T Scale TPF Series User manual

Service manual

TPF / TFB Series Indicator Service Manual

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CONTENTS

1. BASIC INFORMATION……………………………………………………………1

2. PRECAUTIONS……………………………………………………………………..2

3. SPECIFICATION..…………………………………………………………………. 3

4. INSTALLATION……………………………………………………………………. 5

4.1. Unpacking…………………………………………………………………..5

4.2. Installation……………………………………………………………………6

4.3. Calibration Steps……………………………………………………………7

5. OPERATION.………………………………………………………………………8

5.1. Operation..…………………………………………………………………..8

5.2. Operation Limits…………………………………………………………….8

5.3. Load / Unload weighing...………………………………………………….8

6. MAINTENANCE……..........................................................................….9

6.1. Daily Check………………………………………………………………..9

6.2. Cleaning……………………………………………………………….9

6.3. General……………………………………………………………………10

6.4. Determine the problem………………………………………………...10

6.5. Testing Load cell……………………………………………………..10

6.6. Check Indicator voltages………………………………………………..11

6.7. Problems and Solutions…………………………………………………12

6.8. Parts Replacement………………………………………………………13

7. DRAWING…………….…………………………………………………………..15

7.1. Dimension………………………………………………………………….15

7.2. Exploder Drawing.………………………………………………………16

TPF / TFB Series Floor Scale Service Manual

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1. BASIC INFORMATION

1.1 Documentation

These installation instructions contain all data necessary for placing and

commissioning the floor scales.

1.2 Proper Use

This scale is intended to determine the weighing value of material to be weighed.

It is intended to be used as a “non-automatic balance”.

i.e. the goods to be weighed is manually and carefully placed in the center of the

weighing plate, As soon as stable weighing value is reached the weighing value

can be read.

1.3 Improper Use

 Do not leave permanent load on the floor scales.

 Do not load the platform, if there is any evidence of damage to the platform

or supporting structure.

 Changes to the weighing system’s design are not permitted. This may lead

to incorrect weighing results, safety-related faults and destruction of the

balance.

1.4 Monitoring

In the frame work of quality assurance the measuring –related properties of the

weighing system and, if applicable test weight, must be checked regularly.

1.5 General

 Two types of floor scales are available, mild steel and stainless steel.

 The TPF floor scale sizes range from 1190x840mm. TFB sizes range from

1200x170x100m

 Easy accessible stainless steel junction box.

 Four Load cells

 Adjusting leveling foot

 Overload up to 150%

 All models have threated holes in the decks for attaching eyebolts to

facilitate installation and cleaning

TPF / TFB Series Floor Scale Service Manual

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2. PRECAUTIONS

BEWARE OF PINCH POINTS.

USE PROPER LIFITING TECHNICS WHEN

RAISING THE LIFT DECK PLATFORMS.

ENSURE THAT STRUCTURE WHICH SUPPORT

THE FLOOR SCALE IS CAPABLE OF WITH

STANDING THE WEIGHT IF THE SCALE AND ITS

RATED CAPACITY.

2.1 Pay attention to the instructions in the manual.

Carefully read this manual before setup and commissioning, even if you are

already familiar with floor scales.

The appliance may only be operated and maintained by trained personnel.

2.2 Transport and storage

2.2.1 Testing upon acceptance

When receiving the appliance, please check packaging immediately, and the

appliance itself when unpacking for possible visible damage.

2.2.2 Packaging / Transport

Keep all parts of the original packaging for a possibly required for transport.

TPF / TFB Series Floor Scale Service Manual

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3. SPECIFICATION

Model

TPF / TPFS

TFB / TFBS

Capacity

1T / 2T / 3T

1.5T / 3T

Readability

0.5kg / 1kg / 1kg

0.5kg / 1kg

Construction

Mild Steel (A36 Carbon Steel) /

Stainless Steel (Type 304)

Grade Level

Within 3⁰ of level

Operating Temperature

0°C - 40°C / 32°F - 104°F

Resolution

3000

Load Cells

4 load cell

ADC

Sigma Delta

ADC Update

≤1/10 second

Stabilization Time

One seconds typical

Gross Weight

61kg and above

45kg and above

Floor level distance

81mm & above

Packing

Wood Box

TPF / TFB Series Floor Scale Service Manual

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Load cell Specifications

Dimension

s in mm

L

L1

L2

L3

L4

H

H1

B

1

ØD

M

Cap:

500kg to

2T

13

0

15.

8

25.

4

76.

2

54.

2

31.

8

15.

8

31.

8

34

13.

