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Use of DANGER, WARNING, CAUTION, and NOTE This publication includes, DANGER, WARNING, CAUTION and NOTE information where appropriate to point out safety related or other important information. DANGERHazards which could result in severe personal injury or death WARNINGHazards which could result in personal injury CAUTIONHazards which could result in equipment or property damage NOTEAlerts user to pertinent facts and conditions Although DANGER and WARNING hazards are related to personal injury, and CAUTION hazards are associated with equipment or property damage, it should be understood that operation of damaged equipment could, under certain operational conditions, result in degraded process performance leading to personal injury or death. Therefore, comply fully with all DANGER, WARNING, and CAUTION notices.
NOTICE The information in this document is subject to change without notice and should not be construed as a commitment by ABB Automation GmbH. ABB Automation GmbH assumes no responsibility for any errors that may appear in this document. In no event shall ABB Automation GmbH be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB Automation GmbH be liable for incidental or consequential damages arising from use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without ABB Automation GmbHs written permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. The software described in this document is furnished under a license and may be used, copied, or disclosed only in accordance with the terms of such license.
CE-MARKING The ITX000 mounted in cabinets fulfills the EMC Directive 89/336/EEC and the Low Voltage Directive 73/23/EEC, provided that the installation is carried out in accordance with the installation instructions given in Chapter 5, Installation, included in this manual.
3BSE005014/B
Template: 3BSE005015/A
3BDD016542-EN
TABLE OF CONTENTS
Chapter 1 - Introduction
1.1 1.2 Purpose and contents ............................................................................................... 1-1 Function and design ................................................................................................. 1-1
Selection of load cell size ........................................................................................ 4-6 Fixing of the load cells............................................................................................. 4-8 Selection of pressure plate ....................................................................................... 4-9 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.5.6 4.5.7 4.5.8 4.5.9 4.5.10 4.5.11 4.5.12 Selection of rubber pressure plate QGMT 103 and QGMT 204 ............ 4-9 Dimensions of rubber pressure plate QGMT 103................................. 4-10 Compression and side movement of rubber pressure plate QGMT 1034-11 Mounting accessories for rubber pressure plate QGMT 103................ 4-12 Installation requirements for rubber pressure plate QGMT 103........... 4-13 Dimensions of rubber pressure plate QGMT 204................................. 4-16 Compression and side movement of rubber pressure plate QGMT 2044-17 Mounting accessories for rubber pressure plate QGMT 204................ 4-18 Installation requirements for rubber pressure plate QGMT 204........... 4-19 Selection of sliding pressure plate QGMT 105 .................................... 4-22 Dimensions of sliding pressure plate QGMT 105 ................................ 4-23 Installation requirements for sliding pressure plate QGMT 105 .......... 4-24 1
3BDD016542-EN
4.6
Design of safety devices......................................................................................... 4-27 4.6.1 4.6.2 4.6.3 4.6.4 Anti-lift off device................................................................................. 4-27 Lateral movement protection ................................................................ 4-28 Securing tie rods.................................................................................... 4-29 4.6.3.1 Tie rods in tension and compression .............................. 4-29 Overload protection device ................................................................... 4-33 Heat radiation protection....................................................................... 4-34 Protection against dust and moisture..................................................... 4-34 General .................................................................................................. 4-35 Wind pressure........................................................................................ 4-35 Air pressure difference .......................................................................... 4-35 Shunt forces........................................................................................... 4-35 Rigidity of foundation and load carrier................................................. 4-35
4.7
4.8
Designing to avoid interference factors ................................................................. 4-35 4.8.1 4.8.2 4.8.3 4.8.4 4.8.5
4.9 4.10
Design of pipe connections .................................................................................... 4-36 Electric connections ............................................................................................... 4-37 4.10.1 4.10.2 4.10.3 General .................................................................................................. 4-37 Cable selection and dimensioning......................................................... 4-37 Grounding of strain gauge load cells .................................................... 4-38
Chapter 5 - Installation
