Rice Lake RoughDeck CC Caster Cargo User manual

RoughDeck® CC
Caster Cargo Scale with EZ Mount Load Cell Kits
and a TuffSeal® Junction Box
Installation Manual
PN 203881 Rev B
September 20, 2021

An ISO 9001 registered company
© Rice Lake Weighing Systems. All rights reserved.
Rice Lake Weighing Systems® is a registered trademark of
Rice Lake Weighing Systems.
All other brand or product names within this publication are trademarks or registered
trademarks of their respective companies.
All information contained within this publication is, to the best of our knowledge, complete and
accurate at the time of publication. Rice Lake Weighing Systems reserves the right to make
changes to the technology, features, specifications and design of the equipment without
notice.
The most current version of this publication, software, firmware and all other product updates
can be found on our website:
www.ricelake.com

Contents
© Rice Lake Weighing Systems ● All Rights Reserved i
Contents
Technical training seminars are available through Rice Lake Weighing Systems.
Course descriptions and dates can be viewed at www.ricelake.com/training
or obtained by calling 715-234-9171 and asking for the training department.
1.0 Introduction ....................................................................................... 1
1.1 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 Mechanical Installation ..................................................................... 3
2.1 General Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Mount Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.0 Load Cell Wiring ................................................................................ 6
4.0 TuffSeal Junction Box ...................................................................... 7
4.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Junction Box Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3.1 Connect Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Trimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.4.1 Signal Board Trimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.0 Calibration........................................................................................ 13
6.0 Troubleshooting .............................................................................. 14
7.0 Replacement Parts .......................................................................... 15
7.1 EZ Mount 1 Weigh Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.2 TuffSeal JB4SS Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

RoughDeck CC
ii Visit our website www.RiceLake.com
Rice Lake continually offers web-based video training on a growing selection
of product-related topics at no cost. Visit www.ricelake.com/webinars.

Introduction
© Rice Lake Weighing Systems ● All Rights Reserved 1
1.0 Introduction
The installation should be planned by a qualified structural engineer.
Each installation is unique, this manual is meant to serve as a general guideline for installation.
Manuals and additional resources are available from the Rice Lake Weighing
Systems website at www.ricelake.com
Warranty information can be found on the website at www.ricelake.com/warranties
The RoughDeck CC Caster Cargo Scale has a 20,000 lb capacity with a powder coat surface
for durability. Load and unload the caster deck scale in all directions with 360 degree swivel
casters (108 Kalpar Casters model DL55014893).
The EZ Mount kits provide an extremely accurate method for weighing medium and large
capacity structures that are subject to large thermal expansion/contraction or vibration forces.
The design uses a double ended shear beam load cell (700 Ω bridge) and transmits the load
with a sliding pin on the load-bearing groove of the cell. This design is very effective in
providing for thermal expansion/contraction with little friction.
Figure 1-1. Thermal Expansion
In the majority of applications, the assemblies are self-checking and held captive with no need
for check or stay rods, making this mount a good choice for areas with frequent seismic activity.
The sliding pin design eases load cell installation and replacement without the need to raise the
structure a large amount.
The RoughDeck CC uses four stainless steel EZ Mount 1 weigh modules (Section 2.2 on page 4)
containing 10,000 lb stainless steel IP67 load cells (RL70000SS).
The RoughDeck CC also utilizes a JB4SS TuffSeal NEMA Type 4X stainless steel signal trim
junction box. The TuffSeal junction box can be placed in any of the corners of the caster deck
(Section 4.2 on page 8) and accessed through any of the 4 removable deck panels along with
the load cells and mounts.
Thermal
Expansion

RoughDeck CC
2 Visit our website www.RiceLake.com
1.1 Safety
Safety Signal Definitions:
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.
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.
Indicates a potentially hazardous situation that, if not avoided, could result in
minor or moderate injury.
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. Contact any Rice Lake Weighing Systems
dealer for replacement manuals.
Failure to heed may result in serious injury or death.
Do not use for purposes other than weight measurement.
Do not use any load-bearing component that is worn beyond 5% of the original dimension.
Do not use this product if any of the components are cracked.
Do not exceed the rated load limit of the unit.
Do not make alterations or modifications to the unit.
Do not use without the deck completely assembled.
Do not place fingers into slots or possible pinch points.
DANGER
WARNING
CAUTION
IMPORTANT
WARNING

