Avery Weigh-Tronix RLP User manual

Installation and User’s Manual
RLP
Railweight Low-Profile
Track Scale

2RLP Railweight Low-Profile Track Scale Installation and User’s Manual
July 26, 2006 RAILWT_U.P65 PN 29801-0018B e1 Printed in USA

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RLP Railweight Low-Profile Track Scale Installation and User’s Manual
Table of Contents
Table of Contents............................................................................................... 3
Tools Required .................................................................................................. 5
Verification of the Foundation ............................................................................ 5
Installation of the Grout Plates ............................................................................ 5
Installation of the Base Plates ............................................................................ 7
Installation of Weighbridge(s) ............................................................................ 7
Installation of Load Cell Support Plate on Single Weighbridge ........................... 7
Installation of Load Cell Support Plate on Double Weighbridge .......................... 8
Alignment of Load Cells..................................................................................... 8
Inserting the Load Cell Anti-Rotation Pin ............................................................ 9
Installing Load Cells........................................................................................... 9
Grounding ....................................................................................................... 10
Installation of the Checking System .................................................................. 10
Installation of the rails....................................................................................... 11
Grouting .......................................................................................................... 12
Concrete Work ................................................................................................ 12
Connection of the Load Cells and Indicator ...................................................... 12
Installation of the Covers .................................................................................. 13
Testing ............................................................................................................ 13
Maintenance .................................................................................................... 13
Parts List ......................................................................................................... 14
Recommended Spare Parts List...................................................................... 14

4RLP Railweight Low-Profile Track Scale Installation and User’s Manual

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RLP Railweight Low-Profile Track Scale Installation and User’s Manual
1. Transit level
2. Spirit Level
3. 100 ft tape measure
4. Set of heavy duty ratchets/sockets
5. Hand tools for nuts and bolts up to 1 1/2" Dia.
6. Never-sieze grease
7. Shim material, 1/16" and 1/8" thick
8. Wooden blocks (to hold the bridges in place when installing a double
section)
9. 20-ton Jacks (Minimum 2)
10. Crane and necessary cables for lifting the scale weighbridge(s).
11. Certified Test-Weights and Certified Test Car(s) for the calibration and
verification of the scale (As per Local Weights & Measures)
Refer to the Foundation Drawing
Verify the distance between the approach (bottom or top of the rail) and the
top of the concrete where the grout plates will be installed.
Verify the distance from approach to approach and if the scale is installed in
a shallow pit, the length & width of the pit.
Verify the location of the anchor bolts.
Two types of grout plates are used in this scale. One type has provision to
connect the checking system and the other type does not. Refer to the
Foundation / General Arrangement Drawing for the selection and location of
these grout plates.
Tools Required
Verification of the Foundation
Pit Installations: Standard
drawings supplied are for
above ground installation of the
scale. If the scale is installed in
a pit, proper drainage must be
provided.
Proper clearance (24" recom-
mended) must be allowed
between the scale and the pit
wall on the length side. This
clearance is required for the
installation of load cells,
checking system, covers etc.
Installation of the Grout Plates

6RLP Railweight Low-Profile Track Scale Installation and User’s Manual
Install a jam nut and a plate washer on each of the grout plate anchor bolts.
Position the grout plate on the plate washers. Place a second plate washer, a
lock washer, and a hex nut on the top of the base plate.
Adjust the Grout Plates by positioning them per Load Cell centerlines. Level
the Grout Plates to within 1-degree using jam nuts. Use the jam nuts to
adjust the elevation of grout plates so as to maintain the distance between
the top-of-Grout Plates to top-of-Approach Rail Support as shown on the
drawing, by adjusting the jam nuts. Lock all the grout plates in place.
All threaded fasteners should
have a generous coating of
never-sieze grease.

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RLP Railweight Low-Profile Track Scale Installation and User’s Manual
Installation of the Base Plates
Place the base plate on the grout plate. Use supplied washer plates, lock
washers and bolts to hold the base plate in place, but do not tightem them
completely at this time. The base plate will be locked tightly only after the
final positioning and alignment of the load cells.
Check for proper orientation so that weighbridge(s) match the grout plates as
shown on the Foundation/General Arrangement drawing. Lower the
weighbridge(s) onto wooden blocks.
Attach load cell support plates to the weighbridge(s) using the supplied
hardware.
Installation of Weighbridge(s)
Installation of Load Cell Support Plate on Single Weighbridge
All wooden blocks must be of
uniform height.

8RLP Railweight Low-Profile Track Scale Installation and User’s Manual
Installation of Load Cell Support Plate on Double Weighbridge
In double weighbridge scenarios, attach the load cell support plates to the
weighbridges using the supplied hardware.
We suggest you use the load cell alignment tools to facilitate accurate
alignment of weighbridge(s) and load cell base plates before installing the
load cells. See illustration of the tool at left.
If alignment tools are not used, skip to the next section.
Using hydraulic jacks, raise the weighbridge(s) enough to remove the wooden
blocks. Insert the alignment tools on the base plates. Slowly lower the
weighbridge(s) while making adjustments to the base plates so the alignment
tools engage the load cell support plate while maintaining vertical alignment.
When the weighbridge(s) are resting on all the alignment tools, check for
proper clearances and vertical alignment of the alignment tools. Make any
necessary adjustments and tighten all base plate bolts.
Alignment of Load Cells
Alignment tool

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RLP Railweight Low-Profile Track Scale Installation and User’s Manual
Inserting the Load Cell Anti-Rotation Pin
Jack up the weighbridge(s) and remove the alignment tools. Insert the anti-
rotation pins into the lower bearings, and drive them all the way in, using a
hammer. Apply grease to the dowel pins and load cell rotation stops.
Installing Load Cells
Slide the O-rings onto the lower portion of the load cells.
Apply sufficient amount of grease to the top and bottom of the load cells to
protect them from wear, dirt, and corrosion.
Install the load cells in the lower bearings, insuring that the dowel pins are
engaged in the load cell rotation stops.
Install the load cell rubber boots.
If alignment tools are not used, position the lower bearings and load cells on
the base plate such that the load cells are vertically plumb. Slowly lower the
weighbridge(s) onto the load cells. Verify that all load cells are still vertically
plumb.