5.1 5.2 5.3 5.4 General ..................................................................................................................... 5-1 Packaging and delivery ............................................................................................ 5-1 Storage...................................................................................................................... 5-2 Installation of the load cells ..................................................................................... 5-3 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 5.4.9 General .................................................................................................... 5-3 Necessary equipment .............................................................................. 5-3 Cleaning .................................................................................................. 5-3 Anti-corrosion protection ........................................................................ 5-3 Installation procedure.............................................................................. 5-4 Mounting plate ........................................................................................ 5-5 Foundation............................................................................................... 5-6 Mounting of the load cells....................................................................... 5-7 Installation of the pressure plate ............................................................. 5-8 5.4.9.1 5.4.9.2 5.4.10 5.4.11 5.4.12 5.4.13 Rubber pressure plates QGMT 103 and QGMT 204 ....... 5-8 Sliding pressure plate QGMT 105.................................... 5-9
Installation of anti-lift off device .......................................................... 5-10 Lateral movement protection ................................................................ 5-11 Securing tie rods.................................................................................... 5-12 5.4.12.1 Tie rods in tension and compression .............................. 5-12 Overload protection device ................................................................... 5-13
Chapter 6 - Commissioning
2 3BDD016542-EN
General..................................................................................................................... 6-1 Necessary equipment ............................................................................................... 6-1 Actions before mains supply is connected............................................................... 6-1
Chapter 7 - Maintenance
7.1 7.2 7.3 General..................................................................................................................... 7-1 Periodical maintenance ............................................................................................ 7-1 Preventive maintenance ........................................................................................... 7-2
Appendix A - Drawings
A.1 A.2 A.3 A.4 A.5 A.6 A.7 Load cell 9QGPL 5-25 ton, 3BDE700098...............................................................A-1 Load cell 9QGPL 40-160 ton, 3BDE700099...........................................................A-2 Mounting plates, 3BDE700100 ...............................................................................A-3 Mounting unit for QGMT 103, Dimension drawing, 3BDE700101 .......................A-4 Rubber pressure plate QGMT 103, Dimension drawing, 3BDE700102 .................A-5 Rubber pressure plate QGMT 204, Dimension drawing, 3BDE700103 .................A-6 Sliding pressure plate QGMT 105, Dimension sheet, 3BDE700104 ......................A-7
3BDD016542-EN
3BDD016542-EN
Weighing Load Cell User Manual Section 1.1 Purpose and contents
Chapter 1 Introduction
The load cells are installed under a platform or a weighbridge. The applied load is transferred via the rubber pressure plates QGMT 103/204 or the sliding pressure plates QGMT 105 to the load cells. The load cells are connected to the weighing controller via a junction box.
3BDD016542-EN
1-1
1-2
3BDD016542-EN
2.1 General
A scale normally consists of a control unit ABB Weighing controller ITX000 two to four load cells 9QGPL and additional external equipment and cabling. Figure 2-1 shows one platform scale and one hopper scale, which are two typical scale installations using load cells 9QGPL.
Platform scale
Hopper scale
3BDD016542-EN
2-1
2-2
3BDD016542-EN
3.1 General
An ABB Weighing System consists of one or more load cells which are connected via a connection box or an ADC Box to an ABB Weighing Controller ITX000. The control unit supplies the load cells with power, processes the signals from the load cells and transfers measured values to external units. The control unit can be operated by either using the integrated keyboard, by an external operator unit, serial interfaces or digital inputs. Measured values are displayed on the operator unit, connected to analog outputs or transmitted via a serial interface to external displays or other external units. Status signals and alarms are indicated on the operator unit or connected to digital outputs.
Connection box
W1.1~ NET
3289675
Print
12345678901234567890
ADC1 ADC2 F1 BF5
Find
Info
7 4 1 .
8 5 2
9 6 3 -
Clr
X
T
F2 IF6
Del Esc
+12.378
Large scale display
F3 PF7
F8 F4 W V Connection box
0 Y
+
1 A
Esc ` |
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
*
F12
Prt Sc Sys Rq
Delete Scr Lk
Insert Num Lk
!1
"2
$4
%5
^6
&7
*8
(9
)0
_-
+=
Q
CapsLock
W A S Z
Fn
E D X
R F C
Alt
T G V
Y H B
O
2
P
3
{[
}]
PgUp
Printer
J N
K
0
:;
@'
~#
PgDn
|\
Load cells
<,
>.
?/
End
Ctrl
Alt Gr
Ctrl
Figure 3-1. Overview diagram for a Millmate Weighing System with Millmate Controller 400W
3BDD016542-EN
3-1
3-2
3BDD016542-EN
Solder tabs
Carrier
Alignment marks
Figure 3-3. Strain gauge element A fundamental parameter of the strain gauge is its sensitivity to strain, ex-pressed quantitatively as the gauge factor (GF). Gauge factor is defined as the ratio of fractional change in electrical resistance to the fractional change in length (strain):
R R R R GF = -------------- = -------------L L
The gauge factor for metallic strain gauges is typically around 2. To measure small changes in resistance, strain gauges are almost always used in a bridge configuration with a voltage excitation source. The general Wheatstone bridge, illustrated below, consists of four resistive arms with an excitation voltage VEX, that is applied across the bridge.
