RoughDeck® BDP Floor Scale Installation Manual

2.3.1 Installing and Adjusting Feet

For load cell protection during shipping, the scale feet are not installed in the floor scale.

Screw one foot into each load cell and turn all the way in until the top of the foot touches the load cell or the foot stem touches the underside of the deck. Then unscrew each foot six complete turns.

Place a spirit level on the deck. Adjust any “high” corners not in contact with the floor by further unscrewing the feet on those corners until they just contact the floor surface. When all feet are in contact with the floor, check the deck with the spirit level to be sure the scale is within 1/4 inch of level or use the bubble level located in the center of the deck.

2.3.2 Junction Box Wiring

Ten feet of 6-wire cable to connect the scale to the weight indicator is supplied with each scale. The junction box is easily accessible through a top access plate located on the top of the RoughDeck BDP. Use the following steps to wire up the junction box:

1. Remove the two screws using an 1/8 inch allen wrench to remove the scale junction box cover plate.
2. Slide the junction box assembly out of the deck.
3. Open and remove the top of junction box.
4. Push the cable end into the junction box through a cord grip.
5. Connect the wires to the indicator terminal (see Figure 2-2) as shown in Table 2-1.
6. Pull out excess cable and tighten the cord grip to hold the cable snugly.

Table 2-1. Junction Box Connections

A schematic shows the internal wiring of the junction box, including terminals for +Excitation, -Excitation, +Signal, -Signal, and Shield, with connections to potentiometers and indicator terminals.

For permanent installations it's desirable to have the cable routed to the indicator in a manner that will protect the cable from damage. This method of cable protection in non-washdown applications is shown in Figure 2-3.

A cross-section diagram shows a load cell cable running along the floor, protected by a steel cover.

7. When the interface cable is protected and in its final position, complete connections to the indicator. See the indicator installation manual for wiring information.
8. If necessary, trim corners as described in Section 3.2 on page 12.
9. Check all strain relief fittings for tightness.
10. Put the cover back onto the junction box assembly and place the junction box back in the scale.
11. Secure the scale junction box cover plate.

2.4.1 Anchor Plate

For permanent applications with no access ramps the scale should be secured to the floor to prevent sideways movement. Two mild steel, floor anchor plates with holes that slightly exceed the foot diameter are available as an option for that purpose. Use the following steps to install floor anchor plates:

1. Lift the scale so that the feet are approximately one inch off the floor.
2. Slide mounting plates under two diagonally opposed feet.
3. Lower the scale back to the floor, and position the plates as shown in Figure 2-4 so that the boltdown holes are accessible from above.
4. Using the mounting plates as templates, drill pilot holes into the floor for suitable anchor bolts. Bolt the plates to the floor using 1/2 inch anchor bolts.
5. Recheck foot adjustment and deck level after this operation.

NOTE: For installations using access ramps, mounting plates are not necessary as the ramps have built-in mounting plates to secure the scale feet.

A diagram shows the underside of a scale foot and an anchor plate positioned beneath it, with dimensions indicating placement.

2.4.2 Access Ramps

Optional access ramps for the RoughDeck BDP barrel scale come in both mild steel and stainless steel versions and have a standard treaded plate. They are designed to bolt to the floor, with built-in mounting plates that surround the scale feet. When used with anchored access ramps, side movement of the scale is automatically eliminated, and no other mounting plates are necessary.

Access ramps can only be installed to the scale on one of the two scale sides that are opposite the side rails (see Figure 2-5).

A diagram shows the side of the scale platform with side rails and an optional access ramp designed to bolt to the floor.

2.4.3 Backstop

The optional backstop may be attached with the screws from the hardware kit to block weight from falling off one side of the RoughDeck BDP (see Figure 2-6).

A diagram illustrates the attachment of an optional backstop to the edge of the scale platform.

2.4.4 Portability Frame

The RoughDeck BDP has a portability frame option, which makes the RoughDeck BDP easy to move from place to place. The portability frame is compact and sits below the live side rails so it will not interfere with weighing pallets or larger items. The frame contains casters, indicator stand, and mounting hardware. Due to the wheel lever design, the wheels will not interfere with larger items.

WARNING: Do not use casters to transport a load. When lifting or lowering the casters, assist by lifting the end of the scale with one hand while operating the toggle with the other.

A diagram shows the portability frame assembly, including levers for raising/lowering, casters, and attachment points for ramps.

The RoughDeck BDP scale fits inside of the portability frame. Refer to Figure 2-1 on page 7 for the proper lifting technique when setting the scale into the portability frame or removing it out of the frame. Four levers located on the sides of the portability frame are used for raising or lowering the portability frame for movement.

To lower the frame into a stationary position, engage the levers on the sides of the portability frame and lower them down. This lever action will drop the entire frame down onto the floor making the frame and scale stationary.

To raise the scale so that it can be moved, engage the levers on the sides of the portability frame and raise them up. This will raise the entire frame and then the scale can be easily moved from one location to the next.

3.1 Mechanical Adjustments

To accommodate minor floor unevenness, the scale feet can be used to adjust scale height up or down a fraction of an inch. Adjust the feet by hand or with a screw driver until all feet are contacting the floor equally. No jam nuts are supplied for locking the feet, as there is a slight decrease in accuracy when jam nuts are tightened. However, if you feel that your application requires you to secure the feet, we suggest using Teflon® tape or Loctite®.

