Manuals+

Rice Lake iDimension® Flex Pallet Dimensioning System

Assembly Manual

Introduction

This manual provides an overview of the assembly instructions for the iDimension Flex series. It includes assembly instructions for both the floor-mounted independent iDimension Flex system and the suspended iDimension Flex system.

When connecting this device to a third-party program, consult the software manufacturer's documentation for installation and configuration information.

1.1 Supplementary Manuals

iDimension QubeVu Administrator Guide: The iDimension QubeVu® Administrator Guide (Ref. No. 221652) provides an overview for configuring the QubeVu Manager software.

iDimension Ceiling Mount Installation Appendices: The suspended Flex dimensioning system must be mounted on an iDimension mounting frame. The mounting frame uses an 80/20 beam system or a suspended cable system. Consult one of the following appendices for more information on the installation of the corresponding iDimension Flex mounting system:

1.2 Safety

Safety Definitions:

General Safety

Do not operate or work with this equipment unless you have read this manual and understood all instructions. Failure to follow instructions or heed warnings can result in injury or death. For additional manual copies, contact a Rice Lake Weighing Systems distributor.

WARNING: Failure to follow the guidelines below can result in serious injury or death.

Electric Shock Hazard! Ensure the device is disconnected from the power supply before opening the enclosure. Do not remove or obscure the high-voltage label (Part No. 16861). There are no user-serviceable parts. Refer servicing to qualified service personnel. The unit has no power switch. To completely disconnect power to the unit, unplug the power supply from the AC outlet. For plug-connected equipment, the outlet-circuit shall be installed near the equipment and be easily accessible. When power cycling, use the inline power cord into an outlet. Always disconnect the unit from the mains before performing any work on it. Do not allow minors (children) or unqualified persons to use this unit. Do not insert fingers into slots or where they can become pinched. Do not use this product if any of its components are cracked. Do not alter or modify the unit in any way. 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 5-40 °C (41-104 °F). Do not 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 cables or plugs, or loose power outlets. Mount the system on a flat surface. Follow OSHA standards for equipment installation and use.

1.3 Dimensions

1.3.1 Independent Flex Dimensions

The overall dimensions of the four-sensor floor-mounted assembly and the two-sensor floor-mounted assembly are similar.

Diagram Description: A top-down view of the independent iDimension Flex system showing dimensions. The system has four corner posts with dimensions indicated. For example, one side shows 2.66 m (104.88 in) MAX, and another shows 2.16 m (85.09 in). A side view shows a height of 3.69 m (145.38 in) MAX and a width of 2.36 m (93 in).

1.3.2 Suspended Flex System Dimensions

Diagram Description: A top-down view of the suspended iDimension Flex system. It shows a central hub with four arms extending outwards at 90-degree intervals. Each arm has a length of 2.24 m (88.12 in).

2.0 Spare Parts

This section provides an overview of the spare parts for the iDimension Series Flex.

2.1 Independent Flex

Immediately after unpacking the independent iDimension Flex system, visually inspect the contents to ensure all components are included and undamaged. If any part is damaged during shipping, notify Rice Lake Weighing Systems and the carrier immediately. The independent iDimension Flex system is packaged with the following parts:

Diagram Description: An illustration showing the components of the independent iDimension Flex system. Various parts are numbered and correspond to a parts list. Key components include aluminum extrusions, T-nuts, bolts, sensor corner brackets, junction boxes, and remote sensor kits.

Table 2-1. List of iDimension Flex Independent System Parts

Item No. Ref. Description Qty.
1 219534 Extruded aluminum, red slotted aluminum 2 x 2, 2020 series 80/20, 145 in LG 4
2 214421 Extruded aluminum, red slotted aluminum 2 x 2, 2020 series 80/20, 93 in LG 6
3 202320 T-nut, rolled, 1/4 - 20 NC x 1/2 fully threaded hex head, A307 Grade 2 clear zinc plated steel bolt 24
4 14955 Cap screw, 1/4 - 20 NC x 1/2 fully threaded hex head, A zinc plated steel 24
5 215639 Floor mount for 80/20 tube T-slot weld nuts 3/8 - 16, MS 4
6 202141 Junction box, iDim PWD/Flex Mounted on top of sensor assembly, switch, POE, and terminals. 1
7 200164 Remote sensor kit, 4 iDim remote sensors and mounting accessories, installed firmware (Table 2-3 on page 11) 1
8 214415 Sensor corner bracket and shield mount, black, MS 4
9 200168 iDim Flex camera kit option including camera, wiring, and hardware 1
10 215636 80/20 corner weld nut with 3/8 - 16 weld nuts, MS 4
11 215635 80/20 T-weld nut, 3/8 - 16 weld nuts, MS 4
12 132684 Zinc plated steel nut 3/8 - 16 NC, Grade 5 48
13 170550 Bolt, HEX 3/8 - 16NC x 1 Zinc plated steel Grade 5 48
14 220076 Bottom plate, Flex junction box, 5th sensor bracket 1
15 186371 Mounting rod, iDim400 Plus 4