+ -
EX
Figure 3-4. Wheatstone Bridge The output voltage of the bridge VO will be equal to:
R3 R2 V O = ----------------- ----------------- V EX R3 + R4 R1 + R2
From this equation, it is apparent that when R1/R2 = R3/R4, the voltage output VO will be zero. Under these conditions, the bridge is said to be balanced. Any change in resistance in any arm of the bridge will result in a nonzero output voltage, which is measured and displayed by the weighing controller. 3BDD016542-EN 3-3
3.2.3 Definitions
Nominal load (Fnom) is the load for which the load cell is dimensioned and calibrated, i.e the sum of the stationary load and the maximum measured load in the measuring direction. Overload is the range in which transducers experience a permanent change. Max load (Fmax) is the maximum permitted load in the measuring direction without permanent change of data. Breaking load (Fbreak) is the load in the measuring direction for the load cell, above which mechanical damage must be expected. Max. lateral force (FVmax) is the maximum load in the lateral direction without permanent change of data. Accuracy class is defined as the maximum deviation, and is expressed as a percentage of the sensitivity at nominal load. This includes linearity deviation, hysteresis and repeatability error. Sensitivity is defined as the difference in output signal between nominal load and no load. Combined error is defined as maximum deviation from a straight line drawn between the output values of zero and nominal load, related to the nominal load. This includes linearity deviation, hysteresis and repeatability. Repeatability is defined as the maximum deviation between repeated readings under identical conditions. It is expressed as a percentage of the sensitivity at nominal load. Hysteresis is the maximium deviation of the output signal at the same load during a cycle from zero to nominal load and back to zero, related to the sensitivity at nominal load. The hysteresis is proportional to the cycle. Temperature dependence is the drift in %/K related to the sensitivity at nominal load. Zero point drift is defined as the drift in the output signal when there is no load on the load cell. Sensitivity drift is defined as the drift in the output signal at nominal load, excluding the zero point drift. Mounting alternative. The load cells are available with the connection box mounted on the front or back side. In alternative A it is located on the opposite side of the load cell mounting lugs, whilst in alternative B on the same side.
3-4
3BDD016542-EN
Ordering No. 3BDE700000 3BDE700001 3BDE700002 3BDE700003 3BDE700004 3BDE700005 3BDE700006 3BDE700007
3BDD016542-EN
3-5
5 - 25 ton
40 - 160 ton
Figure 3-5. Dimensions Table 3-3. Dimensions (in mm) 9QGPL -5 - 10 - 16 - 25 - 40 - 63 - 100 - 160 D 132 143 154 184 204 224 245 295 H 160 175 185 195 230 255 270 310 H1 148 161 169 179 214 237 252 292 R 19.00 25.40 31.75 31.75 31.75 38.10 38.10 38.10
3-6
3BDD016542-EN
4.1 General
It is of utmost importance for the final result that the selection of load cells and the preparative work to adapt the load cells are carried out rigorously in accordance with the instructions given in the following sections. Note In addition to these general instructions, order-specific instructions may exist. An example of this can be mounting instructions presented to the customer after the order has arrived at ABB.
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4-2
3BDD016542-EN
Weighing Load Cell User Manual Section 4.2.3 Applications with load cells
Which type of pressure plate to use is determinated by requirements on function and installation. Type QGMT 103 is the normally used pressure plate.
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4-3
The minimum dimensions for mounting plates are given in Table 4-1.
Fixing screw
Mounting plate
Figure 4-3. Load cell assembly When mounting on a steel beam or similar, the flanges may normally be reinforced with stiffeners welded in place as close to the fixing holes as possible.