Mechanical Installation
© Rice Lake Weighing Systems ● All Rights Reserved 3
2.0 Mechanical Installation
This section provides an overview of mechanical installation information.
2.1 General Installation Guidelines
The RoughDeck CC system uses four EZ mounts. EZ mounts come assembled to the mount
risers with wooden blocks to keep the load cell from being loaded during shipping.
Figure 2-1. EZ Mount Assemblies
The mounting surface for the mounts must be level within ±0.5°.
If the mounting surfaces are not level, use shims and/or grout to level the mount.
If possible, check that the mount is level when the structure is fully loaded because excessive
deflections in legs and supporting structures may cause additional side forces, which affect
accuracy. Deflection of the mounts top or base plate due to loading should not exceed ±0.5°.
The load on each mount assembly should vary by no more than 20%.
Add shims where necessary to achieve correct load distribution.
During installation, avoid overload damage to the load cells.
Note
Note
WARNING

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2.2 Mount Installation
Secure an EZ Mount assembly to the riser mount plate in each corner of the caster deck. The
access panel top plate and corner caster plate need to be removed to access the mounting
holes to secure the EZ Mount assemblies.
Figure 2-2. EZ Mount Assembly Installation
EZ Mount Orientation
Position EZ Mount assemblies so the load cell cables are positioned on the inside.
Figure 2-3. Load Cell Orientation
The arrow on the load cell should point in the direction of the load.
Access Panel
Top Plate
Corner
Caster Plate
Riser Mount
Plate
Mount Riser
EZ Mount
Note

Mechanical Installation
© Rice Lake Weighing Systems ● All Rights Reserved 5
Secure the EZ Mount Base Plate
Verify that there is no initial misalignment and that the load cells are in the center of the hole in
the top plate loading bracket. Relocate if necessary.
Attach the base plates to the foundation using suitable anchors for concrete or by bolting or
welding to a steel structure.
Verify that the base plates are no more than ±0.5° out of level. Shim if necessary and
fully tighten mounting bolts.
Verify bolts securing the load cell to the base plate are tight. Only torque load cell
bolts to 20 foot-pounds. This allows the double-ended load cell to flex under load.
If surrounding equipment is frequently steam cleaned, or if the load cell is subjected to direct
washdown, a protective shroud for the weighing assembly is recommended.
Proper drainage is necessary so the weighing assembly is not standing in water. All support
points should be equally stiff so that they deflect by the same amount as the structure is loaded.
Figure 2-4. EZ Mount Parts Illustration
Note
Note
Top Plate
Loading Bracket
Cotter Pin
Load Cell Bolt
Load Cell
Base Plate
Load Pin
Locating Pin
Washer
Load Bar

RoughDeck CC
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3.0 Load Cell Wiring
This section provides an overview of load cell wiring information.
1. Route the load cell cables so they will not be damaged or cut. Cable should not be routed
near heat sources greater than 150°F. Do not shorten any load cell cable. The load cell is
temperature compensated with the supplied length of cable. Cutting the cable will affect
temperature compensation. Coil and protect excess cable so it will not be mechanically
damaged or be sitting in water.
2. Provide a drip loop in all cables so that water or other liquids will not run directly down the
cables onto either the load cells or the junction box.
Figure 3-1. Drip Loop
If conduit protection is necessary against mechanical or rodent damage to the load
cell cables, use flexible conduit and conduit adapters at the load cells.
Conduit can also provide protection against moisture ingress into the load cell.
3. Connect cables for RL70000SS load cells to the summing board in the junction box
according to Table 3-1 and the labels on terminal strips of the junction box.
To verify the wiring scheme, see the certification shipped with each load cell.
Wire Color Signal
Red + Excitation
Black – Excitation
Green + Signal
White – Signal
Gray or Bare Shield
Table 3-1. Load Cell Wiring
Drip Loop
Note
Note

