HARDY FLOOR SCALES OPERATION AND INSTALLATION MANUAL Corporate Headquarters 9440 Carroll Park Drive San Diego, CA 92121 Phone: (858) 278-2900 FAX: (858) 278-6700 Email: hardyinfo@hardysolutions.com Web-Site: http://www.hardysolutions.com Hardy Process Solutions Doc. Number: 0596-0335-01 Rev A Copyright June 2014 Hardy Process Solutions.All Rights Reserved. Printed in the U.S.A.
Local Field Service Hardy has over 200 field technicians in the U.S., and more positioned throughout the world to assist you in your support needs. We also have factory engineers who will travel to your facility anywhere in the world to help you solve challenging applications.
CAUTION: UNPACK WITH CARE WHEN UNPACKING, DO NOT DISCARD THE PACKING CASE OR ANY PACKING MATERIAL, UNTIL THE CONTENTS OF THE PACKING CASE ARE INSPECTED AND CAREFULLY COMPARED WITH THE SHIPPING DOCUMENTS.
Table of Contents Table of Contents HARDY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 FLOOR SCALES - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 OPERATION AND INSTALLATION- - - - - - - - - - - - - - - - - - 1 MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Outside the U.
Hardy Floor Scales COMPONENT DESCRIPTIONS - - - - - - - - - - - - - - - - - - - - - 4 SITE PREPARATION - - - - - - - - - - - - - - - - - - - - - - - - - - 6 Precautions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 FLOOR SCALE INSTALLATION - - - - - - - - - - - - - - - - - - - - 7 CALIBRATION - - - - - - - - - - - Pre-Calibration Procedures - - - - C2® Second Generation Calibration Test Weight Calibration (Hard Cal) Requirements: - - - - - - - - Material Substitution:- - - - - - - - - -
Table of Contents Problem: Cause #1 Cause #2: Cause #3: Remedies: Problem:- - - Cause #1: Remedy #1 Cause #2: Remedy #2: Problem:- - - Cause #1: Remedy #1: Cause#2: Remedy #2: Cause #3: Remedy #3: Cause #4: Remedy #4: - - - - - - - - - - - - - - - - - - - - - - - - - - - 36 :36 36 36 36 37 37 :37 37 37 37 37 37 37 37 37 38 38 38 INSTRUMENTATION INTERFACE CABLE COLOR CODES - - - - - - 38 iii
Hardy Floor Scales iv
Table of Illustrations Table of Illustrations HARDY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 FLOOR SCALES - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 OPERATION AND INSTALLATION- - - - - - - - - - - - - - - - - - 1 MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 TABLE OF CONTENTS - - - - - - - - - - - - - - - - - - - - - - - - I TABLE OF ILLUSTRATIONS - - - - - - - - - - - - - - - - - INSTALLING THE CLOSED EYE BOLTS INTO THE TOP PLATE SUMMING
Hardy Floor Scales II
Hardy Floor Scales INTRODUCTION Hardy Floor Scales are designed for applications that require a low profile weighing surface with high commercial accuracy and reliability. The Hardy Floor Scales can be configured with a complete range of accessories. Rugged Hardy Floor Scales are rated for 250,000 load cycles under normal loading conditions.* They can be sized or configured to fit any floor scale application. *Contact Hardy for more information The typical platform height is 3.375 inches (8.6 cm).
Hardy Floor Scales WARNING FOR SCALES FITTED WITH AN INTEGRATED TECHNICIAN SUMMING CARD, DO NOT EXCEED 5 VDC EXCITATION. DOING SO MAY CAUSE PROPERTY DAMAGE. DO NOT USE WITH ANY INSTRUMENT WITH AN EXCITATION VOLTAGE ABOVE 5 VDC. Load Points HARDY ADVANTAGE® Load Sensors • Factory Matched • Stainless Steel • True Hermetic Seal • No Cornering Total Error 0.
Hardy Floor Scales Foot Elastomer • Natural Rubber (Standard) Grade Level In operation, the scale must be firmly and adequately supported at all four corners to accommodate the maximum load in your application. The scale must be installed to within 3º of level. Accessories Ramps, Pit Frames, Bumper Guards, Lift Decks, Lifting Eye Bolts, Bolt Down Plates Anchor Bolt Holds Approvals NEMA Rating Test Criteria UNPACKING 1/2 inch bolts - 9/16” (.5625”) hole, 3.75 inches deep 5/8 inch bolts - 5/8” (.