Stiffeners Figure 4-4. Fastening of the mounting plate and reinforcement of the beam 4-4 3BDD016542-EN
Figure 4-5. Pattern of fixing holes in the mounting plate Table 4-1. Mounting plate dimensions Mounting plate Steel grade: Mild steel A 200 210 235 270 220 240 260 310 T 25 25 30 35 40 50 60 70 R 83.5 88.5 98.5 113.5 85 92 99 120 nD 3 M12 3 M12 3 M16 3 M16 4 M16 4 M20 4 M24 6 M24 Fixing screws Property class 8.8, oil lubr. Size M12 50 M12 50 M16 60 M16 60 M16 60 M20 70 M24 70 M24 90 Qty 3 3 3 3 4 4 4 6 Tightening torque (Nm) 70 70 160 160 160 400 700 700
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4-5
The load cell dimensions are given in Table 4-2 and Figure 4-7. Table 4-2. Dimensions of load cell 9QGPL
Size (ton) 5 10 16 25 40 63 100 160 Cat. No. D D1 H H1 R 19 25.4 R1 R2 B C H2 29 29 37 42 85 92 99 80 80 80 18 126 22 136 26 140 75 95 95 H3 H4 L V V1 Lifting Weight eyes (kg) 10.5 14.5 18 4M8 27 36 2M10 52 66 106
3BDE700000 132 117 160 148 3BDE700001 143 127 175 161
13 14 103 13 14 112 15 16 117 15 16 136 25 47 149 45 490 32 55 159 45 490 35 55 170 45 490
3BDE700002 154 137 185 169 31.75 3BDE700003 184 167 195 179 31.75 3BDE700004 204 3BDE700005 224 3BDE700006 245 3BDE700007 295 230 214 31.75 255 237 270 252 310 292 38.1 38.1 38.1
120 80
4-6
3BDD016542-EN
Weighing Load Cell User Manual Section 4.3 Selection of load cell size
3BDD016542-EN
4-7
Fixing clamp
Table 4-3. Dimensions of the fixing clamps Load cell size L (ton) (mm) 5 - 10 16 - 25 60 77 B (mm) 30 40 H (mm) 29 33 L1 (mm) 13 17 L2 (mm) 25 30 H1 (mm) 4 3 H2 (mm) 17 18 D (mm) 13 17
4-8
3BDD016542-EN
Weighing Load Cell User Manual Section 4.5 Selection of pressure plate
Which type of pressure plate to use is determined by the requirements of function and installation. Rubber pressure plates QGMT 103 are normally used. Sliding pressure plates QGMT 105 are used when no vertical movement is permitted.
4.5.1 Selection of rubber pressure plate QGMT 103 and QGMT 204
The rubber pressure plates consist of two circular steel plates joined by an intermediate layer of vulcanized rubber. QGMT 103 is relatively rigid in compression but resilient in the direction of shear. This permits a certain amount of lateral movement and, due to the resilience of the rubber, the pressure plate is self-centering. Therefore, lateral fixing of the load carrier is normally not required. The rubber pressure plate effectively suppresses the disturbance caused by vibrations in the load carrier or in the foundation. Typical applications for QGMT 103 is in common platform scales, hopper scales and scales in CCM1, i.e. in ladle turret, tundish and roller table. In some applications however, where heavy load impacts may arise, the soft pressure plate QGMT 204 must be used. It has a relative thick rubber layer which will absorb the shock forces, particularly in the vertical direction. Typical applications for QGMT 204 are in rough operations as for example scrap handling where heavy lumps are dropped into a basket or bucket.
1.
3BDD016542-EN
4-9
3BDE700083 254 242 120 85 132 15 13.1 38.1 3BDE700084 320 308 120 85 155 20 13.1 38.1 3BDE700084 320 308 120 85 155 20 13.1 38.1
Weighing Load Cell User Manual Section 4.5.3 Compression and side movement of rubber pressure plate QGMT 103
4.5.3 Compression and side movement of rubber pressure plate QGMT 103
Table 4-5 shows the compression and side movement, at 20 C, in the pressure force direction to nominal load Fnom, and in the direction of shear at a side load equal to FS = 0.1 Fnom. Table 4-5. Compression of rubber pressure plate QGMT 103 Fnom (ton) -5 10 - 25 40 - 100 - 160 Compression (f) in pressure force direction at Fnom 0.4 mm 15% 0.5 mm 15% 0.5 mm 15% 0.8 mm 15% Movement (f) in direction of shear at FS = 0.1 Fnom 6 mm 15% 8 mm 15% 9 mm 15% 9 mm 15%
F (Fnom)
F Fnom
Weighing Load Cell User Manual Section 4.5.5 Installation requirements for rubber pressure plate QGMT 103