2.2 Suspended iDimension Flex Assembly

Immediately after unpacking the suspended iDimension Flex system, visually inspect the contents to ensure all components are included and undamaged. If any part is damaged during shipping, notify Rice Lake Weighing Systems and the carrier immediately. The suspended iDimension Flex system is packaged with the following parts:

Diagram Description: An illustration showing the components of the suspended iDimension Flex system. Parts are numbered and correspond to a parts list. Key components include sensor assemblies, a cube bottom plate, a cube top plate, washers, bolts, nuts, junction boxes, and sensor cover brackets.

Table 2-2. List of Suspended iDimension Flex System Mounting Parts

Item No. Ref. Description Qty.
1 199615 PWD/Flex sensor assembly, sensor arms 4
2 199614 PWD/Flex sensor assembly, cube bottom plate 1
3 199613 PWD/Flex sensor assembly, cube top plate 1
4 15145 Flat washer 1/4 Type A, N series zinc plated steel 16
5 199629 Cap screw, 1/4-20 X 3 Hex head partially threaded Grade 5 zinc plated finish 8
6 14635 Lock nut, 1/4-20NC HEX, nylon insert zinc plated steel 8
7 202141 Junction box, iDim PWD/Flex Mounted on top of sensor assembly, switch, POE, and terminals 1
8 199619 PWD sensor cover bracket 4
9 200168 iDim Flex camera kit option including camera, wiring, and hardware 1
10 186371 Mounting rod, iDim400 Plus 4
11 200164 Remote sensor kit, iDimPWD, 4 remote sensors and mounting accessories, installed firmware 1
12 219193 Kiosk, iDim Flex, assembled cabinet with QubeVu PC and HMI panel 1

2.3 Common Parts

Remote Sensor Kits

Refer to Figure 5.1 on page 23 for installation instructions.

Table 2-3. List of Parts for the Four-Remote Sensor Kit (Ref. No. 200164)

Ref. Description Qty.
186370 Heat sink, iDim LTL/PWD sensor IFM 1
187199 Mounting bracket, iDim sensor 400 Plus 4
194731 Cylindrical head screw M5-0.8x80 18-8 SST 2
195405 Remote sensor, iDimLTL L1, labeled 1 1
195406 Remote sensor, iDimLTL L2, labeled 2 1
195407 Remote sensor, iDimLTL L3, labeled 3 1
195408 Remote sensor, iDimLTL L4, labeled 4 1

Calibration Kit

Refer to the QubeVu User Guide (Ref. No. 198680) for calibration instructions.

Table 2-4. List of Parts for the Calibration Kit (Ref. No. 167963)

Ref. Description Qty.
167940 Calibration object, iDimension, 6 x 7 board with 140 mm squares 1

3.0 Independent Frame Assembly

This section provides an overview of the assembly procedure for the independent iDimension Flex system.

3.1 Introduction

The independent iDimension frame can be mounted in two ways.

3.1.1 Vertical Pivot Mount Steps

The vertical pivot mount process assembles the frame sides at floor level. The sides are held in a vertical position while short bars are inserted into the T-mount connectors. To mount the independent frame using the vertical pivot method, follow the steps below:

  1. First steps of assembly - Section 3.2 on page 13
  2. Vertical pivot frame assembly - Section 3.3 on page 15
  3. Align sensor covers - Section 3.5 on page 20
  4. Junction box assembly - Section 3.6 on page 20

3.1.2 Forklift-Assisted Mount Steps

The forklift-assisted mount process assembles the top of the frame at floor level. The top is then lifted with a forklift, and the legs are inserted into the frame. To mount the independent frame using a forklift, follow the steps below:

  1. First steps of assembly - Section 3.2 on page 13
  2. Forklift-assisted assembly - Section 3.4 on page 18
  3. Align sensor covers - Section 3.5 on page 20
  4. Junction box assembly - Section 3.6 on page 20

3.1.3 Components

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

Diagram Description: An exploded view of the independent frame assembly components. Parts are numbered and include various aluminum extrusions, T-nuts, bolts, sensor covers, junction boxes, and mounting hardware.