TuffSeal Junction Box
© Rice Lake Weighing Systems ● All Rights Reserved 7
4.0 TuffSeal Junction Box
The RoughDeck CC comes with the TuffSeal stainless steel junction box. The TuffSeal JB4SS
is a signal trim junction box that can accommodate four load cells.
Manuals and additional resources are available on the Rice Lake Weighing Systems
website at www.ricelake.com. Refer to the Load Cell and Weigh Module Handbook
(PN 22054) for additional system calibration details.
The TuffSeal JB4SS has a Prevent ® breather vent, which inhibits the buildup of pressure caused
by sudden temperature or environmental changes. It must be changed every six months to a
year, it does become dirty over time. When correctly installed and torqued to 10 in-lb, all models
can withstand 900 PSI water pressure.
All terminals will function properly without modification. However, load cell output can be
individually trimmed with potentiometers which is further explained in Section 4.4 on page 11.
Figure 4-1. TuffSeal Junction Box
Electrostatic Charging Hazard – Clean junction box enclosure with a damp
cloth only.
Note
WARNING

RoughDeck CC
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4.1 Dimensions
Figure 4-2. JB4ES and JB4SS Enclosure Dimensions
4.2 Mounting Location
The TuffSeal junction box can be mounted in any of the four corners of the caster deck to the
top of the riser mount plate. The access panel top plate and corner caster plate need to be
removed to mount the junction box (see Figure 2-2 on page 4).The junction box should be
mounted in a location that is convenient for servicing.
Figure 4-3. Junction Box Mounting Location
Load cell output is temperature compensated for the supplied cable length.
Altering the length can change the cell's signal output.
0.234" Ø
5.75" (146 mm)
6.55" (166 mm)
4.00"
(102mm)
1.60"
(40.6mm)
USC
IntrinsicallySafe, EX ia:
ClassI, Division 1, Groups A, B, C, D
ClassII, Division 1, Groups E, F, G
ClassIII, Division 1 and 2
T4,Ta= 50˚C
Inaccordance with
RiceLake Weighing Systems
installationdrawing number
173044for hazardous locations.
J-BOX
230W. Coleman St. • Rice Lake, WI 54868 • [phone] • www.ricelake.com
USC
IntrinsicallySafe,EX ia:
ClassI,Division1, Groups A, B,C,D
ClassII,Division1, Groups E, F,G
ClassIII,Division1 and 2
T4,Ta=50˚C
Inaccordancewith
RiceLakeWeighingSystems
installationdrawingnumber
173044forhazardous locations.
J-BOX
230W.Coleman St. •Rice Lake, WI 54868 • [phone] •
www.ricelake.com
IMPORTANT

TuffSeal Junction Box
© Rice Lake Weighing Systems ● All Rights Reserved 9
4.3 Junction Box Wiring
The TuffSeal JB4SS junction box has been designed to connect and trim up to four load cells.
Figure 4-4. Junction Box Board Layout
1. Determine the wiring pattern to be used.
2. Route the load cell cables through the cord grips, do not tighten the grips.
3. Strip the wire insulation back 1/4'' to expose the wire.
4. Push in and hold the quick-connect lever with a small screwdriver.
5. Insert the appropriate wire into the exposed wire opening.
6. Release the screwdriver to allow the spring-loaded gate to close and lock the wire in
place.
The spring-loaded terminals will accommodate 12-28 gauge wire.
JP4
PT4 PT3
JP3
JP2
PT1
1
EXP
PT2
JP1
1
CELL4
1
CELL1
1
CELL3
1
CELL2
1
IND
-EX
-SI
SHD
+SI
+EX
M
-SI
S2C
+SI
+EX
-EX
-SI
SHD +SI
+EX
-EX
-SI
SHD
+SI
+EX
+SI
-SI
-EX
SHD
-EX
SHD
+EX
+SE
-SE
Note

