Kistler-Morse Microcell Installation Manual Download

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APPENDIX D. SPARE PARTS RECOMMENDATIONS

Kistler-Morse

recommends the purchase and

maintainance of the following minimum number of
spare parts/tools for the Microcell™ system:

1 Extra per Vessel

Microcell™ Sensor, each complete with:

Sensor

Environmental Cover

#8-32 socket head cap screws (2)

#8 hardened flat washers (2)

1 Extra per Plant

T-handle driver

Sikaflex 1A polyurethane sealant or Dow

Corning RTV 738 or RTV 739

Kistler-Morse

Test Meter

CAUTION

Only use Sikaflex 1A polyurethane sealant
or Dow Corning RTV 738 or RTV 739.

Other

sealants may contain acetic acid, which is
harmful to sensors and electronics.

Summary of Contents for Microcell

Page 1: ...Microcell Installation Manual 97 1012 02 Revision G March 2010 CAUTION It is essential that all instructions in this manual be followed precisely to ensure proper operation of the equipment ...

Page 2: ... after installation of the Microcell system The electrical current of the welder may pass through the Microcell causing damage to the sensor and possibly to the signal processor To avoid damage follow these precautions 1 Disconnect the Microcell cables from the signal processor 2 Ground the welder as close to the welding joint as possible The welding ground must be between the Microcell and the we...

Page 3: ...e 5 Horizontal Distribution of Microcell Sets 6 Vertical Location of Microcell Sets 6 Column Legs without X Braces 6 Column Legs with X Braces 6 Installing Microcell Sets 8 Surface Preparation 8 Drill and Tap 8 Mounting the Microcell Sets 9 Mounting Junction Box 10 Mounting Location 10 Junction Box Installation 11 Wiring Microcells to Junction Box 11 Wiring Junction Boxes Together and to Signal Pr...

Page 4: ...27 Removing a Known Quantity of Material 28 Manual Calibration 28 CHAPTER 6 TROUBLESHOOTING 29 Problem 1 Small Amplitude Changes or Erratic Fluctuations in Display Readings 29 Problem 2 Repeatable Drift Over a 24 hour Period 30 Problem 3 Sudden Change in Weight Reading or System Requires Frequent Recalibration 31 APPENDIX A MICROCELL SPECIFICATIONS 32 APPENDIX B GLOSSARY 34 APPENDIX C ALTERNATE ME...

Page 5: ...maintenance It is immune to electrical noise due to its high level output voltage APPLICATIONS The 3 Microcell can be installed on carbon steel stainless steel or aluminum vessel supports The 2 Microcell can be installed on carbon steel vessel supports only Refer to Appendix A Microcell Specifications for stress limits on each type of Microcell Microcell sets can be installed on leg supported and ...

Page 6: ...t Kistler Morse before proceeding further with a special application ORDER VERIFICATION Prior to beginning installation verify the order is complete and assemble additional equipment needed for the installation MICROCELL ORDER The following are included with the order quantities dependent on application STANDARD Microcell set each complete with Sensor Environmental Cover 8 32 socket head cap screw...

Page 7: ...ne sealant or Dow Corning RTV 738 or RTV 739 Other sealants may contain acetic acid which is harmful to sensors and electronics CHECKING EQUIPMENT CAUTION Handle Microcell sets with care Dropping striking etc can damage the Microcells VISUAL CHECK Visually inspect all equipment in the order including Microcells junction boxes Installation Kit and insulation if provided to verify they were not dama...

Page 8: ...ne DMM lead on the Microcell white wire and the other lead on the red wire Place the Microcell on a stable surface Verify the resistance is within the following limits 3 standardized Microcell light blue cover 8 300Ω 8 700Ω 2 standardized Microcell dark blue cover 1 800Ω 2 200Ω 3 Put one DMM lead on the Microcell white wire and the other lead on the black wire Place the Microcell on a stable surfa...

