Rice Lake RoughDeck BDP User manual

78065
RoughDeck
™
BDP
Barrel Scale
Installation/Operation
Manual

© 2003 Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America.
Specifications subject to change without notice.
Version 1.0, September 2003
Contents
1.0 Introduction and System Overview.............................................................................................. 1
1.1 Model Designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Operating Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 Installation................................................................................................................................... 3
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Site Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4.1 Installing and adjusting feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4.2 Anchor Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Electrical Interface to Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6 Portable Deck Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7 Access Ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.0 Adjustments and Calibration....................................................................................................... 8
3.1 Mechanical Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Corner Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.0 Service Information................................................................................................................... 10
4.1 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3 Load Cell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3.1 Load Cell Wiring to Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.0 Replacement Parts List.............................................................................................................. 13
RoughDeck BDP Portable Barrel Scale Limited Warranty.................................................................... 15
Technical training seminars are available through Rice Lake Weighing Systems. Course
descriptions and dates can be viewed at www.rlws.com or obtained by calling
715-234-9171 and asking for the training department.

Introduction and System Overview 1
1.0 Introduction and System Overview
The Roughdeck BDP is a fully electronic, low profile, NTEP-certified load receiving barrel scale that provides
exceptional performance and serves as an economical solution in general weighing applications.
The BDP comes in two standard platform sizes: 30 in x 31 in (.76 m x .79 m) and 36 in x 37 in (.91 m x .94 m),
and in capacities from 1K- to 2.5K-lbs (500–1250 kg). NTEP-certified, alloy steel shear beam load cells or
stainless steel load cells are available with the cells recessed into the frame channels for protection.Also included
is a signal-trim summing board enclosed in an aluminum or durable stainless steel enclosure that has a
convenient top-access for any necessary corner corrections.
Load cell cables are run through the main channels and held down with replaceable cable ties near each corner,
eliminating the possibility of cable damage in portable applications. Threaded holes, located in the top corners of
the deck, are another useful feature. This allows for placement of removable eyebolts to lift the scale from above
with chains and safely place the scale in a portability frame for portable applications. Because of the possibility
of foot and load cell damage from forklift tines, the scale should always be lifted from above with chains through
the eyebolts.
The adjustable feet are used to allow leveling the scale to make up for minor floor irregularities. The threaded
lifting holes double as foot adjustment holes adding to the ease of installation. Optional floor anchor plates are
available to secure the scale to the floor if access ramps or a portability frame aren’t used. If floor ramps are used,
then the ramps hold the scale in place.
Other available options include portability frames and access ramps for both sizes of the RoughDeck BDP.
Figure 1-1. RoughDeck BDP Barrel Scale (shown with optional portability kit and IQ plus
®
390-DC indicator)
Authorized distributors and their employees can view or download this manual from the Rice Lake
Weighing Systems distributor site at:
www.rlws.com
.

2 Roughdeck BDP Barrel Scale Installation Manual
1.1 Model Designations
An identification tag is located on the frame next to the junction box tray. When ordering replacement parts, be
sure to include both the model and serial number of the scale.
Mild Steel
Mild steel versions come equipped with the following:
•Treaded top plate
• Aluminum NEMA 4 junction box
• Alloy steel load cells
Stainless Steel
Stainless steel versions come equipped with the
following:
• Smooth top plate
• Stainless steel NEMA 4X junction box
•Stainless steel or stainless steel with welded
seal (IP67) load cells
1.2 Operating Requirements
Electrical Grounding
For permanent installations where the scale is connected to a 115 VAC circuit, the indicator must be directly
connected to an earth ground with a ground interface cable of no more than 3W resistance throughout its length.
Load Cell Excitation
Rated Excitation: 10 VDC
Maximum Excitation: 15 VDC
Grade Level Requirements
The supporting surface for the four feet of the scale must be level within 1/4 inch of horizontal.
End Load Capacity
200% for 1K models
80% for 2.5K models
Scale to Indicator Cable Length
10 ft (3 m)
Approvals
NTEP CoC 03-060
•
N
A
T
I
O
N
A
L
C
O
N
F
E
R
E
N
C
E
•
O
N
W
E
I
G
H
T
S
A
N
D
M
E
A
S
U
R
E
S