Hardy Floor Scales • Step 3. Step 4. Step 5. Mild Steel - 1/2 - 13 x 1.5” (Hardy Model Number HIFSEB-PS) Attach a chain, cable or nylon strap to the eyebolts. Use a forklift or crane with rated lifting capacity that is equal to or greater than the total weight of the platform scale to lift the scale high enough to remove from the crate bottom. See Tables 2 & 3 for shipping weights. Be sure to use all safety precautions when lifting the platform so that it does not fall on equipment or personnel.
Hardy Floor Scales 2. ASTM A793-85) floor plate (skid resistant) or smooth stainless steel plate with a bead blast finish. Summing Junction Card Assembly - Accessed by unfastening the face plate on the center side of the platform. (See Fig.2) The summing junction card routes the excitation voltage to each of the four load sensors and sums the weight signal back from them. The C2® second generation electronic calibration is included with your scale. FIG. 2 SUMMING JUNCTION CARD 3. 4. 5.
Hardy Floor Scales SITE PREPARATION • • • Precautions • • • • • • • • • • • • 6 All mounting surfaces for the floor scale should be level to within 3º, corner to corner, end to end. Keep in mind that the adjustable leveling feet have a maximum adjustment of 7mm (.275”). Before welding anything on the floor scale, contact Hardy Process Solutions Service Center for instructions and precautions. Proper drainage must be provided to prevent the load sensors from standing in water.
Hardy Floor Scales Load and unload heavy equipment in this direction only! FIG. 3 DIRECTION WHEN DRIVING HEAVY EQUIPMENT ON AND OFF THE SCALE FLOOR SCALE INSTALLATION Step 1. NOTE: With the scale in place, the clearance around the edge of the platform and pit coping should be 1/4” to 3/8”. Place the platform scale on the operating location. Make sure that the platform height is within 3 to 3.275" as measured from the top of the cover plate to the top of the floor surface. (See Fig. 4) 3.275” (83.
Hardy Floor Scales Step 2. Step 3. Make sure that the platform mounting surface is level to 1/8”. Use a level (Spirit level, Bullseye level or similiar) to check if the platform is level, side to side, corner to corner and diagonally. (See Figs. 9, 10, 11, 12) FIG. 5 SPIRIT LEVEL FIG.
Hardy Floor Scales FIG. 7 CHECKING PLATFORM LEVEL/CORNER TO CORNER FIG. 8 CHECKING PLATFORM LEVEL/DIAGONALLY Step 4. • • Adjust each of the leveling feet in the direction (either up or down), indicated by the level readings. (See Fig. 9) To increase the height rotate the foot counter clockwise. To decrease the height rotate the foot clockwise.
Hardy Floor Scales Foot FIG. 9 ADJUSTING THE FEET FOR LEVEL Step 5. Step 6. Step 7. Place the spirit level on the platform surface again to check the adjustment for level. Keep adjusting the legs until the platform is level and all four leveling feet are firmly on the floor surface. Check the distance from the top of the platform to the floor surface at each corner. All the measurements should be within 3º of each other and the platform should be level.
Hardy Floor Scales Step 3. • • • • • • • • Step 4. Connect the C2 Certified Summing Card Interface Cable to the weight instrument. Color code wires as follows: + Excitation + Sense + Signal - Signal - Sense - Excitation + C2 - C2 Red Blue Green White Brown Black Grey Violet Use the weight instrument/indicator manual for calibration instructions. To purchase C2® certified cable, contact your local Hardy Representative or the Hardy Process Solutions Service Center.
Hardy Floor Scales Material Substitution: • When certified test weights are not available you can use an accurately weighed material instead. The material must be weighed on a secondary, calibrated scale and delivered to the site of the primary floor scale for calibration. The secondary calibrated scale should be of the same accuracy or greater and have a capacity approximately equal to the primary floor scale. • • SCALE VERIFICATION Step 1. Step 2.
Hardy Floor Scales Step 11. If all the readings are not within an acceptable tolerance contact the Hardy Process Solutions Service Center.
