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Cardinal ARMOR Installation Manual

Portable digital truck scale
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Portable
Digital Truck Scale
Installation Manual
1
0330-0410-0M Rev C • Portable Digital Truck Scale

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  • Page 1 Portable Digital Truck Scale Installation Manual 0330-0410-0M Rev C • Portable Digital Truck Scale...
  • Page 2 0330-0410-0M Rev C • Portable Digital Truck Scale...
  • Page 3 Copyright All rights reserved. Reproduction or use, without expressed written permission, of editorial or pictorial content, in any manner, is prohibited. No patent liability is assumed with respect to the use of the information contained herein. Disclaimer While every precaution has been taken in the preparation of this manual, the Seller assumes no responsibility for errors or omissions.
  • Page 4 0330-0410-0M Rev C • Portable Digital Truck Scale...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ........... . . SITE PREPARATION REQUIREMENTS .
  • Page 6 TABLE OF CONTENTS, CONT. DIAGNOSTICS ............On Screen Diagnostics .

  • Page 7: Introduction

    The NTEP legal-for-trade Armor® Portable Truck Scale arrives fully prepared for installation and includes Cardinal’s SmartCell digital load cells and AXIS® heavy duty load cell stands with Frictionless Centering. Every Armor® Portable truck scale is 100% assembled, pre-calibrated, and tested before shipping.

  • Page 8: Site Preparation Requirements

    The purpose of this section is to explain how the user can provide such an environment. Electrical Power Most Cardinal instrumentation is designed to operate at 115 VAC, 50/60 Hz. Where required, the equipment may be ordered for operation at 230 VAC, 50/60 Hz.

  • Page 9: Ac Power Fluctuations

    All of the types listed are available in various sizes from Cardinal Scale or may be purchased locally. 0330-0410-0M Rev C • Portable Digital Truck Scale...

  • Page 10: Voltage

    PROVIDES PROTECTION AGAINST Type Outages Transients Fluctuations Cost Uninterruptible Power Supply High to Moderate    Voltage Regulator Moderate   Isolation Transformer Low to Moderate  Line Filters  Table B – Power Conditioning Device Voltage Voltage (steady state) variations shall not exceed plus (+) 10 percent or minus (-) 15 percent of the nominal value 115 VAC (plus or minus 8 percent for 230 VAC).

  • Page 11: Safety Considerations

    Grounding Installation Instructions, and other surge arresting devices. Heating and Cooling Most standard Cardinal weighing system instrumentations are designed for the office environment. Such an environment is free of excessive dust and moisture and provides a comfortable temperature.
  • Page 12 Scale Site, Cont. 0330-0410-0M Rev C • Portable Digital Truck Scale...

  • Page 13: Installation

    INSTALLATION At this point, the concrete slab or piers shall be in place as specified on the certified Pier Plan drawing. The top of piers shall be in a level plane and a minimum of 4 inches above the ground line. NOTE: Make sure the slab or top of piers are clear of debris and rough spots before setting the scale sections in place.

  • Page 14: Scale Section Installation

    Scale Section Installation The Armor portable digital truck scale is shipped pre-assembled and ready to be placed into position on a prepared and level site. The weighbridge is supplied in three sections. Each section can be lifted by attaching straps, cables or chains to the side rail mounts on each section.

  • Page 15: Load Cells And Load Cell Stands

    Load Cells and Load Cell Stands The load cells and load cell stands (which are bolted to the lower frame) are held in place with shipping brackets, and then the entire weighbridge is held in place in the lower frame with shipping straps for transporting.
  • Page 16 1. Establish the centerline of the concrete slab or pier. Snap a chalk line 5 feet, 7 inches off the centerline to each side. Snap a lateral chalk line 9 1/2 inches from the edge of the end slab or pier (1 foot, 3 1/2 inches if optional ramps are to be installed, refer to Pier Plan). These lines should be 71 feet, 3 inches apart.
  • Page 17 On an installation using the optional lifting lugs, remove them from the first scale section (End Bridge) and install them on the second scale section (opposite End Bridge). Attach the straps, cables or chains to the lifting lugs. Otherwise, attach the straps, cables or chains to the side rail mounts on the second scale section (opposite End Bridge).

  • Page 18: Lower Frame Spacers Installation

    Lower Frame Spacers Installation After the scale sections are in place, and the bridges level and square, install the bolt-on lower frame base spacers between the end weighbridges. Refer to the weighbridge schematic drawing for details. Lower Frame Spacer Attachment Points Lower Frame Spacer The lower frame base spacers are installed between the end weighbridges.

