Scale

Survivor® PLLow Profile Modular Railroad Track ScaleInstallation 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

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.

Survivor PL – Low Profile Modular Railroad Track ScaleContents1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.0 Junction Box and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.1 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.0 Trimming and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124.1 Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4.2 Trim Load Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124.2.1 Static Testing of a Track Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4.2.2 Strain Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135.0 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

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Introduction1.0 IntroductionThis 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 SafetySafety 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 SafetyDo 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.

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 forpouring 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 11/4 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 InstallationFor 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 TradeNOTE: 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.

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2.2 Scale InstallationUse 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

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.

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.

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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 Procedure5. 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 theweigh 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 blockFigure 2-6. Weigh Module on Setting Blocks 7. Set the weigh module on 5 in setting blocks. Center the module between approaches.

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 concreteapproaches.Jack Upper Load Cell Mount PlateLoad Cell Leveling BoltsFigure 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 Plane10. 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.

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Installation2.3 Approach and Dead Space Hardware InstallationUse 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 Bolts1. 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 InstallationThe 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 Location1. 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 GroutingPrior 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.

Survivor PL – Low Profile Modular Railroad Track Scale3.0 Junction Box and GroundingElectrical 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

+SI -SI +EX -EX SHDJ2

Load Cell #7

LC7

LC6

J-Box

Detail B

Expansion/J9SHD +SI -SI +SEN +EX -SEN -EXIndicator/J10SHD +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

+SI -SI +EX -EX SHDJ2

Load Cell #5

Expansion/J9SHD +SI -SI +SEN +EX -SEN -EXIndicator/J10SHD +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 – BlackSHD – Shield +SI – White – SI – Red +SEN – Blue +EX – Green – SEN – Yellow – EX – Black

Detail BFigure 3-1. J-Box Wiring and Conduit

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Junction Box and Grounding3.1 Load Cells to Junction BoxEach 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 ConnectionsEach 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 IndicatorFifty 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 PeripheralsAll 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 ConductorA 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 ConnectionsIMPORTANT: 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.

Survivor PL – Low Profile Modular Railroad Track ScaleThe 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 MountThese, 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

J3 +SI -SI +EX -EX SHD

TRIM R14R17 R18 R19

JP6

VR3

+SI R21-SI R22

+EX

R23

-EX

SHD

TRIM

R26

VR1 R25 R24CELL# SIGNAL

CUT

DISABLE SECT#

VR2 R16 R15CELL# SIGNAL

J1+SI-SI JP7+EX JP8-EXSHDR20+SI -SI JP9 +EX JP10 -EXSHDJ2

VR6

TRIM

JP2 R4

JP3

DISABLE SECT#

JP1

CUT

JP4

R10 JP5

TRIM

R13

TRIM

R40

+SI

J5 +SI

VR7 R42 R41CELL# SIGNAL

-SI

JP17

+EX

R43

+EX

R44

JP18

-EX

R45

SHD

JP16

R46

JP11

TRIM

R27

JP12 R30

R31

JP13

R32

DISABLE SECT#

VR10

DISABLE SECT#

VR9

CUT

+SI R47

+SI R34

-SI

R48

JP19

R35

JP14

+EX

R49

+EX

R36

JP20

JP15

-EX

R38 R37

VR12

SIGNAL VR8 R51 R50CELL# SIGNAL

CELL#

SHD

J8 JP

TRIM

R52

CONNECT BOTH SHUNTS

TO APPLY SIGNAL JP

SHD

TRIM

R39

SIGNAL

DISCONNECT BOTH SHUNTS JP TO REMOVE SIGNAL

VR11 R29 R28CELL# SIGNAL

VR4 R12 R11CELL# SIGNAL

VR5 R3 R2CELL# SIGNAL

SIGNAL

L2R7 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 2005ARGND

Grounding Lug

Ground Lug

10 ga. bare ground wire to DC protection ground connectionbefore indicator

Figure 3-3. Junction Box Ground Wire Connections.

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Junction Box and Grounding186210