Table 4-6. Dimensions of the mounting unit for rubber pressure plate QGMT 103 Size (ton) 5 10 16 25 40 63 100 160 A 160 180 180 180 260 260 330 330 B 62 71 71 71 99 99 122 122 C 8 14 14 14 14 14 14 14 D 25 60 60 60 85 85 85 85 E 14 20 20 20 20 24 29 29 T 10 10 10 10 10 15 20 20 No. of M8-holes 2 2 2 2 2 2 4 4 Fixing screw class 8.8 M8 20 M8 20 M8 20 M8 20 M8 20 M8 25 M8 25 M8 25
Weld
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4-13
Size 5 to 25 ton
Figure 4-14. Load cell assembly with 9QGPL and rubber pressure plate QGMT 103
4-14
3BDD016542-EN
Weighing Load Cell User Manual Section 4.5.5 Installation requirements for rubber pressure plate QGMT 103
Table 4-7. Specification of items in load cell assemblies Item 1 Load cell Size (ton) 5 10 16 25 40 63 100 160 9QGPL 5 10 16 25 40 63 100 160 Item 2 Fixing clamp Item 3 Mounting plate Dimensions Qty. 3 3 3 3 4 4 4 6 Item 4 Screw Dimensions Torque (Nm) property oil lubricated class 8.8 M12 x 50 M12 x 50 M16 x 60 M16 x 60 M16 x 60 M20 x 70 M24 x 70 M24 x 90 70 70 160 160 160 390 660 660
Catalogue no. Qty. Catalogue no. 3BDE700000 3BDE700001 3BDE700002 3BDE700003 3BDE700004 3BDE700005 3BDE700006 3BDE700007 3 3 3 3 3BDE700010 3BDE700010 3BDE700009 3BDE700009
Item 8 Screw
Catalogue no. Qty. Catalogue no. Dimensions 3BDE700078 3BDE700079 3BDE700080 3BDE700081 3BDE700082 3BDE700083 3BDE700084 3BDE700084 2
2 2 2 4 4
3BDE700008
M8 x 20
M8 x 25
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4-15
3BDE700087 210 198 100 65 3BDE700088 257 245 120 85 3BDE700089 309 297 120 85 3BDE700090 380 368 120 95
100 3BDE700091 440 428 120 115 217 160 3BDE700091 462 450 150 125 217
Weighing Load Cell User Manual Section 4.5.7 Compression and side movement of rubber pressure plate QGMT 204
4.5.7 Compression and side movement of rubber pressure plate QGMT 204
Table 4-9 shows the compression and side movement, at 20 C, in the pressure force direction to nominal load Fnom, and in the direction of shear at a side load equal to FS = 0.1 Fnom. Table 4-9. Compression of rubber pressure plate QGMT 204 Fnom (ton) 5 10 - 160 Compression (f) in pressure force direction at Fnom 5 mm 15% 6 mm 15% Movement (f) in direction of shear at FS = 0.1 Fnom 9 mm 15% 9 mm 15%
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4-18
3BDD016542-EN
Weighing Load Cell User Manual Section 4.5.9 Installation requirements for rubber pressure plate QGMT 204
Table 4-10. Dimensions of the mounting unit for rubber pressure plate QGMT 204 Size (ton) 5 10 16 25 40 63 100 160 A 170 180 220 270 B 63 70 82.5 99 C 9 14 14 14 14 14 14 14 D 65 65 65 85 85 95 115 125 E 14 19 19 19 22 26 26 26 T 10 10 10 10 15 20 20 20 No. of M8-holes 2 2 2 2 4 4 4 4 Fixing screw class 8.8 M8 20 M8 20 M8 20 M8 20 M8 25 M8 25 M8 25 M8 25
Weld
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4-19
Size 5 to 25 ton
Figure 4-20. Load cell assemblies with QGPL 105 and rubber pressure plate QGMT 204
4-20
3BDD016542-EN
Weighing Load Cell User Manual Section 4.5.9 Installation requirements for rubber pressure plate QGMT 204
Table 4-11. Specification of items in load cell assemblies Item 1 Load cell Size (ton) 5 10 16 25 40 63 100 160 9QGPL 5 10 16 25 40 63 100 160 Item 2 Fixing clamp Item 3 Mounting plate Dimensions Qty. 3 3 3 3 4 4 4 6 Item 4 Screw Dimensions Torque (Nm) property oil lubricated class 8.8 M12 x 50 M12 x 50 M16 x 60 M16 x 60 M16 x 60 M20 x 70 M24 x 70 M24 x 90 70 70 160 160 160 390 660 660
Catalogue no. Qty. Catalogue no. 3BDE700000 3BDE700001 3BDE700002 3BDE700003 3BDE700004 3BDE700005 3BDE700006 3BDE700007 3 3 3 3 3BDE700010 3BDE700010 3BDE700009 3BDE700009
Item 8 Screw
Catalogue no. Qty. Catalogue no. Dimensions 3BDE700085 3BDE700086 3BDE700087 3BDE700088 3BDE700089 3BDE700090 3BDE700091 3BDE700091 2
2 4 4 4 4
3BDE700008
M8 x 20
M8 x 25
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4-21
4-22
3BDD016542-EN
Weighing Load Cell User Manual Section 4.5.11 Dimensions of sliding pressure plate QGMT 105
Figure 4-21. Dimensions of sliding pressure plate QGMT 105 3BDD016542-EN 4-23
Figure 4-22. Mounting of sliding pressure plate QGMT 105 When mounting the securing tie rods and the load cells, ensure that the clearance in the sliding pressure plate is approximately 5 mm all around.
