iDimension® Flex Series Assembly Manual

This manual provides an overview of the iDimension Flex Series assembly instructions. It includes assembly instructions for both the Free Standing Flex Dimensioning System and the Suspended Flex Dimensioning System.

When interfacing this device to a third party program, refer to the software manufacturer's documentation for setup and configuration information.

Manuals are available from Rice Lake Weighing Systems at www.ricelake.com/manuals. Warranty information is available at www.ricelake.com/warranties.

1.1 Companion Manuals

iDimension QubeVu Administrator Guide

The QubeVu® Administrator Guide (PN 221652) provides an overview to configure the QubeVu Manager software.

iDimension Ceiling Mount Installation Addendums

The Suspended Flex Dimensioning System must be mounted to an iDimension mounting frame. The mounting frame either uses an 80/20 bar system or a suspended cable system. See one of the following addendums for more information on installing the applicable iDimension Flex mounting system:

• iDimension LTL/LTL-XL/Flex 80/20 Mounting Frame Installation Addendum (PN 221406)
• iDimension LTL/LTL-XL/Flex Cable Mounting Frame Installation Addendum (PN 221407)

1.2 Safety

Safety Definitions:

• DANGER: Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. Includes hazards that are exposed when guards are removed.
• WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in serious injury or death. Includes hazards that are exposed when guards are removed.
• CAUTION: Indicates a potentially hazardous situation that, if not avoided, could result in minor or moderate injury.
• IMPORTANT: Indicates information about procedures that, if not observed, could result in damage to equipment or corruption to and loss of data.

General Safety

Do not operate or work on this equipment unless this manual has been read and all instructions are understood. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Rice Lake Weighing Systems dealer for replacement manuals.

• WARNING Electric shock hazard! Failure to heed could result in serious injury or death.
• Ensure the device is disconnected from the power source before opening the enclosure.
• Do not remove or obscure the high voltage sticker (PN 16861).
• There are no user serviceable parts. Refer to qualified service personnel for service.
• The unit has no power switch. To completely remove power from the unit, disconnect the power source at the AC outlet.
• For pluggable equipment, the socket outlet must be installed near the equipment and must be easily accessible.
• When cycling power, use the in-line power cord at a power outlet.
• Always disconnect from main power before performing any work on the device.
• Do not allow minors (children) or inexperienced persons to operate this unit.
• Do not place fingers into slots or possible pinch points.
• Do not use this product if any of the components are cracked.
• Do not make alterations or modifications to the unit.
• Do not remove or obscure warning labels.
• Do not use near water. Avoid contact with excessive moisture.
• Retain packaging. When transporting the unit, always disassemble and pack it in its original packaging.
• Operate between 41–104° F (5–40° C).
• Never modify or attempt to repair the unit. Service must be performed by Rice Lake Weighing Systems only.
• Handle cables and cable connectors with care. Never use damaged power cords or plugs or loose electrical sockets. Never touch the power cord with wet hands.
• Mount on a flat surface.
• Follow OSHA regulations for installation and use of equipment.

1.3 Dimensions

1.3.1 Free Standing Flex Dimensions

Overall dimensions of the four sensor floor mounted assembly and the two sensor floor mounted assembly are similar.

• Free Standing Flex Dimensions:
• Overall Height: 104.88 in (MAX)
• Overall Width: 85.09 in
• Overall Depth: 85.08 in
• Overall Height (with sensor shroud): 105.00 in (MAX)
• Overall Depth (with sensor shroud): 145.38 in (MAX)

A diagram shows the dimensions of the Free Standing Flex, with labels for overall height, width, and depth.

1.3.2 Suspended Flex Dimensions

A diagram shows the dimensions of the Suspended Flex, indicating an 88.12 inch span for the sensor arms and a 93.00 inch overall height.

2.0 Replacement Parts

2.1 Free Standing Flex

Immediately after unpacking the Free Standing iDimension Flex, visually inspect the contents to ensure all components are included and undamaged. If any parts were damaged in shipment, notify Rice Lake Weighing Systems and the carrier immediately.

The Free Standing iDimension Flex is packaged with the following parts:

A diagram shows the components of the Free Standing iDimension Flex with numbered parts.

Table 2-1. Free Standing iDimension Flex Parts List

2.2 Suspended iDimension Flex Assembly

Immediately after unpacking the Suspended iDimension Flex, visually inspect the contents to ensure all components are included and undamaged. If any parts were damaged in shipment, notify Rice Lake Weighing Systems and the shipper immediately.