Page 9: ...tler Morse if special considerations prevent you from installing Microcells at the designated locations MICROCELL SETS BEST PERFORMANCE See Figure 3 1 For best performance Microcells are mounted in a rosette array a vertical Microcell with a horizontal Microcell above it in a T configuration A Microcell set consists of two rosette arrays four Microcells total mounted on opposite sides of a support...

Page 10: ...S See Figure 3 4 If the free leg distance is between 12 in 305mm and 11 ft 3 4m mount the Microcell sets at mid height of the free leg If the free leg distance is more than 11 ft 3 4m mount the Microcell sets at 5 ft 6 in 1 7m above the foundation If the free leg distance is less than 12 in 305mm this is a special application situation Consult Kistler Morse before proceeding further Figure 3 4 Ver...

Page 11: ...in 305mm See Figure 3 6 If the free leg distance is less than 12 in 305mm mount the Microcell sets at the mid height between the lowest braces When mounting between the braces insulation around the adjacent braces is required for best performance This insulation will reduce the effect of sun induced stresses on the support metal Figure 3 6 Vertical Location of Microcell Sets for Legs With Braces a...

Page 12: ...rinder until a bare metal surface is achieved Due to the use of coarse grit the resulting surface is somewhat coarse Figure 3 7 Prepared Mounting Surface 4 Replace the coarse grit sandpaper with the fine grit sandpaper Grind until the surface s is completely down to bare metal and smooth to the touch Note The Microcell must be mounted against smooth bare metal Remove all paint and rust from the ar...

Page 13: ...ap screws and washers Do not tighten the screws If the voltage goes outside the range 100mV to 100mV immediately loosen the screw s Note 3 Microcells for vertical and horizontal installation are slightly different 3 Microcells for horizontal installation are labeled Horizontal 3 Microcells for vertical installation are not labeled CAUTION For proper installation tighten each screw until the T hand...

Page 14: ... where moisture may pool especially along the top edge Verify the sealant forms a continuous watertight seal Ensure the cable exit channel is completely sealed D Repeat Step 10 for the horizontal Microcell if applicable CAUTION Only use Sikaflex 1A polyurethane sealant or Dow Corning RTV 738 or RTV 739 Other sealants may contain acetic acid which is harmful to sensors and electronics Figure 3 9 En...

Page 15: ...on box with 8 32 socket head cap screws and flat washers Tighten the screws until snug Replace the junction box cover and screws if not ready to begin wiring to ensure that no moisture enters the junction box WIRING MICROCELLS TO JUNCTION BOX Note A There are two versions of the junction box PCB One version 63 1135 01 is used for vertical Microcells The other version 63 1135 03 is used for Microce...

Page 16: ...mful to sensors and electronics 4 See Figure 3 13 In the bottom of the junction box locate one of the four small holes closest to the terminal being used for that Microcell Screw the watertight fitting into the hole Figure 3 13 Wiring Microcells to Junction Box Figure 3 12 Inserting Microcell Cable Through Watertight Fitting and Cap 12 ...

Page 17: ...s for non conduited installation The two large holes which are equipped with PG13 5 cable fittings are for wiring the junction box to the other junction boxes and to the signal processor Kistler Morse requires the use of cable trays for non conduited installations Note A The following procedure assumes the conduit cable tray has been installed B Seal all conduit fittings against water entry Instal...

Page 18: ... W terminal and red wire to the R terminal Connect the cable shield wire to the the Shield terminal between TB1 and TB2 4 Route another 3 conductor cable through the fitting into this junction box and attach wires to the TB2 terminal black wire to B terminal white wire to W terminal and red wire to R terminal Connect the cable shield wire to the Shield terminal between TB1 and TB2 5 Repeat Steps 3...