Hardy Floor Scales Tread Plate Deck Painted Smooth Plate Deck Painted MODEL MODEL CAPACITY LBS KGS Overall Size Feet CM Ship Wght LBS (KGS) HIFS-6084-10-PS-T HIFS-6084-10-PS-S 10000 4536 5’ x 7’ 152 x 213 900 (408) HIFS-7296-10-PS-T HIFS-7296-10-PS-S 10000 4536 6’ x 8’ 183 x 244 1150 (522) Table 1: Carbon Steel, Painted Stainless Steel Deck (304 SS) Tread Plate Stainless Steel Deck Smooth Stainless Steel Deck MODEL MODEL CAPACITY LBS KGS Overall Size Feet CM Ship Wght LBS
Hardy Floor Scales Tread Plate Stainless Steel Deck Smooth Stainless Steel Deck MODEL MODEL CAPACITY LBS KGS Overall Size Feet CM Ship Wght LBS (KGS) HIFS-6060-10-SS-T HIFS-6060-10-SS-S 10000 4536 5’ x 5’ 152 x 152 650 (295) HIFS-6084-05-SS-T HIFS-6084-05-SS-S 5000 2268 5’ x 7’ 152 x 213 900 (408) HIFS-6084-10-SS-T HIFS-6084-10-SS-S 10000 4536 5’ x 7’ 152 x 213 900 (408) Table 2: Stainless Steel 15
Hardy Floor Scales REMOVING SUMMING BOX COVER Step 1. Use a Phillips screwdriver and remove the two flat head machine screws that fasten the summing box cover to the floor scale frame. (See Fig. 11) FIG. 11 REMOVING THE SUMMING BOX COVER Step 2. Step 3. 16 Gently pull the frame cover out of the enclosure. You now have access to the summing junction card and C2 Certified Cable as shipped. Using a Phillips head screwdriver remove all the screws that fasten the cover to the summing box. (See Fig.
Hardy Floor Scales FIG. 12 REMOVING THE SUMMING BOX LID Step 4. Take the lid off the junction box so that you can see all the wiring from the load sensors and to the instrument/indicator. (See Fig.
Hardy Floor Scales FIG. 13 REMOVING THE SUMMING BOX LID Installing the Leveling Feet Step 1. Step 2. 18 Remove the lock bolt and nut from the leveling foot. With the scale raised and securely blocked, insert the leveling foot into the load sensor. Make sure the through hole in the foot is aligned with the bottom through hole on the load sensor. (See Fig.
Hardy Floor Scales FIG. 14 INSERTING THE LEVELING FOOT INTO THE LOAD SENSOR NOTE: You may need to push with a little force due to some interference caused by the O-ring that is attached to the foot. DO NOT USE A HAMMER OR TRY TO DRIVE THE FOOT INTO THE HOUSING. Step 3. Step 4. With the through holes aligned, insert the lock bolt going from the center of the scale outward. This eliminates having to remove the load sensors when installing the lock bolt. Screw the nut onto the lock bolt until it is tight.
Hardy Floor Scales FIG. 15 INSIDE VIEW FIG. 16 OUTSIDE VIEW Step 5. 20 Install all four (4) feet. (See Fig.
Hardy Floor Scales FIG. 17 ALL FOUR FEET INSTALLED INSTALLING A LOAD SENSOR Step 1. Step 2. Shut all power off to the floor scale. To gain access to the Summing Card follow the instructions above. You do not have to remove the summing card or the bottom of the Junction box to install a new load sensor. (See Fig. 18) FIG.
Hardy Floor Scales Load Sensor # Connector Load Sensor #1 TB1 Load Sensor #2 TB2 Load Sensor #3 TB3 Load Sensor #4 TB4 To Instrument TB5 Table 3: Summing Card Load Sensor Connectors Step 3. Use a small slotted head screw driver and disconnect the Load Sensor cable. It is a good idea to mark the wires if the wire markers have been removed. Color code wires are as follows: We recommend the use of C2 cable from the weighing instrument to the junction box.
Hardy Floor Scales Step 4. Loosen the cable gland nut for the load sensor cable you want to remove. (See Fig. 19) FIG. 19 CABLE GLAND Step 5. From the load sensor pull the cable out of the junction box and through the channel until all the cable has been removed. Step 6. Use the closed eye bolts and chain, cable or nylon strapping to lift the floor scale high enough to remove the load sensor or turn the scale completely over and let the top plate rest on blocks for easier access to the feet. Step 7.
Hardy Floor Scales Load Cell Bolts FIG. 20 REMOVING LOAD SENSOR BOLTS AND FEET Step 12. Place the new load sensor so that the through bolt holes are aligned with the threaded mounting holes and in the same direction as the old load sensor. DO NOT CUT OR REUSE THE OLD CABLE ON THE NEW LOAD SENSOR. Step 13. Screw in the two (2) load sensor bolts that fasten the load sensor to the mount. Tighten the bolts finger tight. Step 14. Use a Torque Wrench and tighten the bolts to the torque rating in Table 4.