The Suspended iDimension Flex is packaged with the following parts:

A diagram shows the components of the Suspended iDimension Flex with numbered parts.

Table 2-2. Suspended iDimension Flex Assembly Parts List

2.3 Common Parts

Remote Sensor Kits

See Figure 5.1 on page 23 for installation instructions.

Table 2-3. Four Remote Sensor Kit Parts List (PN 200164)

Calibration Kit

See the QubeVu Managers Guide (PN 198680) for calibration instructions.

Table 2-4. Calibration Kit Parts List (PN 167963)

3.0 Free Standing Frame Assembly

This section provides an overview of Free Standing iDimension Flex assembly procedure.

The Free Standing iDimension Flex Frame can be assembled in one of two ways.

3.1 Introduction

3.1.1 Upright Pivoting Assembly Steps

The upright pivoting assembly process assembles the sides of the frame at ground level. The sides are held upright while the short bars are inserted into the T-mount connectors. To assemble the free standing frame with the upright pivoting method, follow the steps below:

1. First Assembly Steps - Section 3.2 on page 13
2. Upright Pivoting Frame Assembly - Section 3.3 on page 15
3. Align Sensor Shrouds - Section 3.5 on page 20
4. Mount J-box - Section 3.6 on page 20

3.1.2 Forklift Assist Assembly Steps

The forklift assist assembly process assembles the top of the frame at ground level. The top is then lifted with a forklift and the legs are inserted into the frame. To assemble the free standing frame with forklift assist follow the steps below:

1. First Assembly Steps - Section 3.2 on page 13
2. Forklift Assist Assembly - Section 3.4 on page 18
3. Align Sensor Shrouds - Section 3.5 on page 20
4. Mount J-box - Section 3.6 on page 20

3.1.3 Parts

The parts in Section 3.0 correspond to the numbers in Figure 3-1 and Table 2-1 on page 9.

A diagram shows the parts inventory for the Free Standing Frame Assembly.

3.1.4 Roll-in T-nut

Roll-in T-nuts are inserted into the channel of the 80/20 bar to bolt accessories to the bar.

1. Insert the T-nut into 80/20 channel at an angle.
2. Rotate nut into the 80/20 channel.
3. Seat T-nut into channel.
4. Fasten bolt into T-nut to secure accessory to the bar.

A diagram illustrates the insertion and fastening of roll-in T-bolts.

3.2 First Assembly Steps

Perform first assembly steps for all methods of assembly.

3.2.1 Floor Mount Assembly

Attach one of the four floor mounts to one of the four, longer 80/20 bars.

1. Slide the end of a long 80/20 bar (Pt.1) into the floor mount (Pt.5).
2. Tighten the bolts (Pt.13 and Pt.12) in the floor mount.
3. Perform procedure for all four floor mounts.

A diagram shows the floor mount installation.

3.2.2 Mount Sensor Shrouds

Attach one of the four sensor shrouds (Pt.8) to one of the four vertical 80/20 bars (Pt.1).

1. Insert roll-in t-nuts (Pt.3) into the 80/20 channels as in Section 3.1.4 on page 13.
2. Loosely attach the shroud (Pt.8) to the 80/20 bar with the bolts (Pt.3) and roll-in t-nuts (Pt.2).
3. Slide the shroud to the center of the bar.
4. Perform procedure for four sensor shrouds.

A diagram illustrates sensor shroud installation.

3.2.3 T-Mount Bars

Attach two T-mount connectors and two three-way connectors to two of the short, red 80/20 bars.

1. Slide two T-mounts (Pt.11) onto a short, red 80/20 bar (Pt.2).
2. Center the T-mounts on the bar 11 inches apart from t-extension to t-extension.
3. Tighten bolts to secure position.
4. Slide the 3-way connector (Pt.10) onto the ends of the 80/20 bars.
5. Perform procedure for two short bars.

A diagram shows the T-mount bar installation.

3.3 Upright Pivoting Frame Assembly

To assemble the free standing frame by the upright pivoting method, follow all steps in Section 3.2 on page 13 then follow the procedures below.

3.3.1 Assemble T-Mount Side Frames

Attach two long bars (Pt.1) to each of the two three-way connectors on the short 80/20 bars assembled in Section 3.2.3 on page 14.

1. Lay T-mount bar down so that T-mounts face upward.
2. Lay long bars (Pt.1) down.
3. Attach one long bar to each three-way connector (Pt.10) as in Figure 3-6.
4. NOTE: Position sensor shrouds to face the same direction as the elbow of the three-way connector.
5. Tighten bolts to secure position.
6. Perform procedure for both assembled T-mount bars.

