Rice Lake RoughDeck PW-1 User manual

RoughDeck®PW-1
Low Profile Floor Scale
Installation Manual
PN 179344

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 i
Contents
1.0 Introduction..................................................................................................................................... 1
1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Operating Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 Installation ...................................................................................................................................... 3
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4.1 Adjusting Feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4.2 Mounting Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Electrical Interface to the Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.0 Adjustments and Calibration .......................................................................................................... 6
3.1 Mechanical Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Corner Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.0 Service information ........................................................................................................................ 8
4.1 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Load Cell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.1 Remove Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.2 Install Load Cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.3 Load Cell Wiring to the Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3.4 Replacement Parts List and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
RoughDeck Limited Warranty ................................................................................................................... 12
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.
© Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America.
Specifications subject to change without notice.
Rice Lake Weighing Systems is an ISO 9001 registered company.
December 13, 2016

ii RoughDeck PW-1 Installation Manual
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 1
1.0 Introduction
RoughDeck® floor scales are fully electronic, low profile load receivers. The RoughDeck PW-1 is available in mild
or stainless steel in sizes 48'' x 48'' (1.2 m x 1.2 m), 48'' x 60'' (1.2 m x 1.5 m), 60'' x 60'' (1.5 m x 1.5 m) and
capacities of 2500 lb or 5000 lb (1000 kg or 2500 kg).
All models use four corner-mounted, FM-approved load cells, with the cells recessed into the frame for protection.
The load cell cables are enclosed and held down with replaceable cable ties near each corner, eliminating the
possibility of cable damage. A signal-trim summing board for any necessary corner corrections is enclosed in a
stainless steel NEMA Type 4X junction box.
A wheel kit option is available for portable applications or the scale can be moved by lifting it with a chain through
the eye bolts in the end of the unit. The eye bolts can be removed once the scale is in place.
Adjustable feet are used for leveling the scale to compensate for minor floor irregularities. For permanent
installations, two of the four feet can be held in place with optional floor mounting plates to guard against deck
movement.
See Section 4.3.4 on page 10 for replacement part and optional equipment part numbers.
1.1 Safety
Safety Signal Definitions:
DANGER
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.
WARNING
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.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, could result in minor or
moderate injury.
Important
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. Failure to follow the instructions or heed the warnings could
result in injury or death. Contact any Rice Lake Weighing Systems dealer for replacement
manuals.
WARNING
Failure to heed may result in serious injury or death.
Ensure every individual operating or working with this unit has read and understands the following safety
information.
Do not allow minors (children) or inexperienced persons to operate this unit.
Do not operate without all shields and guards in place.
Do not jump on the scale.
Do not use for purposes other than weight taking.
Do not place fingers into slots or possible pinch points.
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 remove or obscure warning labels.
Do not use near water.
Keep hands, feet and loose clothing away from moving parts.

2RoughDeck PW-1 Installation Manual
1.2 Operating Requirements
Electrical Grounding
For systems 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 3 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'' of horizontal.
Nominal Scale Height
2500 lb to 5000 lb (1000 kg to 2500 kg) models: 3.0'' to 3.5'' (76mm to 89 mm).

Installation 3
2.0 Installation
2.1 Overview
Standard installation of the RoughDeck PW-1 floor scale consists of the following steps:
1. Select a site.
2. Ensure the site is level and smooth.
3. Unpack the scale.
4. Install the mounting plates to the floor, if used.
5. Connect the cable from the junction box to the indicator.
6. Calibrate the unit.
2.2 Site Preparation
Consider the following when choosing a site for the RoughDeck PW-1.
• Select a site where overweight loads can maneuver easily without crossing the platform
• Avoid areas where damage could occur from side impacts of wheels or forklift tines
• Avoid areas where falling objects could cause shock damage
• Avoid areas where water may damage a scale not meant for a washdown environment
• The scale must be level within 1/4'' of horizontal
• The interface cable between the scale and the indicator must be protected against crushing, cutting and
moisture damage
The scale must not be loaded beyond capacity, even momentarily.
Choose a site where the floor is level to 1/4
'' to avoid excessive shimming. The floor may
require modification if unable to select an area up to this standard.
If the chosen site has potential dangers to cable integrity, some method of protection, such as
running the cable in conduit, is required.
Important