5

M12X1.7

5

Model

H8C

Rated Capacity ( Emax)

500kg / 1T / 2T

Sensitivity

3.0 ± 0.003mV/V

Accuracy Class

C3

Zero Balance

± 1% F.S

Input Impedance

400 ±20Ω

Output impedance

352 ±3Ω

Insulation Impedance

≥ 5000MΩ

Temperature Range ( Compensated)

-10°C ~ +40°C

Temperature Range (Operating)

-30°C ~ +70°C

Maximum Safe Overload

150%F.S

Ultimate Overload

180%FS

Excitation , Recommend

10~12V DC

Excitation, maximum

15V DC

Protection Class

IP68

Construction

Alloy Steel

Cable

4mtr

TPF / TFB Series Floor Scale Service Manual

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4. INSTALLATION

4.1 Unpacking

Floor is relatively heavy. Always use a suitable lifting device and technics to lifit it

out of the packaging or to transport it to the required installation site.

Do not step under the suspended load, risky of injury.

When you received the goods, inspect it to make sure that it is not damaged and

accessories according to the customer’s order.

 Remove all components from their packing material.

 Keep the shipping container and packing material for future use.

 Check the packing list.

 Collect all necessary installation manuals for the equipment and

accessories.

 Open the equipment and perform an inspection.

4.2 Installation

Accurate weighing results require a floor scale with perfect horizontal alignment.

During initial installation and after each change of work area it is necessary to

level the floor scale.

 Select a location that is flat, solid, level and full supports the weight of

platform with full capacity load.

 Use a forklift or other lifting means, along with chains,

Cables or nylon straps to remove the scale from the crate bottom.

 Set the scale so that the interface cable exits in a direction where it can be

protected.

Placing the floor scale with access ramps or foot plates

 Select place the floor scale

 Place the floor scale correctly on the marked area of the floor scale.

Adjustable foot area wants to observe the evenness and level alignment

If any minor height difference, want to adjust adjustable foot for to

compensate level.

 Connect the scale cable to the proper to the indicator.

TPF / TFB Series Floor Scale Service Manual

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Load Cell Connector Connections



4.3 Calibration Steps

Adjust the analog interface indicator to the platform.

 Install all the corners to within one division of each other at 25% of the

rated capacity.

 Follow the appropriate indicator manual to ensure a proper calibration

Note: The floor scale is shipped fully assembled,

wired and corners calibrated.

Corner (s) Calibration:

The Junction Box (Summing Box) Assembly has four extended range, multi-

turn potentiometer (trim pot), and one or two for each load cell.

7Pin

Connection

Pin 1

Signal -

Pin 2

Signal +

Pin 3

Shield

Pin 4

Exc -

Pin 5

Sen -

Pin 6

Sen +

Pin 7

Exc +

5Pin

Connection

Pin 1

Signal +

Pin 2

Signal -

Pin 3

Shield

Pin 4

Exc -

Pin 5

Exc +

Trim pot

1

2

3

4

Interface

TPF / TFB Series Floor Scale Service Manual

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STEPS

1. Center the trim pot by turning the adjustment screw counter clock wise

position until a clicking sound is heard, then turning each of them back

clock wise 10 turns

2. Identify the platform corner numbers.

3. Place a test weight (25% of the scale capacity) on the

corner No.1, then move it to No.2, No.3 and No.4.

Note that displayed reading on each corner.

4. Identify the lowest reading.

If scale corners require to do adjustment,

5. Place the test weight at the location of the lowest weight reading.

6. Turn the adjustment on the potentiometer clockwise to the displayed

weight. It can read the same as the highest reading.

7. Proceed clockwise; repeat the adjustment to all corners of the scale until

reading reach all corners is same. Because the trim pot interact with one

another, any adjustment will affect the weight readings at all four corners

of the scale

Note:

If junction box has two trim ports for each load cell,

want to adjust both ports for each corner.

When moving the test weight (s) from the corner to

corner, do not zero the scale. Corner adjustment is to

adjust the corners to be same, not for calibration.

8. Perform a zero reference check with an unload platform

9. Repeat the corner test to ensure all readings are the same before

proceeding.

10. Ensure all corners are same.

11. Remove all weights

12. Perform a final calibration with test weights and appropriate indicator

manual.

Then you can start your operation

2 3

PLATFORM

1 4

TPF / TFB Series Floor Scale Service Manual

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5. OPERATION

5.1 Operation

 Interface connection (power is supplied via the connecting cable of the

display unit)

 Initial Commissioning

 Connection of peripheral devices

 Adjustment, linearization and verification (Only it can be verifiable,

when it’s connected with suitable display unit)

And the correct operation will be in the operation instructions included of

the display unit.