  • Page 19: Connect The Load Cell Cables

    Connect the Load Cell Cables All digital scales are connected together with a daisy-chained CAN cable. The load cell connection loop can begin at any convenient load cell, and may continue clockwise as shown or counter-clockwise if preferred. Note that in the example below there is not a connection between cells 4 and 6.
  • Page 20 If needed, run the load cell cables through the conduit installed in the bridges between the load cells. Install the load cell cable connectors on the load cell fittings, and hand- tighten the connectors. If needed, insert load cell cable into Install load cell cable connectors on scale conduit.

  • Page 21: Install Homerun Cable

    Home Run Cable Connector Pack. Refer to the table below for cable and connector information. Cable and Connector Information ITEM and DESCRIPTION CARDINAL PART NO. HOMERUN CABLE, 5 CONDUCTOR, 18 AWG 6980-1083 CONNECTOR PACK, HOME RUN CABLE...

  • Page 22: Indicator Connection

    Indicator Connection The homerun cable should be routed through the metallic gland connector installed in 225D rear panel (lower right). Optional 2XX-USBA (Serial, Connectors Isolated Inputs or Outputs) AC Power (Serial, 100-240 VAC 0.4 Amp Max. Isolated Fiber Inputs or Optic Outputs) Cable...
  • Page 23 6. Next, remove approximately 1 1/2 inches of the inner insulating jacket, exposing the internal wires. 7. Now, remove 1/4 inch of insulation from the end of each of the five wires. 8. Make sure the inner insulating jacket extends past the outer braided jacket approximately 3/4 inch.

  • Page 24: Load Cell Connection

    5-pin connector from the Homerun Cable Connector Pack. Refer to the table below for cable and connector information. Cable and Connector Information ITEM and DESCRIPTION CARDINAL PART NO. HOMERUN CABLE, 5 CONDUCTOR, 18 AWG 6980-1083 CONNECTOR PACK, HOME RUN CABLE...
  • Page 25 IMPORTANT: Clean all connectors and plugs with electrical contact cleaner. Take care that the wires to pins 1-4 do not contact the center pin (#5). Apply dielectric grease inside the connector and plugs before sealing. Refer to the connector diagram on the previous page and the images below. 1.
  • Page 26 0330-0410-0M Rev C • Portable Digital Truck Scale...

  • Page 27: Grounding Installation Instruction

    Grounding Installation Instructions The ground rod shall be copper plated 0.5 in. (1.27 cm.) minimum diameter, with clean exterior surfaces, and shall not be covered with paint, enamel, or other materials, which are poor conductors. The ground rod shall be embedded below permanent moisture level at least 8 ft. (2.44 m.) where practicable.

  • Page 28: Access Plate Installation

    Access Plate Installation The access plates in the scale are at one end in the corner of the weighbridge. Before installing the access plates, perform the following steps: Replace the cable tray removed earlier. Roll up any excess load cell cable and place on the cable tray. Make sure the cables are clear of the access plate opening.

  • Page 29: Setup And Calibration

    225DLC controller (installed in the indicator Digital Load option card slot). Cell Controller The scale must contain Cardinal 225D Weight Indicator digital load cells (SmartCells) in order to communicate with the 225D. Setup and Configuration All digital scales are connected together with a daisy-chained CAN cable. The load cell connection loop can begin at any convenient load cell, and may continue clockwise as shown or counter-clockwise if preferred.

  • Page 30: Addressing Cells

    Addressing Cells Each cell has a serial number (S/N) marked on the cell. This is an 8 digit hexadecimal number. It is also known as the cell ID. Each cell ID must be matched with a cell address. In the example above, the addresses would be 1-8.

  • Page 31: Balancing Weighbridge Dead Load

    Balancing Weighbridge Dead Load Before calibration, it is very important that the dead load of the weighbridge be evenly distributed between the pair of cells in a section. Begin by powering up the 225D and proceeding to the Diagnostics Menu to the LOADCELL WEIGHTS screen.
  • Page 32 Insert Shim Insert Here Shim Here Insert Shim Here Install shims between the load cell pivot plate and the weighbridge load cell block to evenly distribute the deadload. 0330-0410-0M Rev C • Portable Digital Truck Scale...

  • Page 33: Calibration

    Calibration If, after test loading the scale, it is determined that adjustments are required, follow the procedure below. This section describes the procedure necessary to calibrate a Cardinal Digital Truck Scale. 1. Before any adjustments are made, turn on power to the digital weight indicator.