Ground Wire

RICE LAKE WEIGHING SYSTEMS

J3 +SI -SI +EX -EX SHD

TRIM R14R17 R18 R19

JP6

VR3

+SI R21-SI R22

+EX

R23

-EX

SHD

TRIM

R26

VR1 R25 R24CELL# SIGNAL

CUT

DISABLE SECT#

VR2 R16 R15CELL# SIGNAL

J1+SI-SI JP7+EX JP8-EXSHDR20+SI -SI JP9 +EX JP10 -EXSHDJ2

VR6

TRIM

JP2 R4

JP3

DISABLE SECT#

JP1

CUT

JP4

R10 JP5

TRIM

R13

TRIM

R40

+SI

J5 +SI

VR7 R42 R41CELL# SIGNAL

-SI

JP17

+EX

R43

+EX

R44

JP18

-EX

R45

SHD

JP16

R46

JP11

TRIM

R27

JP12 R30

R31

JP13

R32

DISABLE SECT#

VR10

DISABLE SECT#

VR9

CUT

+SI R47

+SI R34

-SI

R48

JP19

R35

JP14

+EX

R49

+EX

R36

JP20

JP15

-EX

R38 R37

VR12

SIGNAL VR8 R51 R50CELL# SIGNAL

CELL#

SHD

J8 JP

TRIM

R52

CONNECT BOTH SHUNTS

TO APPLY SIGNAL JP

SHD

TRIM

R39

SIGNAL

DISCONNECT BOTH SHUNTS JP TO REMOVE SIGNAL

VR11 R29 R28CELL# SIGNAL

VR4 R12 R11CELL# SIGNAL

VR5 R3 R2CELL# SIGNAL

SIGNAL

L2R7 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 2005ARGND

Grounding Lug

JB8SPT Junction BoxWith Transient Protection RLWS PN 91783

RICE LAKE WEIGHING SYSTEMS

J3 +SI -SI +EX -EX SHD

TRIM R14R17 R18 R19

JP6

VR3

+SI R21-SI R22

+EX

R23

-EX

SHD

TRIM

R26

VR1 R25 R24CELL# SIGNAL

CUT

DISABLE SECT#

VR2 R16 R15CELL# SIGNAL

J1+SI-SI JP7+EX JP8-EXSHDR20+SI -SI JP9 +EX JP10 -EXSHDJ2

VR6

TRIM

JP2 R4

JP3

DISABLE SECT#

JP1

CUT

JP4

R10 JP5

TRIM

R13

TRIM

R40

+SI

J5 +SI

VR7 R42 R41CELL# SIGNAL

-SI

JP17

+EX

R43

+EX

R44

JP18

-EX

R45

SHD

JP16

R46

JP11

TRIM

R27

JP12 R30

R31

JP13

R32

DISABLE SECT#

VR10

DISABLE SECT#

VR9

CUT

+SI R47

+SI R34

-SI

R48

JP19

R35

JP14

+EX

R49

+EX

R36

JP20

JP15

-EX

R38 R37

VR12

SIGNAL VR8 R51 R50CELL# SIGNAL

CELL#

SHD

J8 JP

TRIM

R52

CONNECT BOTH SHUNTS

TO APPLY SIGNAL JP

SHD

TRIM

R39

SIGNAL

DISCONNECT BOTH SHUNTS JP TO REMOVE SIGNAL

VR11 R29 R28CELL# SIGNAL

VR4 R12 R11CELL# SIGNAL

VR5 R3 R2CELL# SIGNAL

SIGNAL

L2R7 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 2005ARGND

Grounding Lu g

JB8SPT Junction BoxWith Transient Protection RLWS PN 91783

UJB-3T6 DC Transient ProtectionRLWS PN 21134

TP-232 DC Transient ProtectionRLWS PN 33185

SOLA S1K520 AC Transient ProtectionRLWS PN 110812AC Outlet

AC Outlet

SOLA S1K 520 AC Transient ProtectionRLWS PN 110812

Ground Wires

Power Company Ground Rod*Always verify that installed wiring is properly groundedFigure 3-4. Single-Point Grounding Diagram

AC Power Supply#10 Copper Ground WireSerial CommunicationHomerun CableLoad Cell Cable

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)

Weight

Cart

Section 1

Weight

Cart

Section 2

Trim Section (1, 4; 2, 3)

Figure 4-1. Load Cell Trimming Diagram4.1 Equipment RequiredThis 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.

4.21. 2. 3. 4.5.6.

Trim Load CellsConnect 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

Scale Section 2

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 thereading 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.

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Trimming and Calibration4.2.1 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.

Survivor PL – Low Profile Modular Railroad Track Scale5.0 SpecificationsGross capacity 85 tons to 170 tonsSectional capacity 85 tonsModule sizes 12 ft 6 in, 15 ft, 18 ft, 25 ft availablePlatform width 7 ft 8 in, 8 ft 7 in low profile designTop Plate Bolted, Checkered SteelRail Size Designed for 115 lb, 132 lb, and railChecking Assemblies Longitudinal and lateral checking assemblies with top accessLoad Cells 100K CSP1-100K Accessible from sides of scaleConfiguration Single, Single/Single, Single/Double, Double, Double/DoubleAccuracy 0.1% in accordance with NIST, AAR, and AREMA requirements. Based on rail cars uncoupled at both endsStandard 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 runsOptions 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 standsCertifications · NTEP Certified, CC#02-087, 98-009 · Measurement Canada AM-5850 · Meets Cooper E-80 design specifications · Meets AAR and AREMA specifications

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Configuration

Specifications

ModelPL-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

Survivor PL – Low Profile Modular Railroad Track Scale

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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

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PN 98740 Rev E

References

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Posted

2023-02-20

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