Continuous optimal performance is guaranteed;

 For Weighing operation, all objects must be placed centrically of the floor

scale and may not hang over the edges or the ramps

 Check adjustment at regular intervals

 Avoid falling load, shock loads and impacts from the

side.

5.2 Operation Limits

 The floor scales are designed extremely robust. The load limits according

to the following table should not be exceeded..

 Depending on the type of load receptacle, the static carrying capacity. The

maximum admissible load is

Weighing Range

1000kg

2000kg

3000kg

Centre

3000kg

4500kg

Side stress

2000kg

3000kg

One side

1000kg

2000kg

5.3 Load / Unload weighing

 Place the load on the scales using a crane or forklift or using proper lifting

technics. Ensure the load is not swinging when it is placed onto the scales.

 Lift the load first vertically at least 10cm above the scales before it is

removed or newly placed

TPF / TFB Series Floor Scale Service Manual

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6. MAINTENENCE

WARNING

BEWARE OF PINCH POINTS.

USE PROPER LIFITING TECHNICS WHEN

RAISING THE LIFT DECK PLATFORMS.

ENSURE THAT STRUCTURE WHICH SUPPORT

THE FLOOR SCALE IS CAPABLE OF WITH

STANDING THE WEIGHT IF THE SCALE AND ITS

RATED CAPACITY

Permit only qualified persons to service the instrument.

Before connecting or disconnecting any components, remove the

power.

Failure to observe these precautions bodily harm or damage to or

destruction of the equipment.

6.1. Daily Check

 Ensure that all four feet are in contact with the floor.

 Ensure that the connecting cable to the display unit and the network

connection cable of the display unit are not damaged.

 Ensure that the balance is free from dirt, especially under the edges of the

balance.

6.2. Cleaning

 Remove regularly corrosive substances.

 Keep IP protection.

 Protect weighing cells against splash water

 When using optional ramps or foot plates, keep clean the air gap at the

edge of the weighing scale.

 Wipe the surfaces with a damp cloth.

 Only use common household cleaner.

 Do not use water jet or high-pressure cleaner.

TPF / TFB Series Floor Scale Service Manual

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6.3. General

If the scale does not operate properly, find out the problem as possible.

Determine whether the problem is constant or alternate. Be aware that problems

can be caused by mechanical or electrical influences.

Check the following.

 Water

 Corrosive materials

 Vibrations or temperature or wind

 Physical damage

Check the indicator cables for damage, and check all connections and

connecters for any loose contact or incorrect connection

6.4. Determine the Problem

Determine whether the problem is in the indicator or the platform

 Remove power from the system, and disconnect the indicator from the

platform

 Connect the indicator to a load cell simulator

 Reapply power and test the indicator

 If problem goes away, its source is probably in the platform. Check the

wiring, connecter, load cells and mechanical components of the platform.

If problem persists, its source is probably in the indicator. Check the

indicator voltages, connecters, cables and function programs.

6.5. Testing Load cell

For testing load cell, remove power from the system, and disconnect the PCB

from the Load cell

Physical Test:

 Check the moisture, or foreign material inside.

 Check load cell surface badly rusted or corroded

 Check the strain gauge areas become compressed

 Check any physical damage (body bent or twisted) to the load cell

 Check load cell cable, all leads are connected, any cut, splits or tears.

 Check load cell for proper input and output resistances

Electrical Test:

Use an accurate multimeter to check the ohms

Load Cell Connections

TPF / TFB Series Floor Scale Service Manual

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Signal + Green

Supply + Red

Signal - White

Supply - Black

Shield

Resistance

Leakage Resistance

 Check each of the load cell wires to the load cell cable screen.

 Check each of the load cell wires to the load cell body.

These readings should be greater than 1000mΩ or OL.

If this reading is less than 1000 mΩ, then this load cell has leakage between

the internal circuit and the load cell body or cable screen

Zero Balance

 Connect the load cell to a stable DC source of between 5 to 10V

 Connect multimeter to mV and connect to the load cell signal wires

 The meter should read 0.00mV ± approximately 1 % of full load.

If the output reads greater than ±10% of full scale capacity, then the load cell

will require replacement.

6.6. Check Indicator Voltages

If the problem is in the Indicator, use a multimeter to check the following voltages

 AC Power

 Adaptor Voltage

 PCB Input Voltage

 Check Battery Voltage and Charging Voltage

Follow the instructions in the Indicator manual for to check the voltages.

Measuring Points

Resistance

+ Exc to –Exc (Input)

350 ± 3.5 Ω

+Sig to –Sig (Output)

351 ± 2 Ω

TPF / TFB Series Floor Scale Service Manual

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6.7. Problems and Solutions

Problems

Possible cause

Common Solutions

OL or -------

Maximum capacity

exceeded. Load cell or

mechanics damaged.