4-24
3BDD016542-EN
Weighing Load Cell User Manual Section 4.5.12 Installation requirements for sliding pressure plate QGMT 105
Size 5 to 25 ton
Figure 4-23. Load cell 9QGPL with sliding pressure plate QGMT 105
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4-25
Table 4-13. Specification of items in load cell assemblies Item 1 Load cell Size (ton) 5 10 16 25 40 63 100 160 9QGPL 5 10 16 25 40 63 100 160 Item 2 Fixing clamp Item 3 Mounting plate Dimensions Qty. 3 3 3 3 4 4 4 6 Item 4 Screw Dimensions Torque (Nm) property oil lubricated class 8.8 M12 x 50 M12 x 50 M16 x 60 M16 x 60 M16 x 60 M20 x 70 M24 x 70 M24 x 90 70 70 160 160 160 390 660 660
Catalogue no. Qty. Catalogue no. 3BDE700000 3BDE700001 3BDE700002 3BDE700003 3BDE700004 3BDE700005 3BDE700006 3BDE700007 3 3 3 3 3BDE700010 3BDE700010 3BDE700009 3BDE700009
Item 7 Fixing screw Dimension M12 M12 M12 M16 M16 M20 M20 M20
Catalogue no. Qty. 3BDE700092 3BDE700093 3BDE700094 3BDE700095 3BDE700095 3BDE700096 3BDE700096 3BDE700096 4 4 4 4 4 4 4 4
4-26
3BDD016542-EN
Weighing Load Cell User Manual Section 4.6 Design of safety devices
Figure 4-24. Anti-lift off device The dimensions of the anti-lift off devices are given in Table 4-14. Anti-lift off devices are dimensioned so that they can be welded to a foundation when necessary. In these cases the welded joint must be of sufficient strength to withstand the applied load. The devices are designed for an upward load which is equal to the nominal load of the load cells up to a limit of 20 ton. Devices for forces of greater values and larger load cells are individually dimensioned.
Table 4-14. Dimensions for anti-lift off devices Max. lift force (ton) 5 10 20 Load cell size Fnom 5 t Fnom 10 t Fnom 20 t A max (mm) 5 5 7 D min (mm) 20 30 40 T min (mm) 4 6 8
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4-27
Weighing Load Cell User Manual Section 4.6.3 Securing tie rods
3BDD016542-EN
4-29
The diagrams in Figure 4-27 should be referred to for the selection of suitable tie rods. One of the diagrams gives the allowable compression loading as a function of the free length of the tie rod for various tie rod diameters, and with a fracture factor of 3.2. The curves are drawn up considering Euler's Equation of Motion, case 2, when allowance cannot be given for elastic mountings. The diagram in Figure 4-29 shows the spring constant F/f, as a function of the tie rod length, for various tie rod diameters. The deflection has been calculated from the following formula: f = F L3 / (10 E I), i.e., not 100% rigid The curves are not valid for forces which exceed the limits of elasticity of the material. f = F L3 / (12 E I) where: E = 210 103 N/mm2 I = moment of inertia (see Table 4-16) F = force f = deflection L = rod length Note The bending load b, must be included in the calculation when buckling of the tie rod is to be considered.
L (Rod length)
10
F Figure 4-27. The maximum rod length is a function of the compression force for round bar
4-30
3BDD016542-EN
Weighing Load Cell User Manual Section 4.6.3 Securing tie rods
where:
E = 210 103 N/mm2 I = moment of inertia (see Table 4-16) F = force f = deflection L = rod length
Deflection
Table 4-16. Rod dimensioning data Rod diameter Cross section Flexurale resistance area W (mm2) (mm) (mm3) 10 12 16 20 25 30 40 50 60 79 113 201 314 490 707 1257 1964 2827 98 169 402 785 1534 2651 6283 12270 21210 Moment of inertia I (mm4) 0.49 103 1.02 103 3.22 103 7.85 103 19.2 103 39.8 103 126 103 307 103 636 103
3BDD016542-EN
4-31
Figure 4-29. The spring constant is a function of the rod length and the rod diameter The bending stresses can be confirmed by calculation using the following formula:
L b = F ------------ 100 N / mm2 (2W)
4-32
3BDD016542-EN
Weighing Load Cell User Manual Section 4.6.4 Overload protection device
3BDD016542-EN
4-33
4-34
3BDD016542-EN
Weighing Load Cell User Manual Section 4.8 Designing to avoid interference factors
3BDD016542-EN
4-35
4-36
3BDD016542-EN
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4-37
4-38
3BDD016542-EN
Chapter 5 Installation
5.1 General
Although the Weighing System is a precision measuring system which is intended for severe operating conditions in a harsh industrial environment, it must be handled with care when unpacking, during storage and installation.