A diagram shows the T-Mount Side Frame Installation.

3.3.2 Assemble Horizontal Connecting Bars

1. Carefully stand up the side frames that were assembled in Section 3.3.1 on page 15.
2. WARNING: Lift each u-frame with 2-3 people. If u-frames are unstable once upright, use a person at each vertical bar to support the u-frames during assembly. Use PPE such as hard hats to avoid injury during assembly.
3. Space u-frames apart by approximately the length of the short 80/20 bar (Pt.2) apart.
4. Position two ladders next to the u-frames.
5. Fully insert short bar 2c into three-way connector 10a.
6. Securely bolt short bar 2c into three-way connector 10a.
7. Insert the second side of short bar 2c about 1.5 in into three-way connector 10c.
8. Screw bottom bolt into three way connector 10c so that the short bar is secured in place, but has limited ability to pivot the joint slightly wider than 90 degrees.
9. Fully insert short bars 2d, 2e and 2f into T-mount 11a, T-mount 11b and three-way connector 10b.
10. Tighten bolts on T-mount 11a, T-mount 11b and three-way connector 10b onto short bars 2d, 2e and 2f.
11. Align and insert short bars 2d, 2e and 2f into T-mount 11c, T-mount 11d and three-way connector 10d.
12. Loosen the bolt that connects three-way connector 10c to short bar 2c. (Bolt was inserted in Step 7 on page 16)
13. Seat all of the short bars fully into the connectors using a rubber mallet.
14. Tighten all bolts.

Diagrams illustrate the set-up of side frames and the installation of short bars.

3.4 Forklift Assist Assembly

To assemble the Free Standing iDimension Flex with a forklift assist, follow Section 3.2 on page 13 before the procedures in this section.

3.4.1 Assemble Top

Attach short 80/20 bars to T-mount bars assembled in Section 3.2.3 on page 14.

1. Space T-mount bars 2a and 2b approximately the length of the short 80/20 bar apart.
2. Insert short bars 2c, 2d, 2e and 2f into connectors on side 2a as in Figure 3-11.
3. Tighten bolts on all connectors.
4. Insert short bars 2c, 2d, 2e and 2f into connectors on side 2b as in Figure 3-11.
5. Tighten bolts on all connectors.

A diagram shows the Frame Top Installation.

3.4.2 Lift Top of Frame

1. Stand frame legs adjacent to the assembled top of frame.
2. Center tines of a forklift under the top of frame and secure frame to tines.
3. CAUTION: Frame must be secured to forklift tines to prevent frame from falling.
4. Lift the top of frame with the forklift tines until the 3-way connectors are slightly below the height of the legs.
5. Tilt long 80/20 bar (Pt.1) up and slide under the 3-way connectors.
6. NOTE: Position frame legs so sensor shrouds face the center of the assembly. Forklift angle may need to be adjusted to insert bars into 3-way connectors.
7. Lower top of frame to fully seat the connectors onto the legs.
8. NOTE: Ensure that the legs are seated fully into the 3 way connectors using a rubber mallet.
9. Tighten all bolts.

Diagrams illustrate setting legs next to the top of the frame and lifting the top of the frame and aligning legs.

3.5 Align Sensor Shrouds

1. Slide sensor shrouds to top of vertical 80/20 bar.
2. Tighten t-bolts to secure sensor shrouds.
3. Repeat the previous steps for each sensor.

A diagram shows the Remote IFM Sensor Assembly Attachment.

3.6 Mount J-box

Attach the J-Box to the top of the enclosure.

1. Attach the top of the j-box (Pt.6) to top of 80/20 bars 2d and 2e with the four bolts (Pt.4) and four roll-in t-nuts (Pt.3).
2. Attach bottom of the j-box (Pt.14) to bottom of 80/20 bars 2d and 2e with four bolts (Pt.4) and four roll-in t-nuts (Pt.3).

Diagrams show J-Box Installation.

4.0 Suspended Flex Assembly

This section provides an overview of Suspended Flex assembly procedure.

NOTE: Mount Suspended Flex assembly to an 80/20 mounting frame or a cable suspended mounting frame. See iDimension 80/20 Mounting Frame Installation Addendum (PN 221406) or iDimension Cable Mounting Frame Installation Addendum (PN 221407) for mounting frame installation instructions.