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4.3.1 Connect Indicator
The indicator terminal strip is used to connect the main cable to an indicator. This equipment
was examined and approved for the connection to a single indicator only.
1. Determine the indicator’s load cell input connections from the indicator manual.
2. Run a cable from the indicator terminal into the junction box through the cord grip.
Figure 4-5. Indicator Cable Location
3. Strip the wire insulation back 1/4'' to expose the wire.
4. Push in and hold the quick-connect lever with a small screwdriver.
5. Insert the appropriate wire into the exposed wire opening.
6. Release the screwdriver to allow the spring-loaded gate to close and lock the wire in
place.
If cables could be exposed to water or other liquids, bend a short downward loop in all cables
near the cord grips so any fluids draining down the cables will drip off before reaching the
junction box.
Figure 4-6. Drip Loop Cable
Indicator Cable

TuffSeal Junction Box
© Rice Lake Weighing Systems ● All Rights Reserved 11
4.4 Trimming Procedure
Trimming is a process of equalizing the output from multiple individual load cells. If needed,
load cell output can be individually trimmed with potentiometers.
If more than 5% of normal output needs to be trimmed to equalize output, check for other
possible problems. When all errors except cell mismatch and cable extensions or reductions
have been corrected, continue with the trimming.
4.4.1 Signal Board Trimming Procedure
Use the following steps to properly trim the TuffSeal JB4SS junction box.
1. Determine the number of load cells needed.
2. Ensure jumpers are in place to enable trimming the load cells. Remove jumpers for
unused cells.
3. Set all potentiometers fully clockwise to give maximum signal output from each cell.
Figure 4-7. Junction Box Board
4. Zero the indicator.
5. Place calibrated test weights over each load cell in turn. The amount of test weights to be
used will depend on the scale configuration.
Refer to Handbook 44 Field Manual, published by NIST (National Institute of
Standards and Technology, for weight recommendations. For a four cell platform, it’s
25% of scale capacity is recommended.
PT4 PT3
PT1
1
EXP
PT2
1
CELL4
1
CELL1
1
CELL3
1
CELL2
1
IND
-EX
-SI
SHD
+SI
+EX
-SI
S2C
+SI
+EX
-EX
-SI
SHD +SI
+EX
-EX
-SI
SHD
+SI
+EX
+SI
-SI
-EX
SHD
-EX
SHD
+EX
+SE
-SE
Potentiometers
JP1 JP2
JP3JP4
Potentiometers
M
R
N
I
I
A
G
I
S
G
A
L
T
M
S
I
N
L
T
R
Note

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6. Record the value displayed on the indicator once test weight is placed on each corner,
directly over the load cell. Do not allow weight to overhang the sides.
7. Allow scale to return to zero each time to check for friction or other mechanical problems.
8. Select the load cell which has the lowest value as the reference point. This cell will not be
trimmed.
9. Place the same test load over one of the other load cells.
10. Use the corresponding potentiometer to trim the load cell equal to the reference load cell.
11. Repeat Steps 9 and 10 until all remaining load cells have been trimmed.
12. Once trimming is complete, check all loads cells again for repeatability. If necessary,
repeat Steps 4 through 11.
13. Pull excess cable out of the enclosure.
14. Tighten the cord grip assemblies with a wrench. To be watertight, each cord grip must be
tightened so the rubber sleeve begins to protrude from the hub.
15. Plug unused hubs to prevent moisture entry.
16. Place the supplied desiccant filter it in the junction box.
17. Replace the cover and tighten the screws in an alternating pattern to be certain the
gasket is compressed equally in all locations.
See the Electronic Replacement Parts and Components catalog to order extra
hole plugs if needed for Step 15.
Inspect the desiccant during normal service and change the desiccant as
needed.
IMPORTANT

Calibration
© Rice Lake Weighing Systems ● All Rights Reserved 13
5.0 Calibration
Calibration of the load cells in the EZ Mounts should be performed by a service technician.
Please contact a local scale dealer for assistance with calibration.
Use certified test weights to calibrate the scale after the EZ Mount assemblies are installed
under the RoughDeck CC scale deck (Section 2.2 on page 4) and the junction box corner
trimming procedure has been performed (Section 4.4 on page 11).
Rice Lake Weighing Systems recommends using weights greater than 20% of the scale’s rated
capacity and that the weights be evenly distributed when calibration is performed.
The greater the weight used to perform calibration the more linear the scale will be.
Note