Power supply faulty

Check the platform is installed

correctly. Try to turn on the scale

again. Do the calibration again

------- or NULL

displayed

Weight is on the

platform is below

permissible limit. Pan

not installed correctly.

Power supply faulty.

Load cell or

mechanism faulty

Check the platform is installed

correctly. Try to turn on the scale

again.

Do the calibration again

Display is

unstable

Goods touching

somewhere. Air

variation or any

vibrations.

Temperature

changed . Load cell or

connections faulty.

Power supply faulty

Check the scale is in acceptable

location.

Check the connecters and load cell.

Check the power supply and battery

Weight value

incorrect

Calibration error.

Platform of load cell

touching somewhere.

Wrong weighing unit

Use accurate weight for to do the

calibration

Check the pan and load cell is

installed proper and touching.

Check the parameter settings.

Check the load cell and connecters

Can not use full

capacity

Over load protection

stoppers or transport

locks are not removed.

Parameters are set

incorrectly.

AD problem.

Load cell or

mechanism damaged

Check the stoppers and locks under

the platform.

Check the weighing unit and

parameter settings.

Check the load cell.

Platform Corner

Weight different

Over load protection

stoppers or transport

locks are not removed.

Load cell or

mechanism damaged

Check the stoppers and locks under

the platform.

Use accurate weight for to do the

calibration

Check the load cell.

TPF / TFB Series Floor Scale Service Manual

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6.8 Parts Replacement:

Load Cell Replacement:

 Remove power from the Indicator terminal and disconnect the instrument

cable.

 Remove the junction box cover and locate the defective load cell.

 Disconnect the defective load cell’s cable from its terminal on the junction

box PCB (Summing PCB).

 Remove the load cell from the junction box.

 Carefully position the platform on a stable supporting surface that allows

access to defective load cell and cable.

 Tie a string to the end of the cable attached to the defective load cell. The

string should be strong and long enough to pull the new load cell’s cable

through the platform structure.

 The load cells (s) are fastened to the platform using two Head Cap Bolts.

Remove this load cell mounting bolts with a box spanner, retaining the

screws for reinstallation. Lift the load cell and spacer plate from the

mounting surface.

 Carefully pull the defective load cell cable through the platform while

feeding the string in at junction box opening. Once the string reaches the

load cell mounting location, untie it from the load cell cable.

Spacer

Load Cell

Flat Washer

Spring Washer

Bolt

Adjustable

Foot

TPF / TFB Series Floor Scale Service Manual

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 Remove the leveling foot from the defective load cell and reinstall it in the

new load cell.

 Tie the string to the new load cell cable and carefully pull the new cable

through the platform structure to the junction box opening. Coil any excess

cable and store it within the platform.

 Bolt the new load cell and spacer plate to the platform. Apply an anti-seize

compound such as “Never –Seez” to the threads of the mounting screws

and tighten them with a calibrated torque.

 Thread the load cell cable through the connector of the junction box.

 Wire the new load cell cable to the proper summing connector.

 Level the scale with the leveling feet.

 Reattach the instrument cable and power up the scale terminal.

 Perform a corner test and recalibrate the scale.

TPF / TFB Series Floor Scale Service Manual

- 15 -

7. DRAWING

7.1 Dimensions in mm

TPF / TPFS

TFB /TFBS

T

TPF / TFB Series Floor Scale Service Manual

- 16 -

7.2 Exploder Drawing

TPF / TPFS Drawing

22

TPF / TPFS Parts List:

No

Parts Name

Qty

Material

Spec

1

Star Screw

4

SUS

M6x10

2

Junction Box Housing Cover

1

3

Hexagon Screw

6

SUS

M5x10

4

Junction Box Cover

1

SUS

5

Star Screw

4

S18C

M4x8

6

Junction Box PCBA

1

7

Insulation Washer

8

EPDM

8x4.5

8

Internal hexagon Screw

2

SUS

M6x10

9

Junction Box Case

1

SUS

10

Cable Gland

5

11

Scale base

1

12

Screw Plug

4

M14

TPF / TFB Series Floor Scale Service Manual

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13

Internal Hexagon Screw

2

S18C

M8x65

14

Washer

8

SPCC

16.5x8.5

15

Wheel

2

16

Nut

2

S18C

M8

17

Spacer

4

18

Load Cell

4

19

Flat Washer

8

SPCC

23x12.5

20

Adjustable Foot

4

SUS304

21

Bolt

8

S18C

22

Spring Washer

8

TFB /TFBS Drawing

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