4RoughDeck PW-1 Installation Manual
2.3 Unpacking
Remove all packing material and inspect the scale for damage possibly caused during shipment. Contact Rice Lake
Weighing Systems and the shipper immediately if there is damage to the scale.
All RoughDeck PW-1 models have eye bolts in the end of the deck for use when lifting the scale with chains and a
spreader bar.
Lift the scale only with a properly designed spreader bar as shown in Figure 2-1.
Lifting force must be vertical to avoid bending the eye bolts.
Figure 2-1. Proper Lifting Technique
2.4 Assembly
The following sections describe the assembly of the components of the RoughDeck PW-1 scale.
2.4.1 Adjusting Feet
The scale feet are shipped detached from the load cells for load cell protection during shipping. The feet are
secured to the shipping pallet along with the load cell cable and product literature.
1. Unpack all parts.
2. Ensure each foot is screwed in until the foot touches either the load cell or the underside of the deck; then,
unscrew each foot three complete turns.
3. Place a spirit level on the deck.
4. Adjust corners not contacting the floor by unscrewing the feet on those corners until they just contact the
floor surface.
5. When all the feet are in contact with the floor, check the deck with the spirit level to ensure the scale is
within 1/4'' of level.
2.4.2 Mounting Plate Installation
The scale should be secured to the floor to prevent sideways movement for permanent applications. Two optional
mounting plates, with holes slightly exceeding the foot diameter, are available for that purpose.
1. Lift the scale until the feet are approximately 1'' off the floor.
2. Slide the mounting plates under two diagonally opposed feet.
3. Lower the scale back to the floor and position the plates as shown in Figure 2-2 with the boltdown holes
Important

Installation 5
accessible from above.
4. Use the mounting plates as a templates and drill pilot holes into the floor for suitable anchor bolts.
5. Bolt the plates to the floor using 1/2'' anchor bolts.
6. Recheck foot adjustment and deck level.
Figure 2-2. Mounting Plate Installation
2.5 Electrical Interface to the Indicator
Each scale is supplied with 20' of 6-wire cable with a 6-pin connection at one end. The corresponding receptacle
connector is on the short cable coming from the junction box at the top end of the scale To connect the two cables:
1. Plug the pin end from the indicator cable into the receptacle end of the junction box cable.
2. Push the outer band on the pin connector toward the receptacle connector.
3. Turn the band one quarter to one half turn until it is finger-tight to secure the connectors together. The
cables are correctly connected if the connectors do not come apart when pulled gently.
Figure 2-3. Scale Connection to Indicator
Figure 2-4. Quick Connectors
0.562" DIA
SCALE DECK
3.50"
MOUNTING PLATE
FOOT
To Indicator

6RoughDeck PW-1 Installation Manual
3.0 Adjustments and Calibration
3.1 Mechanical Adjustments
Jam nuts are not supplied for locking the feet due to a slight decrease in accuracy when the jam nuts are tightened.
If the scale application requires jam nuts to secure the feet, they may be added. The feet must be unscrewed beyond
the minimum height to allow room for the jam nuts between the foot pads and the load cells.
Adjust the Feet
1. Slightly lift the scale corner of the foot needing adjustment with a pry bar.
2. Turn the foot until it is contacting the floor
3. Repeat as needed until all feet are contacting the floor equally.
4. When height adjustments are complete, check level of the deck with a spirit level. The deck must be level
within 1/4".
When adjusting the scale feet, prevent the scale foot from bottoming out against the underside
of the load cell. In addition, the foot stem may be damaged by bending or stripping threads if
extended beyond the maximum height adjustment.
3.2 Corner Corrections
All RoughDeck scales are delivered with the junction box corner-trimmed; however, corner trimming is necessary
after replacing a load cell.
For this process, the indicator must be connected, calibrated and indicate an approximate weight value; an exact
weight value is not necessary. A test weight of 25% of scale capacity recommended for this procedure.
Example: 500 lbs for 2000 lb models, 5000 lbs for 20,000 lb models.
1. Remove the junction box cover and identify the correct load cell terminal corresponding to each corner,
labeled CELL 1, CELL 2, CELL 3 and CELL 4. See Figure 4-2 on page 9 for scale deck corner numbering.
2. With no weight on the scale, zero the indicator.
3. Turn all four potentiometers (shaded areas of Figure 3-1) until a clicking sound is heard from each
potentiometer. This ensures the maximum signal from each load cell.
4. Place the test weight on one corner and record the indicated weight.
5. Repeat Step 4 for each of the other three corners. The load cell with the lowest corner reading is used as the
reference point and will not be trimmed.
Figure 3-1. Potentiometers
6. Place the test weight on one of the other three corners and use that load cell’s potentiometer to adjust the
load cell output down to the reference cell output.
7. Repeat Step 6 with the other two high output 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.
Important
CELL 1
CELL 4
CELL 2
CELL 3
INDICATOR
+EX
–EX
+SI
–SI
100K
+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
100K
100K 100K