3.1.4 Rolled T-Nut

Rolled T-nuts are inserted into the 80/20 beam channel to secure accessories to the beam.

  1. Insert the T-nut into the 80/20 channel at an angle.
  2. Turn the T-nut in the 80/20 channel.
  3. Place the T-nut in the channel.
  4. Secure the bolt into the T-nut to secure the accessory to the beam.

Diagram Description: Four steps illustrating the insertion and tightening of a rolled T-nut into an 80/20 extrusion.

3.2 First Steps of Assembly

Perform the first assembly steps for all mounting methods.

3.2.1 Floor Mount Assembly

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

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

Diagram Description: An illustration showing the installation of a floor mount. A floor mount bracket (5) is shown being attached to an 80/20 bar (1) using bolts (12 and 13).

3.2.2 Mount Sensor Covers

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

  1. Insert the rolled T-nuts (3) into the 80/20 channels, as shown in Section 3.1.4 on page 13.
  2. Loosely attach the cover (8) to the 80/20 bar with the bolts (3) and the rolled T-nuts (2).
  3. Slide the cover to the center of the bar.
  4. Repeat the procedure for the four sensor covers.

Diagram Description: An illustration showing the installation of a sensor cover. T-nuts are inserted into the extrusion, and the cover is attached with bolts.

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-mount brackets (11) onto a short red 80/20 bar (2).
  2. Center the T-mount brackets on the bar with a separation of 11 inches from one T-extension to the other T-extension.
  3. Tighten the bolts to secure the position.
  4. Slide the 3-way connector (10) onto the ends of the 80/20 bars.
  5. Repeat the procedure for two short bars.

Diagram Description: An illustration showing the installation of T-mount bars. T-mount brackets and three-way connectors are attached to short 80/20 bars.

3.3 Vertical Pivot Frame Assembly

To assemble the independent frame using the vertical pivot method, follow all steps in Section 3.2 on page 13 and then follow the procedures outlined below.

3.3.1 Install Vertical T-Mount Side Frames

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

  1. Position the T-mount bar so that the T-mounts face upward.
  2. Position the long bars (1) downward.
  3. Attach one long bar to each three-way connector (10) as shown in Figure 3-6.
  4. NOTE: Position the sensor covers in the same direction as the elbow of the three-way connector.
  5. Tighten the bolts to secure the position.
  6. Repeat the procedure for the two mounted T-mount bars.

Diagram Description: An illustration showing the installation of the vertical T-mount frame. Long bars are attached to three-way connectors on short bars.

3.3.2 Mount Horizontal Connection Bars

WARNING: Carefully lift each U-frame between 2-3 people. If the U-frames are unstable once in a vertical position, have one person in each vertical bar to hold the U-frames during assembly. Use personal protective equipment, such as helmets, to prevent injury during assembly.

  1. Carefully lift the side frames assembled in Section 3.3.1 on page 15.
  2. Separate the U-frames approximately the length of the short 80/20 bar (2).
  3. Place two ladders next to the U-frames.
  4. Diagram Description: An illustration showing the mounting of the side frames. U-frames are positioned apart, with ladders placed nearby.
  5. Fully insert the short bar 2c into the three-way connector 10a.
  6. Secure the short bar 2c to the three-way connector 10a with bolts.
  7. Insert the second side of the short bar 2c approximately 1.5 in. into the three-way connector 10c.
  8. Screw the bottom bolt into the three-way connector 10c so that the bar is secured in place, but with limited ability to pivot the joint slightly beyond 90 degrees.

Diagram Description: An illustration showing the installation of the first short bar. Details of a three-way connector and the attachment of a short bar are shown.

Diagram Description: An illustration showing the installation of the first short bar. Details of three-way connectors and short bars are shown, indicating the insertion and securing of bars.