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6.0 Troubleshooting
This section provides an overview of troubleshooting information.
Issues associated with load cells are often non-load cell related. Ensure all parts of the device
are properly connected and secured prior to troubleshooting:
1. Check load cell mount for debris restricting load cell movement or debris between scale
and structure.
2. Check that the structure and mounts are plumb, level, and square at critical areas.
3. Check the load cell cables for damage.
4. Check all electrical connections.
If the system can be calibrated but does not return to zero, loses calibration, or demonstrates
non-linearity or non-repeatability, see Table 6-1 for troubleshooting information.
If issues persist:
1. Check possible indicator malfunction by using a load cell simulator to input a known good
signal into the indicator.
2. Disconnect each load cell’s signal leads at the junction box and check individual load cell
outputs with a multimeter then check input/output impedances for comparison with load
cell manufacturer’s specifications.
If previous troubleshooting does not resolve the issue, see the following procedure:
1. Reconnect all but one load cell.
2. Replace the load cell with a load cell simulator. Alternate so that each load cell is
individually disconnected and replaced with a simulator.
If there is a problem with a particular load cell, the symptom should disappear when
that load cell is disconnected and replaced with simulator.
Symptom Possible Cause
Not returning to zero Mechanical binding or debris in seals or under load cells;
May have lost system calibration
Non-linearity Thermal expansion or deflection under load causing binding or side load
Non-repeatability Loose load cell mount;
Drifting caused by moisture;
Load cell overload or shack damage;
Mechanical binding
Lost calibration Out of level or plumb;
Moisture problem;
Mechanical binding
Drifting readout Moisture in junction box, cables or load cells;
Mechanical binding
Table 6-1. Troubleshooting Information
Note

Replacement Parts
© Rice Lake Weighing Systems ● All Rights Reserved 15
7.0 Replacement Parts
7.1 EZ Mount 1 Weigh Modules
Figure 7-1. EZ Mount Stainless Steel Replacement Parts Diagram
Item No. Part No. Description Qty
1 18370 Base Plate, EZ Mount 5K/20K SST 1
2 18267 Pin, Load Bearing 1-1/2 DIA x 2 SST 2
3 30432 Load Cell, DEB RL70000SS-10K SST 1
4 14774 Bolt, 5/8-18 x 3-1/8, Hex Head SST 2
5 15178 Washer, Flat 5/8 SST 2
6 18270 Load Pin, 3/4 DIA SST 1
7 18373 Locating Pin, 1/2 DIA SST 1
8 193590 Top Plate Weldment, EZ Mount 1, 5K/20K SST 1
9 191645 Quick Release Pin, 3/16 DIA x 1-5/8 Usable Length 2
Not Shown 208534 Shim Kit 4
Table 7-1. EZ Mount Stainless Steel Replacement Parts List
NOTE: ONLY HAND
TIGHTEN ITEM 4
4
5
9
8
2
3
4
7
6
1

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7.2 TuffSeal JB4SS Junction Box
Figure 7-2. TuffSeal JB4SS Replacement Parts Diagram
PG11 Cord Grip Nuts to be tightened to 33 in-lb
PG7 Cord Grip Nuts to be tightened to 22 in-lb
Breather Vent Nut to be tightened to 10 in-lb
USC
Intrinsically Safe, EX ia:
Class I, Division 1, Groups A, B, C, D
Class II, Division 1, Groups E,F, G
Class III, Division 1 and 2
T4, Ta = 50˚C
In accordance with
Rice Lake Weighing Systems
installation drawing number
173044 for hazardous locations.
J-BOX
230 W. Coleman St. • Rice Lake, WI 54868 • [phone] • www.ricelake.com
1
3
2
2
13
3
9
4
5
64
1
2
87
11
10
12
1
2
3