Installation 3
2.0 Installation
The RoughDeck BDP can be installed either permanently or used as a portable scale depending on the intended
location. There are certain requirements for installation based on the desired location of the BDP. The following
sections describe the correct installation procedures for installing the RoughDeck BDP as a permanent scale or a
portable scale.
Both types of installations require some basic steps that are characteristic to both types:
1. Selecting a site
2. Checking levelness and smoothness of site
3. Unpacking the scale
2.1 Site Preparation
The scale must not be loaded beyond its capacity, even momentarily. Avoid areas where the scale might receive
damaging side impacts from wheels or forklift tines, or shock damage from falling objects. Avoid areas where
water may damage a scale not meant for a washdown environment.
The interface cable between the scale and the indicator must be protected against crushing, cutting, or moisture
damage. If the chosen site has such potential dangers, some method of protection, such as running the cable in
conduit, is necessary if using the scale in a permanent location.
In operation, the scale must be level within 1/4 inch. Either choose a site where the floor is close to this standard
to avoid excessive shimming, or modify the floor at the chosen site to meet this standard. Use the bubble level in
the center of the scale deck to determine if the scale is level.
2.2 Unpacking
Remove all packing material and visually inspect the floor scale for visible damage caused during shipment. If
any parts were damaged in shipment, notify Rice Lake Weighing Systems and the shipper immediately.
Scale Only
The shipping container for the scale should contain the following:
• Floor scale
• Floor scale feet • Installation manual •Ten foot length of load cell cable
Portability Frame
The shipping container for the portability frame should contain the following:
• Scale frame
• Indicator stand
• Mounting hardware
All BDP models have four threaded eyebolt holes located in the corners of the deck to allow installation of
eyebolt hooks for use when lifting the scale with chains.
It’s recommended to use 1/2 in-13NC eyebolts in 1K–2.5K-lb capacity scales.
Figure 2-1. Proper Lifting Technique

4 Roughdeck BDP Barrel Scale Installation Manual
3.0 Permanent Installation
The following steps are needed to install the BDP in a permanent location.
1. Adjust the four feet on the scale
2. Install mounting plates to the floor (if not using access ramps)
3. Connect cable to the indicator
4. Calibrate the unit
Access ramps are described in Sections 3.2.
3.1 Assembly
The following paragraphs give instructions for installing and adjusting the scale feet and anchor plate.
3.1.1 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 ten 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.
3.1.2 Anchor Plate Installation
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 3-1 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.
Figure 3-1. Anchor Plate Installation
3.50"
.56" DIA (2K–10K models)
ANCHOR PLATE
SCALE DECK
FOOT

Permanent Installation 5
3.2 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 attach
to the scale feet. When used with access ramps, side movement of the scale is automatically eliminated, and no
other mounting plates are necessary.
Access ramps can only be attached to the scale on one of the two scale sides that are perpendicular to the
longitudinal axis of the load cells and that are perpendicular to the side rails. For example, the scale shown below
could have an access ramp on the left side as shown, and/or on the right side. The top and bottom sides, however,
will not accept the ramp mounting plates.
Figure 3-2. Optional Access Ramp
3.3 Electrical Interface to Indicator
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 (Figure 3-3) as shown in Table 3-1.
6. Pull out excess cable and tighten the cord grip to hold the cable snugly.
Side rails
Cable Color Code Junction Box
Red + Excitation
Black - Excitation
Green + Signal
White - Signal
Bare Shield
Yellow + Sense
Blue - Sense
Table 3-1. Junction Box Connections

6 Roughdeck BDP Barrel Scale Installation Manual
Figure 3-3. Junction Box Wiring Diagram
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 3-4.
Figure 3-4. Load Cell Protection
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 5.2.
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.
Figure 3-5. Junction Box Diagram
CELL 1
CELL 4
CELL 2
CELL 3
INDICATOR
+EX
–EX
+SI
–SI
100 K
+SE
–SE
+EX
+EX +EX
+EX
–EX
–EX
–EX
–EX +SI
+SI
+SI
+SI
–SI
–SI
–SI
–SI SHD
SHD
SHD
SHD
23126
Rev. A
SHD
JU1 JU2
JU3
JU4
100 K
100 K 100 K
Indicator terminal
location
FLOOR
LOAD CELL CABLE
STEEL COVER

Portable Deck Installation 7
4.0 Portable Deck Installation
The RoughDeck BDP offers an optional portability frame kit, which makes the BDP easy to move from place to
place and can easily convert a permanent scale into a portable one. The portability frame is compact and sits
below the live siderails so it will not interfere with weighing pallets or larger items. The frame contains casters,
indicator stand, and mounting hardware. Due to the wheel engager design, the wheels will not interfere with
larger items.
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.
Figure 4-1. Portability Frame Kit Diagram
The BDP scale fits inside of the portability frame. Refer to Figure 2-1 on page 3 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.
4.1 Hinged Access Ramps
Optional hinged access ramps are available with the portability frame. The BDP’s low profile design allows the
ramps to sit flush with the ground eliminating a speed bump, yet hinged so the operator can rest them on the
scale’s surface when moving the scale. Ramps come in either mild steel or stainless steel. The hinged access
ramps attach to the portability frame by attaching them to the access ramp tabs (as shown in Figure 4-1), with
1/4-20 bolts and nuts.
Warning
Levers (x4) to
raise and lower
the BDP portable
scale. Hinged access
ramp tabs