3.4 Forklift-Assisted Mount

To mount the independent iDimension Flex system with the help of a forklift, follow the instructions in Section 3.2 on page 13 before the procedures in this section.

3.4.1 Mount the Top Section

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

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

Diagram Description: An illustration showing the installation of the frame's top section. Short bars are inserted into T-mount bars on both sides.

3.4.2 Lift the Top Section of the Frame

  1. Place the frame legs next to the assembled top section of the frame.
  2. Center the forklift forks under the top section of the frame and secure the frame to the forks.
  3. CAUTION: Secure the frame to the forklift forks to prevent it from falling.
  4. Lift the top section of the frame with the forklift forks until the 3-way connectors are slightly below the height of the legs.
  5. Tilt the long 80/20 bar (1) upward and slide it under the 3-way connectors.
  6. NOTE: Position the frame legs so that the sensor covers face the center of the assembly. The forklift angle may need to be adjusted to insert the bars into the 3-way connectors.
  7. Diagram Description: An illustration showing the placement of the frame legs next to the top section of the frame, with forklift forks positioned underneath.
  8. Lower the top section of the frame to fully seat the connectors in the legs.
  9. NOTE: Ensure the legs are fully seated in the 3-way connectors using a rubber mallet.
  10. Tighten all bolts.
  11. Diagram Description: An illustration showing the lifting of the frame's top section and aligning the legs. The top section is being lowered to seat the connectors in the legs.

3.5 Align Sensor Covers

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

Diagram Description: An illustration showing the attachment of the remote IFM sensor assembly. Sensor covers are slid onto the vertical bar and secured.

3.6 Junction Box Assembly

Attach the junction box to the top of the enclosure.

  1. Attach the top part of the junction box (6) to the top of the 80/20 bars 2d and 2e using the four bolts (4) and the four rolled T-nuts (3).
  2. Attach the bottom part of the junction box (14) to the bottom of the 80/20 bars 2d and 2e using the four bolts (4) and the four rolled T-nuts (3).

Diagram Description: An illustration showing the installation of the junction box. The junction box is attached to the 80/20 bars using bolts and T-nuts.

4.0 Suspended Flex System Assembly

This section provides an overview of the assembly procedure for the suspended Flex system.

NOTE: Mount the suspended Flex assembly on an 80/20 mounting frame or a cable-suspended mounting frame. Consult the 80/20 iDimension Mounting Frame Installation Appendix (Ref. No. 223824) or the iDimension Cable Mounting Frame Installation Appendix (Ref. No. 233909) for mounting frame installation instructions.

  1. Extend the sensor assembly mounting arms to 90-degree angles.
  2. NOTE: Position the steel tab on the end of each arm counterclockwise.
  3. Diagram Description: A diagram showing the sensor assembly attachment. Sensor arms are extended at 90-degree angles, with labels for outer ring bolts, inner ring bolts, junction box, sensor assembly plate, and sensor assembly arms.
  4. Diagram Description: A diagram showing the orientation of the sensor assembly mounting arm. It indicates the 90-degree typical angle.
  5. Secure the inner ring of the bolts to the sensor assembly mounting arms and to the top and bottom plates of the sensor assembly cube.
  6. Align the junction box with the holes in the outer ring of the steel plate.
  7. Secure the outer ring of the bolts through the junction box, steel plates, and sensor assembly arms.
  8. Diagram Description: A diagram showing the attachment of the sensor assembly. Inner ring bolts are secured to the sensor arms and cube plates.
  9. Diagram Description: A diagram showing the attachment of the junction box. The junction box is aligned with the outer ring holes and secured with bolts.
  10. Lift the sensor assembly mounting assembly to the mounting frame.
  11. Secure the sensor assembly mounting assembly to the mounting frame.

5.0 Accessories and Wiring

5.1 Sensors

The sensor assembly and its installation in the sensor shield is similar for both the independent Flex system mount and the suspended Flex mount. Follow the steps below to mount the sensors:

  1. Attach the sensor mounting bracket to the sensor following the IFM remote sensor instructions supplied with the unit.
  2. Place the two halves of the bar bracket into the bar support clamp.
  3. Slide the bar into the bar support.
  4. Tighten the bolt to secure the bar.

Diagram Description: An illustration showing the assembly of the IFM remote sensor. It includes a mounting bracket, sensor, bar, bar support clamp, and bolts.