  • Page 34: Smart Calibration

    Center the weight over scale X and press ENTER to take a weight sample. Repeat steps 5 and 6 for each cell in the order prompted by the 225D. (This is the same order as other Cardinal scales e.g. 1, 3, 5, 7, 8, 6, 4, 2). ZERO CALIBRATION Zero Calibration does not affect the trimming of the cells or affect span.

  • Page 35: Span Adjust

    SPAN ADJUST Span adjust allows the user to tweak the span of the entire scale at once. Press 4 and ENTER. The 225D will display the current live scale weight “SCALE WT = XXXXX.X” in high- resolution mode. Place the test weight at any location on the scale. Press SET_WT soft key.
  • Page 36 0330-0410-0M Rev C • Portable Digital Truck Scale...

  • Page 37: Diagnostics

    DIGITAL SCALE DIAGNOSTICS There are four main components to Digital Scale Diagnostics: • On Screen Diagnostics – Critical errors that alert operator from main screen of setup issues or hardware problems. • Diagnostic Menu – A set of diagnostic tools that give a technician more information about each load cell.
  • Page 38 COMMUNICATION ERROR BETWEEN LOAD CELLS X AND Y NO WEIGHT  -------    COMMUNICATION ERROR BETWEEN LOAD CELLS 1 AND 3 COUNT Probable Cause Items to Check There is a loss of • Check that cable is connected correctly. communication between load •...
  • Page 39 LOAD CELL X HAS BEEN REPLACED NO WEIGHT -------    LOAD CELL 2 HAS BEEN REPLACED. SCALE NOT LEGAL FOR TRADE UNTIL CALIBRATED. PRESS ENTER TO CONTINUE Probable Cause Items to Check A load cell has been replaced. Replaced load cells are automatically detected as long as only one load cell was replaced.
  • Page 40 LOAD CELL ID 8F07E8F HAS NO ADDRESS NO WEIGHT  -------    LOAD CELL ID 8F07E8F HAS NO ADDRESS COUNT Probable Cause Items to Check A load cell is responding, but Go to the addressing menu and assign the load cell ID to it is not addressed in the an address.
  • Page 41 DIGITAL SCALE BOARD NOT DETECTED NO WEIGHT  -------   DIGITAL SCALE CARD NOT DETECTED COUNT Probable Cause Items to Check The 225D cannot • Check that the card is seated properly and fastened communicate with the option correctly. card or the option card is not •...

  • Page 42: Diagnostic Menu

    Diagnostic Menu To enter the diagnostic menu press SHIFT + CELL_DIAG soft key. All diagnostic information except software version update once per second. LIVE LOAD CELL WEIGHTS (This can be zeroed as needed.) LOAD CELL WEIGHTS -106 -120 PREVIOUS NEXT EXIT MINIMUM AND MAXIMUM WEIGHTS (This can be zeroed as needed.)
  • Page 43 SOFTWARE VERSION OF CELL LOADCELL SOFTWARE VERSIONS 1. 1.0.14 6. 1.0.14 2. 1.0.14 7. 1.0.14 3. 1.0.14 8. 1.0.14 4. 1.0.14 5. 1.0.14 PREVIOUS NEXT EXIT NOTE: The controller’s version number, in contrast, is displayed upon startup of the 225D indicator.
  • Page 44 DLC CARD COMMUNICATION ERROR COUNTS DLC CARD COMMUNICATION ERROR COUNTS FIFO Ovr Ack Err Bus Off CRC Err CAN Err Form Err Bit1 Err Stuf Err Bit0 Err PREVIOUS NEXT EXIT This is the count of any missed messages from the DLC card buffer that FIFO Ovr were not kept up with.
  • Page 45 CELL POWER SUPPLY VOLTAGES CELL POWER SUPPLY VOLTAGES *Approx. 14.355 14.191 13.950 14.530 14.334 14.260 14.211 14.267 * 0.184 Amps PREVIOUS NEXT EXIT NOTES: • The  on cell number 5, indicates the cell voltage measurement was not calibrated but is an approximate value based on the raw counts.
  • Page 46 SNAP COMMUNICATIONS DIAGNOSTICS When the SNAP SmartMedia Box communications is enabled, an additional page of the Digital Scale Diagnostics is available. This will scan and list the IDs of any SmartMedia boxes that it finds on the same channel that the indicator is set to.

  • Page 47: Hardware Diagnostics

    Hardware Diagnostics The digital controller (option card) has four LED’s for diagnostic purposes. LED1 LED2 LED3 LED4 LED1 (RED) – MAIN BOARD TX/RX: Toggles each time the DLC controller and the 225D Mainboard exchange messages. LED2 (RED) – TX TO LOAD CELL: Toggles each time a message is sent from the DLC controller to the load cells.