Page 19: ...umber of braces Brace wrap 60 in by 85 in 1 5m by 2 2m Tie wraps The following are used for installation Flexible tape measure Heavy duty knife INSTALLING BRACE WRAP 1 See Figure 3 17 Using a flexible tape measure measure and record the wrap width required allowing for a minimum 2 in 51mm overlap 2 See Figures 3 17 ad 3 18 Lay the wrap on a flat surface Mark and cut it at the distance from Step 1 ...

Page 20: ...Figure 3 18 Cutting Wrap Width Figure 3 19 Installing Brace Wrap 16 ...

Page 21: ...e optimal system performance Consult Kistler Morse if special considerations prevents the installation of the Microcells at the designated locations MICROCELL SETS See Figure 4 1 Microcells are mounted on beams in a shear mounting set A Microcell is set at a 45 angle to the horizontal with another Microcell set perpendicular to it on the other side of the support beam Both Microcells are mounted w...

Page 22: ...Figure 4 2 Microcell Mounting Locations 18 ...

Page 23: ...locations may be adjusted up to 12 in 305mm in any directon to avoid obstacles If adjusting locations maintain the configuration of the set i e if you move one Microcell in the set from its ideal location move the other Microcell as well The top of Microcell A points toward the load point from the vessel putting the Microcell in compression when the load is applied Microcell B is mounted on the ot...

Page 24: ...ace is completely down to bare metal and smooth to the touch for Microcell A Repeat for Microcell B Note The Microcell must be mounted against smooth bare metal Remove all paint and rust from the area where the Microcell is to be fastened DRILL AND TAP 1 Using the 8 32 top thread the template mounting hole drilled during SURFACE PREPARATION until the tap is cutting complete threads through the oth...

Page 25: ...h screw until the T handle driver flexes in torsion turn past the point where the screw stops turning Repeat this flexing procedure several times to ensure the screw is tight When both screws are tight the voltages must be in the range of 100mV to 100mV Follow the procedure in Steps 6 through 8 to achieve this goal 6 Using the T handle driver slowly tighten the top screw While turning the T handle...

Page 26: ...y sealed D Repeat Step 11 for Microcell B CAUTION Only use Sikaflex 1A polyurethane sealant or Dow Corning RTV 738 or RTV 739 Other sealants may contain acetic acid which is harmful to sensors and electronics Figure 4 8 Environmental Cover 12 If you created any holes that go completely through the web spread sealant Sikaflex 1A polyrethane sealant or Dow Corning RTV738 or RTV 739 over the open hol...

Page 27: ...Junction box PCB 63 1135 03 is used for Microcell sets on beams Ensure you have this PCB in the junction box See Figure 4 13 B The four small holes in the bottom of the junction box are for wiring the Microcells to the junction box 1 Remove the junction box cover 2 See Figure 4 12 Place a plastic washer on a watertight fitting Thread the Microcell cable through a cap and watertight fitting Leave a...

Page 28: ...ing the junction box to the other junction boxes and to the signal processor 2 Two large holes for non conduited installation The two large holes which are equipped with PG13 5 cable fittings are for wiring the junction box to the other junction boxes and to the signal processor Kistler Morse requires the use of cable trays for non conduited installations Note A The following procedure assumes the...

Page 29: ... black wire to the B terminal white wire to the W terminal and red wire to the R terminal Connect the cable shield wire to the the Shield terminal between TB1 and TB2 4 Route another 3 conductor cable through the fitting into this junction box and attach wires to the TB2 terminal black wire to B terminal white wire to W terminal and red wire to R terminal Connect the cable shield wire to the Shiel...

Page 30: ...Figure 4 16 Wiring Junction Boxes Together Non Conduited Installation 26 ...

Page 31: ...ual Calibration does not take into account the actual response to changes in weight Theoretically a change in weight results in a proportional change in digital counts However the structure s actual response to load and interaction with piping catwalks roof discharge chutes etc prevents the system from achieving theoretical values Manual Calibration is a good start but to obtain the highest accura...