Table 5-1. Weight of the equipment units Unit Wall cabinet Floor standing cubicle Weighing controller ITX000 Connection box/ADC Box Load cell 9QGPL (depending on size) Pressure plate QGMT 103/204 Pressure plate QGMT 105 Large display (depending on type and size) Weight (kg) max. 15 up to 200 2 <5 10.5 - 106 6 - 190 2 - 21 8 - 85
3BDD016542-EN
5-1
5.3 Storage
Limits for various combinations of temperature and humidity when storing electronic equipment during prolonged periods are shown in Figure 5-1. If, for any reason, the control unit must be stored prior to the installation, the relative humidity in the storage area must not exceed the values indicated in Figure 5-1. If the humidity is higher the units must be stored in air-tight packaging, or in shielded and air conditioned rooms with filtered air. Relative Relativ humidity (%) (%) luftfuktighet 100 100
90 90
80 80 70 70 60 60 50 50 40 40 30 30 20 20 10 10 -60 -50 -60 -50 -40 -40 -30 -30 -20 -20 -10 -10 0 0 +10 +20 +30 +30 +40 +40 +50 +50 +10 +20 Temperature (C) Temperatur (oC) Best storage Bsta environment lagringsmilj Unsuitable Olmplig storage environment lagringsmilj 6 6 months mnader eller or longer lngre 1 2 mnader months 1 --2
Figure 5-1. Permissible values regarding temperature/humidity at prolonged storage of electronic equipment
5-2
3BDD016542-EN
Weighing Load Cell User Manual Section 5.4 Installation of the load cells
5.4.3 Cleaning
Clean all pressure surfaces in the load cell package thoroughly with recommended solvent. NOTE When mounting, be careful that the pressure surfaces do not become grimy.
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set the load cell with its mounting plate in position under the pressure plate and lower the load carrier with the mounting unit and pressure plate onto the load cell. adjust the load carrier and load cells to their correct positions. check the clearances to the foundation. check the centering of the pressure plates.
install the earth core between the foundation and the load carrier at each strain gauge load cell. make certain that the clearance in the sliding pressure plate (if installed) is approx. 5 mm all around. weld the load cell mounting plate to the foundation. when more than three load cells are used in association with a rigid load carrier, the load distribution must be checked after commissioning of the electrical equipment. When necessary the overall height of the load cell assembly can be adjusted by placing shims between the pressure plate and the mounting unit. CAUTION If pressure plate QGMT 103 or QGMT 204 is used, the thickness of the shims placed above a pressure plate must not exceed 2 mm. The shims must be placed under the load cell mounting plate when the shim thickness is greater than 2 mm.
adjust the clearances in the lateral movement protection devices, the anti-lift off devices and finally the overload protection devices, before these items are welded in position. Complete the installation by fitting the anti-lift off devices, securing tie rods and radiation heat shields for the load cells.
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When mounting on a steel beam or similar, the flanges must be reinforced with stiffeners welded in place as close to the fixing holes as possible.
Stiffeners
Figure 5-2. Fastening of the mounting plate and reinforcement of the beam
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5.4.7 Foundation
When mounting on a concrete base, a foundation plate should be located under the mounting plate to permit vertical adjustment during the installation. The foundation plate is dimensioned and fixed to take up lateral forces, those transferred to the load cell via the rubber pressure plate when used and those to which the securing tie rods and lateral movement protection are subjected, if used. If an anti-lift off device is used, consideration must be given to the tension forces to which the foundation plate is subjected. When the foundation is of concrete, the securing tie rods, lateral movement protection and antilift off device should be mounted on separate foundation plates so that the foundation plate under the load cell is not affected by interference forces.
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Weighing Load Cell User Manual Section 5.4.8 Mounting of the load cells
Figure 5-4. Load cell 9QGPL, 5 - 25 ton, fixed with fixing clamps The load cells of size 40 to 160 ton are directly fixed to the mounting plate by four or six screws through the bottom flange of the load cell.
Figure 5-5. Load cell 9QGPL, 40 - 160 ton, fixed with screws
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Figure 5-6. Installation of rubber pressure plates QGMT 103 and QGMT 204 Dimensions for the mounting of rubber pressure plates are given in Table 4-4.