  • Page 48: Board Replacement

    NEW card to the existing scale. OPTION CARD REPLACEMENT If an option card is replaced, the 225D will boot up to this screen: BY CARDINAL Revision 0.1.04 NEW CARD FOUND! WAS DIGITAL SCALE CARD REPLACED? NO The 225D indicator will check whether the option card has been replaced in order to reconfigure the new option card to the existing scale.

  • Page 49: Maintenance Instructions For High Usage Weighments

    Maintenance Instructions for High Usage Weighments 1. A High Usage Weighment Scale is one with 150 or more weighments per day. 2. A weekly maintenance inspection should be performed. A. Check all load cells for and clear debris around load cells. 3.
  • Page 50 0330-0410-0M Rev C • Portable Digital Truck Scale...

  • Page 51: Troubleshooting Guide

    Before calling Cardinal Scale for assistance, there are a few things to check first that can be done to get the system back up and running. Remember, that there is a logical explanation for all problems and for troubleshooting to be successful, it must be approached in a logical and rational manner.
  • Page 52 LOW VOLTAGE DETECTED CELL X, Cont. SOLUTION: I. If the system voltage is below 9 VDC, proceed as follows: J. First remove the White (V+ Bus) and Blue (V- Bus) wires from the Homerun cable on the DLC Card, and using a DVM, read the voltage on the connector. This should be minimum of 14 VDC on the 225DLC (11.5 VDC on the 825-DLC).

  • Page 53: Current Draw More Than 150% Of Capacity

    CURRENT DRAW MORE THAN 150% OF CAPACITY SOLUTION: A. Cut the end off of an extra load cell cable and strip back the wires to make a test cable. B. Ensure the scale is powered up. C. Remove the End Node (terminator) from the last load cell in the loop, and connect the test cable to the port on the load cell where the End Node (terminator) was.

  • Page 54: Load Cell X Not Responding

    IDs and their corresponding scale locations (NOT the location in the data loop). C. If a Cardinal Digital Load Cell Simulator is available, remove the Homerun cable from the first load cell in the loop and attach it to the simulator.
  • Page 55 COMMUNICATIONS ERROR BETWEEN INDICATOR AND SCALE, Cont. SOLUTION: H. If a NEST is not available, proceed with the following instructions to check the Homerun cable for shorts: 1. Disconnect the Homerun cable from the load cell (Start Node). 2. Starting with one wire, check the resistance between it and each of the other wires one at a time.

  • Page 56: Load Cell X Has No Address

    LOAD CELL X HAS NO ADDRESS SOLUTION: A. Go to the Scale Setup screen and enter the load cell ID in the correct scale location. COMMUNICATION ERROR BETWEEN LOADCELLS X AND Y SOLUTION: A. Use the NEST to test the suspect load cell cable for defects. B.

  • Page 57: Load Cell Or Scale Communication Problems

    LOAD CELL OR SCALE COMMUNICATIONS PROBLEMS SOLUTION: A. Go to the Diagnostics screen LOAD CELL COMMUNICATIONS ERRORS and observe the historical error counters for each load cell. B. Record these numbers. C. Press EXIT(?) to zero the counters on the 225D. For the 825D, press C)lear to zero the counters.
  • Page 58 0330-0410-0M Rev C • Portable Digital Truck Scale...

  • Page 59: Isite Configuration

    CONFIGURATION The 225D will periodically send indicator, scale, and cell data to the Cardinal iSite Webserver for diagnostic logging. This information will be used by the server to determine if there are problems with the scale(s) that need to be addressed.
  • Page 60 The following information is available: A. IP address (if available). B. Ethernet cable state – “ETHERNET DETECTED” or “ETHERNET NOT DETECTED”. C. The status of the connection. The following statuses should occur in order while making a connection after boot up: a.

  • Page 61: Parts Identification

    PARTS IDENTIFICATION 0330-0410-0M Rev C • Portable Digital Truck Scale...

  • Page 62: Weighbridge Assembly

    Weighbridge Assembly (Quantity shown for 70’ x 11’ scale) See Optional Lifting Lug See Detail D Lower Frame Base Spacer Assembly Detail See Grounding Detail 0330-0410-0M Rev C • Portable Digital Truck Scale...