Page 32: ..._Cal current live load 6 Refer to the signal processor manual to input the calibration values Example 1 Microcells on Vertical Legs You are using 3 Microcells in rosette arrays on vertical column legs The vessel has four W10x39 carbon steel legs and no braces The vessel currently contains 50 000 lb of material and can hold a maximum of 200 000 lb Following the procedure 1 Counts mV 699 05 from sig...

Page 33: ...l to sensors and electronics EXPLANATION Fluctuations can be caused by a damaged Microcell Problem Likely to be Noticed Shortly after initial installation or on system that previously functioned correctly Solution Using Digital Multimeter DMM or ohmmeter check resistance for individual Microcells 1 Set meter resistance scale to accommodate measured range up to 20 000Ω 2 Remove one Microcell wire f...

Page 34: ...h one lead to earth ground and other lead to white wire check resistance on disconnected Microcell wires A If reading is less than infinite i e there is resistance short is indicated Replace shorted Microcell B If no short is indicated disconnect next Microcell wires from junction box and check resistances Repeat for each Microcell wired to junction box until short is located Replace the shorted M...

Page 35: ...rocell is not indicated perform the following procedure 1 Carefully remove environmental cover from Microcell 2 Tighten Microcell 8 32 socket head cap screws following procedure in appropriate Microcell Installation Chapter Chapter 3 for vertical column legs or Chapter 4 for horizontal beams 3 Replace environmental cover on Microcell Follow procedure in appropriate chapter on installation CAUTION ...

Page 36: ... 12V EXCITATION Sensitivity 3 Microcell 70mV 1 1 000 psi 70mV 1 0 7kg mm2 2 Microcell 56mV 1 1 000 psi 56mV 1 0 7kg mm2 Zero Strain Output 0mV 25mV Non linearity 0 1 of full scale output Repeatability and Hysteresis 0 05 of full scale output Output Impedance 3 Microcell Standardized 7 5kΩ 75Ω at 70 F 21 C Non Standardized 1 0kΩ 100Ω at 70 F 21 C 2 Microcell 1kΩ 100Ω at 70 F 21 C ENVIRONMENTAL Rati...

Page 37: ...33 ...

Page 38: ...n sensor readings for repeated loadings under identical loading and environmental conditions SENSITIVITY The ratio of the change in electrical output to the change in load or stress SIGNAL PROCESSOR The electronic firmware and software box connected to a sensor such as a Microcell or transducer array If it is augmented with software the first stage of the signal processor is an A D converter A sig...

Page 39: ...g 1 See Figure C 1 Connect the red wire from the Microcell cable to the R terminal on terminal block TB3 in the junction box Connect the black wire to the B terminal on TB3 2 Connect the signal probe of the DMM to the white wire from the Microcell cable DO NOT connect the white wire to the terminal block 3 Connect the common probe of the DMM to TP1 on the junction box circuit board If a test point...

Page 40: ...ensor each complete with Sensor Environmental Cover 8 32 socket head cap screws 2 8 hardened flat washers 2 1 Extra per Plant T handle driver Sikaflex 1A polyurethane sealant or Dow Corning RTV 738 or RTV 739 Kistler Morse Test Meter CAUTION Only use Sikaflex 1A polyurethane sealant or Dow Corning RTV 738 or RTV 739 Other sealants may contain acetic acid which is harmful to sensors and electronics...

Page 41: ...APPENDIX E TECHNICAL DRAWINGS This appendix contains the following technical drawing s DRAWING NUMBER DRAWING TITLE TI MC FM 01 FM Approved Intrinsically Safe Interconnect Diagram Microcell Sensor 37 ...

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Page 44: ... All rights reserved All data subject to change 97 1012 02 Revision G March 2010 150 Venture Boulevard Spartanburg SC 29306 800 426 9010 Toll Free 864 574 2763 Phone 864 574 8063 Fax www kistlermorse com sales kistlermorse com ...

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