When adjusting scale feet, use care to prevent the scale foot from bottoming out against the underside of the load cell. Also, the foot stem can be damaged by bending or stripping threads if extended beyond the maximum height adjustment.

When height adjustments are complete, recheck the bubble level located in the center of the deck. The scale deck must be level within 1/4 inch.

3.2 Corner Correction

Corner trimming is necessary after replacing a load cell. To calibrate the scale, the output from each load cell must be matched by adjusting the signals with potentiometers in the junction box—a process known as trimming.

Remove the junction box cover and identify the correct load cell terminal corresponding to each corner (labeled CELL 1, CELL 2, and so on). See Figure 4.2 on page 14 for scale deck corner numbering.

The indicator must be connected and calibrated approximately, but it need not indicate the exact weight value. A test weight is required. The recommended test weight for all RoughDeck BDP models is 25% of scale capacity; for example, 250 lbs for 1K-lb models, 650 lbs for 2.5K-Lb models.

With no weight on the scale, zero the indicator. Then turn all four potentiometers (see Figure 3-1) clockwise to increase the reading until a clicking sound is heard from each potentiometer. This ensures the maximum signal from each load cell.

A schematic of the summing board within the junction box shows potentiometers and terminal connections.

With all potentiometers at full signal, place the test weight over one corner and record the indicated weight. Repeat the process for each of the other three corners. The load cell with the lowest corner reading is used as a reference point and will not be trimmed.

Next, place the test weight over one of the other three corners and use that cell's potentiometer to adjust the cell output down to the reference cell output. Repeat this procedure with the other two high corners. Adjustments are somewhat interactive, and adjusting the three higher outputs may affect the reference cell output, especially in smaller scale decks. Rezero the indicator and repeat the test until all corners read within ±0.1% of the test weight used.

3.3 Calibration Procedure

Refer to the indicator manual to determine correct calibration procedures.

It is recommended that the scale be “exercised” before calibration to be certain that everything is seated. Use the following steps:

1. Load the scale to near capacity two or three times.
2. With no load on the scale, place the indicator in its calibration mode and perform a zero calibration.
3. Place test weights on the platform equal to 70% - 80% of the scale's capacity. If several weights are used, they should be evenly distributed around the platform. Perform a span calibration.
4. Remove the test weights and check the zero reading.
5. Repeat the calibration process if necessary.

4.1 Troubleshooting Guide

Table 4-1 lists some of the common problems and their suggested solutions.

Table 4-1. Troubleshooting Table

4.2 Periodic Maintenance

The space between the platform side, the portable deck assembly and the surface beneath the platform must be cleaned frequently to prevent debris build up. Do not attempt to use scales with load cells that are not hermetically-sealed in washdown applications. Water damage is a common cause of failure in non-hermetically-sealed load cells. Use care with high pressure steam washdowns for hermetically-sealed load cells. The steam may not damage the load cells, but the elevated temperatures may cause incorrect readings until the unit cools to room temperature.

4.3 Load Cell Replacement

Lift the scale with a chain and remove foot, then remove the defective load cell. Disconnect load cell cable from the junction box and cut cable ties. When the cable is freed, pull cable out of the scale frame channels.

A diagram shows a single load cell with its mounting hardware and cable.

Follow the steps below to install new load cells.

1. Lay out the four load cells near the corners where they are to be installed.
2. Thread the cable from each load cell in the frame and into the junction box according to the wiring diagram in Figure 4-2 on page 15.

NOTE: Both the scale and the junction box are viewed from the bottom. To verify correct load cell/junction box terminal matching, see the numbers on the terminals inside the junction box and the corner numbering diagram in Figure 4-4 on page 16.

A diagram shows the underside of the scale platform, indicating the locations of the four load cells (numbered 1-4) and the junction box.

3. Check that the threaded holes for the load cell screws are free of debris. Use compressed air to blow out holes if necessary.
4. Position load cells with alignment arrows pointed up toward the deck and loosely install the hex head cap screws provided, as shown in Figure 4-1 on page 15. If the base is used with an access ramp, position the load cell to maintain the dimension shown in Figure 4-3 on page 16. With the torque wrench, tighten all bolts to 75 ft-lbs.

A diagram shows a side view of a scale foot pad with a specific dimension (.765).

5. Route the load cell cables near each corner so that the cable is free from possible contact with each foot. Hold the cable in position with the supplied adhesive-backed cable ties.

NOTE: Do not cut load cell cables. Coil the extra cable and slide it into the scale between the top and bottom plates. A slot in the main channel is provided for this purpose.

6. After coiling excess cable, pass each individual end of load cell cable through its grommet in the junction box.

NOTE: Corner correction trimming and calibration is necessary after load cell replacement. Follow instructions in Section 3.0 on page 12.

5.1 RoughDeck BDP Scale

An exploded view diagram of the RoughDeck BDP scale, with numbered components corresponding to replacement parts.

Table 5-1. RoughDeck BDP Replacement Parts List

5.2 Portability Frame

An exploded view diagram of the portability frame, with numbered items corresponding to replacement parts.

Table 5-2. Portability Frame Replacement Parts List