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Weighing Load Cell User Manual Section 5.4.9 Installation of the pressure plate
Figure 5-7. Mounting of sliding pressure plate QGMT 105 When mounting the securing tie rods and the load cells, ensure that the clearance in the pressure plate is approximately 5 mm all around.
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Weighing Load Cell User Manual Section 5.4.11 Lateral movement protection
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Parallel surfaces
Horizontal
Locked e.g. by cotterpin Spherical washers provide compensation for nonparallel alignment. Figure 5-10. Mounting of tie rods The diagrams in Figure 4-27 and Figure 4-28 should be referred to for the selection of suitable tie rods. One of the diagrams gives the allowable compression loading as a function of the free length of the tie rod for various tie rod diameters, and with a fracture factor of 3.2. The curves are drawn up considering Euler's Equation of Motion, case 2, when allowance cannot be given for elastic mountings. The other diagram shows the spring constant F/f, as a function of the tie 5-12 3BDD016542-EN
Weighing Load Cell User Manual Section 5.4.13 Overload protection device
rod length, for various tie rod diameters. The deflection has been calculated from the following formula: f = F L3 / (10 E I), i.e., not 100% rigid The curves are not valid for forces which exceed the limit of elasticity of the material. f = F L3 / (12 E I) where: E = 210 103 N/mm2 I = moment of inertia (see Table 4-16) F = force f = deflection L = rod length Note The bending load b, must be included in the calculation when buckling of the tie rod is to be considered.
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Chapter 6 Commissioning
6.1 General
The actual procedure for commissioning load cells is simple, provided that the load cells and cables have been properly installed. Installation and commissioning of the control unit is described in the control units manual. The instructions in this chapter should be followed carefully in order to obtain the best possible weighing results. It is assumed that the weighing system has been installed in accordance with the instructions given in Chapter 5, Installation. Check the following: that the load cells have been installed and aligned correctly that all screws have been tightened to the correct torque that all cables are correctly installed and connected that all connectors are plugged in
When this is done, the measuring system is ready to be switched on. The detailed actions are described in the control units manual and the manuals of all remaining external devices.
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Chapter 7 Maintenance
7.1 General
Weighing Systems ABB load cells are very reliable and require no daily service. Preventive maintenance should be carried out on parts which are subject to mechanical wear.
Table 7-1. Maintenance interval Maintenance interval Equipment Enclosures and cabinets Operator unit Load cells Action Cleaning Checking cables Cleaning Cleaning Visual inspection Cabling Weight checking Visual inspection x x x x 3 months 6 months x x x 1 year
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8.1 General
It is important to be thoroughly familiar with the description of function in chapter 2 before starting fault tracing. Fault messages can be read and acknowledged from the control units display. The fault inspection is described in Section 8.4, Fault inspection.
8.2 Interchangeability
The load cells are interchangeable with other load cells of the same type and measuring range, however, the scale must be recalibrated and new reference values must be stored. The storing of reference values is described in the calibration manual of the corresponding weighing controller.
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ADC Err
Either a short circuit in the load cell cable could be present. Check the the load cell cabling.
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ADC Ovrg
Either a wiring error of the load cell is present or the load cell is defective. Check the load cell cabling and the load cell. After corrective measures the error message must be acknowledged by means of the key or any other specified action. After acknowledging the error message the program is continued.
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8.4 Faulty weight values but no fault indication from the scale
There may be a fault in the mechanical installation. If the weight value appears to be abnormal, although the scale seems to be working normally and no fault messages are shown on the operator unit display, this may be as a result of a problem in the mechanical installation. The following checks should be carried out: Check the mechanical installation of the load carrier. Check the clearances in the overload protection, lateral movement protection and the anti-lift off protection. Check that the dust and heat protections do not transfer any force to parts not being weighed. Check fixed connections to the scale. Check cables, cable ducts and connections. NOTE It is important that the connection restraints are minimized and constant. Load the scale with a test weight and check the results. Carry out loadings repeatedly (with the test weight in the same position) to check if the results are repeatable. Move the test weight to different positions to subject the load cells to uneven loads. Try, if possible, to mainly load one load cell at a time. Since the total weight in all load cases is the same, the reading should also be the same. A different reading in any of the load cases may indicate that the load cell being loaded is faulty. Smaller weight deviations occurring during a test may be caused by the load cells and pressure plates not being centered correctly. It is possible to test the centering by lifting the load carrier slightly to make the pressure plate loose contact with the load cell. The pressure plate should not move appreciably sideways when lifting or lowering the pressure plate (max. 0.5 mm).
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