Diagram Description: An illustration showing the wiring of the IFM remote sensor. It indicates power and Ethernet connections.

  1. Attach the IFM remote sensor bar to the shield bracket through the slotted hole of the shield bracket.
  2. NOTE: Orient the sensor downward with the power connector pointing toward the sensor shield.
  3. Connect the power and Ethernet cables to each sensor.
  4. Connect the IFM remote sensor Ethernet cables (green) to the junction box Ethernet ports (Figure 5-4 on page 26).
  5. Strip 3/8 in. of insulation from the cable at the junction box end of the FMI sensor power cables.
  6. Connect the IFM remote sensor power cables to the junction box terminal block (Figure 5-4 on page 26).
  7. Repeat the operation for each sensor.

5.2 Junction Box

The junction box is similar in both the independent Flex system and the suspended Flex system mounts. Follow the steps below to access the junction box and connect the cables:

  1. Remove the three small screws from the outside of the junction box.
  2. Remove the steel cover.
  3. Connect the junction box cables as shown in Figure 5-4 on page 26.
  4. Replace the steel cover.
  5. Replace the three small screws to secure the junction box cover.

Diagram Description: An illustration showing the assembly of the junction box cover. Screws are removed to access the inside of the box.

5.3 Kiosk

5.3.1 Kiosk Wiring

Route the power and Ethernet cables from the junction box to the kiosk.

IMPORTANT: Ensure all cables are secured to fixed objects between the junction box and the kiosk so they do not pose a tripping or entanglement hazard.

NOTE: If installing the kiosk on the optional stand, route the cables through the kiosk and stand opening. Do not install the kiosk icotek block. Refer to Section 5.3.2 on page 29 for installation on the optional kiosk stand.

  1. Remove the entire icotek cable gland block.
  2. Route all power and Ethernet cables through the cable glands.
  3. NOTE: Drill a hole in each cable gland as necessary to pass the wiring through the block.
  4. Diagram Description: An illustration showing the kiosk assembly. Components include a touchscreen, switch, computer, Ethernet ports, cable glands, and an icotek cable gland block.
  5. Reinstall the icotek cable gland block.
  6. IMPORTANT: When reinstalling the icotek cable gland block, leave the cable gland block slightly loose to allow for cable slack and prevent damage to the cables.

5.3.2 Kiosk Stand Installation

  1. Align the bottom of the kiosk with the openings in the top of the kiosk stand.
  2. Bolt the kiosk to the top of the stand.
  3. Route all cables through the icotek cable gland at the base of the stand and through the bottom of the kiosk, as in Section 5.3 on page 27.

Diagram Description: An illustration showing the optional kiosk stand. It depicts the kiosk being bolted to the stand and cables being routed through cable glands.

5.3.3 Optional Kiosk Mount

  1. Place the first U-bolt into the pillar.
  2. Thread the U-bolt's threads through the holes of the upper mounting plate.
  3. Screw the mounting plate into place.
  4. CAUTION: Tighten each bolt to 25 ft-lb to prevent injury and damage from the kiosk falling.
  5. Repeat Steps 1 through 3 with the second U-bolt through the holes of the lower mounting plate.
  6. NOTE: If adding the optional kiosk shelf (Ref. No. 212260), it must be mounted between the kiosk and the mounting plate (refer to Figure 5-9).

Diagram Description: An illustration of the optional kiosk mount. It shows U-bolts, mounting plates, and hardware for attaching the kiosk.

Table 5-1. Optional Kiosk Mount Parts Kit (Ref. No. 220137)

Item No. Ref. No. Description Qty.
1 132684 Nut, 3/8-16NC HEX zinc plated steel 4
2 170550 Bolt, 3/8-16NC HEX zinc plated steel 4
3 214413 U-bolt, square 2
4 220135 Kiosk mounting plate iDim 80/20 1

5.4 IP Camera (Ref. No. 200168)

  1. Install the IP camera on a sensor assembly mounting arm or on an independent frame. Use the hardware supplied in the optional IP camera kit.
  2. NOTE: It is recommended to install the IP camera in the center of the sensor assembly mounting arm. Do not install it near any IFM remote sensor to avoid interference.
  3. Cable the IP camera through the sensor assembly mounting arm.

Diagram Description: An illustration of an optional IP camera. It shows the camera mounted on an arm.

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