Hardy Floor Scales Step 15. Run the load sensor cable through the channel to the summing box. Bundle up any excess cable and store it in the channel. DO NOT CUT THE CABLE TO MAKE IT FIT BETTER. If you cut the cable, you will not get correct readings from the load sensors. Step 16. Reconnect the cable wires according to the color code in Step 3 to the correct load sensor connector. WARNING LOAD CELL CABLE LENGTH HAS BEEN CALCULATED INTO C2 CALIBRATION DATA.
Hardy Floor Scales cable exit. Locate the conduit to match the hole location. Step 1. Place the pit frame in the approximate position it will occupy on the floor. (See Fig. 21) 3.4375 (87.3mm) 11” (279.4mm) FIG. 21 FOUNDATION FOR THE PIT FRAME Step 2. 26 Mark out the position of the hole to be made. The hole MUST be a minimum of 12" larger than the pit frame on all sides. (See Fig.
Hardy Floor Scales 8” Typ 8” Typ FIG.
Hardy Floor Scales Size Platform Size Material HIFSPF-3030-PS 30in x 30in 76m x 76cm Painted Carbon Steel HIFSPF-3636-PS 36in x 36in 91cm x 91cm Painted Carbon Steel HIFSPF-4848-PS 48in x 48in 122cm x 122cm Painted Carbon Steel HIFSPF-4860-PS 48in x 60in 122cm x 152cm Painted Carbon Steel HIFSPF-4872-PS 48in x 72in 122cm x 183cm Painted Caron Steel HIFSPF-6060-PS 60in x 60in 152cm x 152cm Painted Caron Steel HIFSPF-6084-PS 60in x 84in 152cm x 213cm Painted Caron Steel HIFSPF-
Hardy Floor Scales 2x4 Wire Pit Frame Assembly FIG. 24 EXCAVATED PIT AND SUPPORT FOR THE PIT FRAME Step 5. Step 6. Step 7. Step 8. Step 9. • • • • • Set the frame in the hole supported at about the correct height. Set two 2 x 4 's on edge (longer than the width of the hole) across the opening. (See Fig.
Hardy Floor Scales • Cure to a minimum of 2000 psi before pulling the interface cable through the conduit. Step 10. Pull the interface cable through the conduit. OPTIONAL PORTABILITY KIT A portability kit is designed to convert a Hardy Floor Scale from a stationary scale to a mobile weighing system for pallets, drums and other large items. The kit makes it easy to move the scale using a hand jack or standard forklift tines without damaging the scale so you can place it where it is needed.
Hardy Floor Scales FIG. 25 RAMP WITH RETAINER PLATES Step 3. Step 4. Drill the two (2) outer holes using a hammer drill. (See Specifications/Anchor Bolt Holds above for hole dimensions) Insert the anchor bolts with the nut and washer already ON. (See Fig. 26) FIG.
Hardy Floor Scales Step 5. Tap the anchor bolt into the hole then tighten the nuts securely. Step 6. Lift the Platform out and away form the foot retainer plate. Step 7. Drill the two (2) inner holes using a hammer drill. (See Specifications/Anchor Bolt Holds above for hole dimensions) Step 8. Insert the anchor bolts with the nut and washer already ON. Step 9. Tap the anchor bolts into the hole then tighten the nuts securely Step 10.
Hardy Floor Scales FIG. 27 FOOT RETAINER PLATES INSTALLATION NOTE: Foot Retainer Plates Installation The platform has been removed for clarity purposes. Step 1. Step 2. Step 3. Step 4. Step 5. Place the Floor Scale in position. Place the foot retainer plate under the foot, plate edge should extend out from under the scale. Drill two (2) holes using a hammer drill. (See Specifications/Anchor Bolt Holds above for hole dimensions) Insert anchor bolts with the nut and washer already attached.
Hardy Floor Scales NOTE: If ramps are NOT installed and foot retainer plates are needed, then a set of four (4) foot retainer plates are required. OPTIONAL BUMPER GUARDS Bumper guards are designed to help protect the platform from direct hits from forklift traffic. The guards are slightly higher than the scale and will help deflect the forks. Installing Bumper Guards Step 1.
Hardy Floor Scales FIG. 28 BUMPER GUARD/GAP REQUIREMENT FIG. 29 BUMPER GUARD/INSTALLATION Step 2. Step 3. Drill the holes using a hammer drill. (See Specifications/Anchor Bolt Holds above for hole dimensions) Insert the anchor bolts with the nut and washer already installed.