  • Page 63: Optional Lifting Lug

    Weighbridge Assembly, Cont. (Quantity shown for 70’ x 11’ scale) QTY. ITEM DESCRIPTION 0330-0177-0A BRIDGE AND LOWER FRAME ASSEMBLY 0330-0182-0A WEIGHBRIDGE, DROP-IN MODULE 0330-0183-0A LOWER FRAME BASE SPACER 0330-0046-0A ACCESS PLATE ASSEMBLY Optional Lifting Lug Lifting lugs are available for the lifting of scale sections. Note that the lifting lugs are shipped on the last section loaded on the truck at the factory.

  • Page 64: Grounding Detail

    Grounding Detail ITEM QTY. DESCRIPTION 6980-0054 GROUND ROD .625" DIA X 10 FT. 6980-0036 GROUND WIRE, 1 1/2” FLAT BRAID #3 AWG 6980-0035 WIRE 10GA STRANDED, GREEN 6610-5023 GOUNDING CLAMP Lower Frame Base Spacer Assembly Detail DETAIL D – LOWER FRAME BASE SPACER ASSEMBLY 6024-0051 LOCK WASHER, 1/2"...

  • Page 65: Lower Frame Bolt-Down Anchor Assembly Detail

    Lower Frame Bolt-Down Anchor Assembly Detail QTY. ITEM DESCRIPTION 0330-0197-08 BOLT DOWN ANGLE, HR ANG. 4" X 4" X 3/16" X 4" 6007-0361 HEX HEAD BOLT, 1"-8 UNC 2A X 2 1/2" 6024-0060 LOCK WASHER, 1" HELICAL SPRING 6013-0160 HEX NUT, 1"-8 UNC 2A 0330-0410-0M Rev C •...

  • Page 66: Load Cell Stand And Parts Detail

    Load Cell Stand and Parts Detail Load Cell Stand and Parts Detail (Quantity shown for 70’ x 11’ scale) QTY. ITEM DESCRIPTION 0330-0178-0A LOWER FRAME ASSEMBLY 0331-0066-0A WEIGHBRIDGE, END MODULE 0330-0216-0A LOAD CELL STAND ASSEMBLY 0330-0125-18 PIVOT PLATE, TS FB 3/8 X 1-3/8 ANNEALED A-2 6007-0009 HEX HEAD BOLT, 1/4"-20 UNC 2A X 1/2"...

  • Page 67: Interconnection Cables

    Interconnection Cables (Quantity shown for 70’ x 11’ scale) ITEM QTY. DESCRIPTION HOME RUN CABLE, 5 CONDUCTOR, 18 AWG 6980-1083 3502-0681-0A CONNECTOR PACK, HOME RUN CABLE 0330-0065-08 INTERCONNECT CABLE, 15’ (4572mm), 22AWG 0330-0066-08 INTERCONNECT CABLE, 27’, (8230mm), 22AWG 6540-1619 CAP, VINYL, FOR 1/2”-9/16” X 3/4” LONG, BLACK 0330-0067-08 END TERMINATOR Load Cell Shims...

  • Page 68: Decal And Name Plate Mounting View Detail

    Decal and Name Plate Mounting View Detail 0330-0410-0M Rev C • Portable Digital Truck Scale...
  • Page 69 Decal and Name Plate Mounting View Detail (Quantity shown for 70’ x 11’ scale) ITEM DESCRIPTION QTY. 5930-D091-08 NAME PLATE 6680-0210 POP RIVET DECAL, "REMOVE SHIPPING ASSEMBLY" 0145-B453-08 DECAL, " CAUTION DO NOT WELD . . . " 0145-B393-08 DECAL SECTION 1 0145-B392-18 DECAL SECTION 2 0145-B392-28...
  • Page 70 STATEMENT OF LIMITED WARRANTY WARRANTY TERMS Cardinal Scale Manufacturing Company warrants the equipment we manufacture against defects in material and workmanship. The length and terms and conditions of these warranties vary with the type of product and are summarized below:...
  • Page 71 This warranty sets forth the extent of our liability for breach of any warranty or deficiency in connection with the sale or use of our product. Cardinal will not be liable for consequential damages of any nature, including but not limited to loss of profit, delays or expenses, whether based on tort or contract.
  • Page 72 Cardinal Scale Mfg. Co. 203 E. Daugherty, Webb City, MO 64870 USA Ph: 417-673-4631 or 1-800-641-2008 Fax: 417-673-2153 www.cardinalscale.com Technical Support: 1-866-254-8261 E-mail: tech@cardet.com Printed in USA 0330-0410-0M Rev C 05/19 0330-0153-0M Rev A • Digital Truck Scale...

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