10 RLP Railweight Low-Profile Track Scale Installation and User’s Manual
The checking system consists of longitudinal and cross checking. One end of
the checking is bolted down to the grout plate and the other end to the
weighbridge.
First, attach the longitudinal checking plate and cross checking channels to
the grout plates, with spacers (one above and one below), then bolts and
washers. Next, attach them to the weighbridge. See note at left.
Once the checking system is installed, check once more that the load cells
are vertical and lock the checking system in place.
Make sure the rubber boots are installed on all the load cells.
Install the ground straps between the weighbridges, base plates and ground
rods using the hardware supplied.
Installation of the Checking System
Grounding
Before completely tightening
the checking system, ensure
that the load cells are still
vertically plumb.

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RLP Railweight Low-Profile Track Scale Installation and User’s Manual
The rails MUST be installed using proper rail clips and special bolts. (Rail
clips and bolts may have been supplied with the scale as an option). Insure
that you have proper rail clips and hardware.
Anti-creep devices MUST be installed at each end of the scale, one set on
the scale and one set on the approaches to prevent the rail from slipping
and causing a weighing error.
The rails on the scale weighbridge MUST NOT have any joints.
Installation of the rails
Rails MUST be installed
precisely using appropriate
clips, bolts, and other hard-
ware. You MUST meet all local
AREMA requirements. It is
highly recommended to get the
rails installed by a rail special-
ist.

12 RLP Railweight Low-Profile Track Scale Installation and User’s Manual
Verify the elevation and position of the scale and vertical alignment of the load
cells.
Grout the grout plates, using non-shrinking epoxy grout, while making sure
that there are no air pockets.
Pour concrete ballast into the weighbridge(s).
Refer to the General Arrangement drawing for the type and amount of con-
crete required.
Connect the load cells to the junction box(es) and join all the junction boxes
per the wiring diagram included in the foundation general arrangement draw-
ing.
Grouting
Concrete Work
Connection of the Load Cells and Indicator

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RLP Railweight Low-Profile Track Scale Installation and User’s Manual
Installation of the Covers
Testing
Flush Deck Scale:
A flush deck scale has special
main covers that make the main
beams of the scale flush with the
rails. Install the main covers, the
load cell covers, and then the
junction box shields. Main covers
and the load cell covers must be
installed before installing the
junction box shields
Maintenance
Install the junction box shield, cable covers and the load cell covers.
The scale is now ready for testing.
Scale MUST be tested using certified test weights and certified test car(s).
The number of certified test-weights and test car(s) vary depending on
Weights & Measures or the local serving rail company. Please refer to your
local controlling authority for details.
Avery Weigh-Tronix recommends a regular maintenance program of a mini-
mum of two visits per year by an authorized distributor. The number of visits
per year may vary depending on the traffic and environment. Items 1-5, below,
should be checked on a frequent and regular basis by the scale operator.
During each visit, the following MUST be done as a minimum:
1. Visually inspect the deck,checking for debris in the clearance under the
scale. If any debris, remove it.
2. Visually inspect approach at each end of the scale. If the scale is in-
stalled in a pit, insure the proper clearance between the main covers (or
grating part of the pit) and the scale bridge. If needed, repair or report it
for immediate repairs.
3. Visually inspect the rails, to make sure they have the minimum clearance
between the approach rails and the deck rails. If rubbing or too close,
repair or report it for immediate attention.
4. Make sure that all the load cells are plumb, and adjust them if neces-
sary.
5. Verify the grounding connections on the load cells and the
weighbridge(s). Repair as necessary.
6. Verify the scale weighing precision using a test car or certified test
weights, for the section and span reading. Adjust as required.

14 RLP Railweight Low-Profile Track Scale Installation and User’s Manual
No spare parts are normally recommended for this scale. However, you
might choose to store a load cell and a junction box, depending on the cost
of the scale downtime and the availability of parts in the surrounding area.
Recommended Spare Parts List

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RLP Railweight Low-Profile Track Scale Installation and User’s Manual

Weigh Bar®is a registered trademark of Weigh-Tronix Inc.
Avery Weigh-Tronix USA
1000 Armstrong Dr.
Fairmont, MN 56031 USA
Telephone: [phone]
Facsimile: 507-238-4195
e-mail: [email protected]
www.wtxweb.com
Avery Weigh-Tronix UK
Foundry Lane
Smethwick, West Midlands
England B66 2LP
Tel: [phone]
Fax: [phone]
Email: [email protected]
Web site:www.averyweigh-
tronix.com
Avery Weigh-Tronix Canada, ULC
217 Brunswick Boulevard
Pointe Claire, QC H9R 4R7 Canada
Telephone: [phone]
Toll free: 800-561-9461
Facsimile: 514-695-6820
www.weigh-tronix.ca