Hardy Floor Scales Step 4. Optional Indicator Column Tap the anchor bolts into the hole then tighten the nuts securely. Many Floor Scale installations require the weight to be displayed DIRECTLY at the scale. An Indicator column allows the site to mount an instrument directly by the scale for ease of reading. Hardy Floor Scales feature an optional 4 ft. Indicator column for mounting a Hardy controller or weight processor directly above the floor scale.
Hardy Floor Scales • • • Problem: Cause #1: Remedy #1: Scale indication is not linear. Packing material or debris wedged or built up underneath the platform • • Cause #2: Remedy #2: Cause #1: Remedy #1: Carefully lift the platform high enough to safely remove the built up debris. Check for loose connections or broken wires. Weighing instrument or floor scale is not calibrated. • • Problem: Check for loose connections or broken wires.
Hardy Floor Scales Remedy #3: Make sure that the weigh instrument and the floor scale platform cover are both connected to earth ground. Cause #4: High static electricity present. Remedy #4: Install a ground strap from the floor scale platform cover to earth ground. WARNING INSTRUMENTATION INTERFACE CABLE COLOR CODES 38 DO NOT CONNECT THE GROUND STRAP NEAR OR ON THE LOAD SENSORS. THEY ARE GROUNDED THROUGH THE SUMMING JUNCTION BOX. TO DO SO WILL DAMAGE THE LOAD SENSORS.
Index Numerics 304 stainless steel platform 1-5 A About Pit Frames 1-25 Acceptable tolerance 1-13 Access Ramp Installation 1-30 Accessories 1-3 Active elements 1-1 Allen Bradley module manual 1-12 Approvals 1-3 Attach a chain 1-4 B Blind Hole Load Introduction technology 1-1 Block the floor scale 1-23 Bolt-Down Plates Installation 1-33 Bundle 1-25 C Certified Summing Card Interface Cable 1-11 C2® Certified cable 1-11 C2® Second Generation Calibration 1-12 C2® Second Generation Calibration system 1-1 Cable
Hardy Floor Scales D Diamond tread floor plate 1-30 Direct hits 1-34 E End to end 1-6 Endloading 1-2 Excitation 1-1 Eyebolts 1-4 F Flat head machine screws 1-16 FLOOR SCALE INSTALLATION 1-7 Foot Elastomer 1-3 forklift 1-4 forklift traffic 1-34 G Grade Level 1-3 H hammer drill 1-31 Hardy Floor Scales 1-1 Hardy Instruments Service Center 1-6 Hardy weight or rate controller manuals 1-12 hostile applications 1-29 I Increase the height 1-10 Inner holes 1-32 Installing Load Sensors 1-21 Installing the Leveling F
Index L Level readings 1-10 Leveling Feet 1-6 Load forces 1-1 Load sensor bolts 1-24 Load Sensors 1-5 Loops 1-29 M Material Substitution 1-12 Maximum Overload 1-2 Mild Steel Deck, Painted 1-14 Mild steel ramp 1-30 Model Code Breakdown1-14 N Natural Rubber 1-3 NEMA 4 1-3 NEMA Rating 1-3 Non-Hostile applications 1-29 Non-level floor 1-1 Non-scale traffic 1-34 Nylon strap 1-4 Nylon strapping 1-23 O Optional Foot Retainer Plates 1-11, 1-32 Optional Bumper Guards 1-34 Optional Pit Frames 1-25 P Paint 1-2 Philli
Hardy Floor Scales Platform Height 1-1 Platform Material 1-1 Position #1 1-12 Position #2 1-13 Position #3 1-13 Position #4 1-13 Pre-Calibration Procedures 1-11 Precautions 1-6 Proper drainage 1-6 R Rated lifting capacity 1-4 Repeatable weighments 1-1 Requirements 1-12 S Safety precautions 1-4 Scale platform 1-25 Scale Verification 1-12 Site Preparation 1-6 Skid Resistant 1-30 Slotted head screw driver 1-22 Socket wrench 1-23 Soft wire 1-29 Soil bearing pressure 1-25 Spirit level 1-8 Stainless Steel ramps
Index Test Weight Calibration (Hard Cal) 1-12 Torque Wrench 1-24 Total Error 1-2 Troubleshooting 1-36 U Unpacking 1-3 W Welding 1-6
Hardy Floor Scales