1. Extend the sensor array mount arms into 90 degree angles.
2. NOTE: Position steel tongue at the end of each arm to face counter clockwise.

Diagrams show Sensor Array Assembly Attachment and Sensor Array Mount Arm Orientation.

1. Secure the inner ring of bolts into the sensor array mount arms and sensor array hub top and bottom plates.
2. Align j-box with the holes of the outer ring of the steel plate.
3. Secure outer ring of bolts through the j-box, the steel plates and the sensor array arms.
4. Lift the sensor array mount assembly to the mounting frame.
5. Secure the sensor array mount assembly to the mounting frame.

5.0 Accessories and Wiring

5.1 Sensors

Sensor assembly and installation into the sensor shield is similar on both the Free Standing and Suspended Flex assemblies.

Follow the steps below to assemble the sensors:

1. Secure the sensor mounting bracket to the sensor by following the remote IFM sensor instructions provided with the unit.
2. Place the two halves of the rod mount into the rod mount bracket.
3. Slide rod into the rod mount.
4. Tighten bolt to secure rod.
5. Secure rod of the remote IFM sensor assembly to shield mount through the slotted hole on the shield mount.
6. NOTE: Orient the sensor downwards with the power connector pointing towards the sensor shield.
7. Connect the power and ethernet cables to each sensor.
8. Connect remote IFM sensor ethernet cables (green) to the j-box ethernet ports (Figure 5-4 on page 26).
9. Strip back 3/8 in of wire insulation at the j-box end of the IMF sensor power cables.
10. Wire the remote IFM sensor power cables to the j-box terminal block (Figure 5-4 on page 26).
11. Repeat for each sensor.

A diagram shows the Remote IFM Sensor Assembly and Remote IFM Sensor Wiring.

5.2 J-Box

The j-box is similar on both the free standing and Suspended flex assemblies.

Follow the steps below to access and wire the j-box:

1. Remove the three small screws on the exterior of the j-box.
2. Remove steel cover.
3. Wire j-box according to Figure 5-4 on page 26.
4. Replace steel cover.
5. Replace the three small screws to secure cover of the j-box.

A diagram shows the J-Box Cover Assembly.

A wiring diagram for the J-Box is provided.

5.3 Kiosk

5.3.1 Kiosk Wiring

1. Run ethernet and power cables from the j-box to the kiosk.
2. IMPORTANT: Ensure that all cables are secured to stationary objects between j-box and kiosk so that they do not pose as a catching or tripping hazard.
3. NOTE: If installing kiosk onto optional kiosk stand, run cables through the hole in the kiosk and stand. Do not install kiosk icotek block. See Section 5.3.2 on page 29 for installation onto optional kiosk stand.
4. Remove the entire icotek® cable gland block.
5. Feed all ethernet and power cables through cable gland grommets.
6. NOTE: Punch a hole into each required cable grommet to allow wiring to be fed through the block.
7. Reinstall icotek cable gland block.
8. IMPORTANT: When reinstalling the icotek cable gland block, leave the cable gland block slightly loose to allow for cable slack to prevent potential cable damage.

A diagram shows the Kiosk Assembly.

5.3.2 Optional Kiosk Stand

1. Align bottom of kiosk to openings in top of kiosk stand.
2. Bolt Kiosk to top of stand.
3. Run all wires through the icotek cable gland at the base of the stand and into the bottom of the kiosk as in Section 5.3 on page 27.

Diagrams illustrate the Optional Kiosk Stand assembly and cable routing.

5.3.3 Optional Kiosk Mount

1. Position the first U-bolt on the pillar.
2. Place the U-bolt threads through the top mount plate holes.
3. Bolt the mounting plate in place.
4. CAUTION: Torque each bolt to 25 ft-lb to prevent injury and damage from falling kiosk.
5. Repeat Step 1 through Step 3 with the second U-bolt through the bottom mount plate holes.
6. NOTE: If adding the optional kiosk shelf (PN 212260), mount it between the kiosk and the mounting plate (see Figure 5-9).

Table 5-1. Optional Kiosk Mount Part Kit (PN 220137)

5.4 IP Camera (PN 200168)

1. Install the IP camera to a sensor array mount assembly arm or freestanding frame. Use hardware provided in the Optional IP Camera Kit.
2. NOTE: It is recommended to install the IP camera at the center of the sensor array mount assembly arm. Do not install near any remote IFM sensor to avoid causing interference.
3. Wire the IP camera through the sensor array mount assembly arm

A diagram shows the Optional IP Camera.