Kistler-Morse Microcell Bedienungsanleitung

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.

NOTICE

The content of this document is the intellectual property of Kistler-Morse® Corporation. Any

reproduction or translation of this document without the written authorization of a Kistler-Morse®

corporate ofcer is prohibited.

CAUTION

Follow these rules if welding is done on the vessel 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 weld joint to prevent the welding current from going through the Microcell™

to earth ground.

TABLE OF CONTENTS

CHAPTER 1. INTRODUCTION ................................................................................................................ 1

Equipment Description ......................................................................................................................... 1

Applications .......................................................................................................................................... 1

Manual Conventions ............................................................................................................................. 1

CHAPTER 2. PRE-CHECK PROCEDURES ............................................................................................ 2

Introduction ................................................................................................................................................ 2

Application Verication ............................................................................................................................... 2

Order Verication ........................................................................................................................................ 2

Microcell™ Order ................................................................................................................................. 2

Microcell™ Installation Equipment ....................................................................................................... 3

Junction Box and Field Wiring Equipment ........................................................................................... 3

Checking Equipment .................................................................................................................................. 3

Visual Check ......................................................................................................................................... 3

Functional Check .................................................................................................................................. 3

Testing with Kistler-Morse® Test Meter ........................................................................................... 3

Testing with Digital Multimeter (DMM) ............................................................................................. 4

CHAPTER 3. MICROCELL™ INSTALLATION ON VERTICAL COLUMN LEGS .................................... 5

Introduction ................................................................................................................................................ 5

Mounting Locations .................................................................................................................................... 5

Microcell™ Sets ................................................................................................................................... 5

Best Performance ........................................................................................................................... 5

Standard Performance ................................................................................................................... 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 Processor ....................................................................... 13

Installing Insulation for Outdoor Vessels (Optional) .................................................................................. 15

Insulation Order and Installation Equipment ...................................................................................... 15

Installing Brace Wrap ......................................................................................................................... 15

CHAPTER 4. MICROCELL™ INSTALLATION ON HORIZONTAL BEAMS .......................................... 17

Introduction .............................................................................................................................................. 17

Mounting Locations .................................................................................................................................. 17

Microcell™ Sets ................................................................................................................................. 17

Distribution of Microcell™ Sets .......................................................................................................... 17

Installing Microcell™ Sets ........................................................................................................................ 20

Surface Preparation ............................................................................................................................ 20

Drill and Tap ........................................................................................................................................ 20

Mounting Microcell™ Sets ................................................................................................................. 21

TABLE OF CONTENTS

Mounting Junction Box ............................................................................................................................ 22

Mounting Location.............................................................................................................................. 22

Junction Box Installation .................................................................................................................... 22

Wiring Microcell™ Sets to Junction Box .................................................................................................. 23

Wiring Junction Boxes Together and to Signal Processor ....................................................................... 24

CHAPTER 5. SYSTEM CALIBRATION .................................................................................................. 27

Introduction .............................................................................................................................................. 27

Live Load Calibration ............................................................................................................................... 27

Adding a Known Quantity of Material ................................................................................................. 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 METHOD FOR CHECKING OUTPUT ...................................................... 35

APPENDIX D. SPARE PARTS RECOMMENDATIONS ......................................................................... 36

APPENDIX E. TECHNICAL DRAWINGS ............................................................................................... 37

CHAPTER 1. INTRODUCTION

Figure 1-1. The Kistler-Morse® Microcell™.

EQUIPMENT DESCRIPTION

The Microcell™ (Figure 1-1) is a highly sensitive

bolt-on strain gage sensor used to determine the

weight of material contained in storage vessels.

Microcell™ sets bolt onto a vessel’s metal support

structure. As weight is added to or removed from

the vessel, the vessel support structure

experiences strain changes proportional to the

weight changes. The Microcell™ detects the

strain changes and produces a voltage output

proportional to those changes, thus indicating the

change in weight. Kistler-Morse® signal

processors convert the Microcell™ voltage outputs

to weight or level. Refer to Appendix A for

specications.

The Microcell™ is easy to install. It mounts to the

surface of the structural support and never comes

in contact with the vessel contents. Used in many

different industries, it can weigh any type of

material stored in a vessel with metal support

members. The Microcell™ is rugged, can operate

in industrial environments, and requires no periodic

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™ Specications) for stress limits on

each type of Microcell™.

Microcell™ sets can be installed on leg-supported

and beam-supported vessels. Refer Chapter 3

for installation details on installing Microcell™ on

vertical column legs. Refer to Chaper 4 for

installation details on installing Microcell™ on

horizontal beams.

Contact Kistler-Morse® for information on

non-standard applications.

Be sure to read the entire installation procedure

pertaining to your application before beginning

installation.

MANUAL CONVENTIONS

Three kinds of special explanations appear

throughout the manual. The format and

signicance of each is dened below:

WARNING

Possible danger to people. Injury may result

if this information is ignored.

CAUTION

Possible risk to the product. The Microcell™

or other equipment may be damaged if this

information is ignored.

Note

Contains additional information about a step or

feature critical to the installation or operation of

the Microcell™.

CHAPTER 2. PRE-CHECK PROCEDURES

INTRODUCTION

This chapter describes the pre-check procedures

for Microcell™ sets. Verifying the application and

checking the Microcell™ sets before installation

will ensure installation of properly working

equipment that will provide accurate monitoring

of vessel contents.

APPLICATION VERIFICATION

Prior to ordering Microcell™ sets, be sure to have

read the Microcell™ Selection Guide

(Kistler-Morse® #97-5023) and completed the

appropriate Application Data Form (Kistler-Morse®

#97-5025 for Microcells™ on vertical column legs

or Kistler-Morse® #97-5024 for Microcells™ on

horizontal beams). A copy of the completed form

was returned with both the order acknowledgment

and equipment shipment. If you cannot locate the

form, contact Kistler-Morse® to get another copy

before proceeding. Review the information on the

form now to verify the application details.

Note

If the calculated stress on the Application Data

Form is outside the following ranges, this is a

special application:

3” Microcell™: 2,500 psi - 7,500 psi

(1.8kg/mm2 - 5.3kg/mm2)

2” Microcell™: 3,750 psi - 11,250 psi

(2.6kg/mm2 - 7.9kg/mm2)

Contact 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 screws (2)

#8 hardened at washers (2)

JB1 or JB2 Junction Boxes, each complete with:

Terminal board

Watertight ttings (4)

Watertight plugs (for any cable openings that

will not be used)

Installation Kit, each complete with:

Microcell™ drill template with #8-32 socket

head cap screw

#29 drill bit

#8-32, 2-ute, spiral-point tap

Sikaex 1A polyurethane sealant or Dow

Corning RTV 738 or RTV 739 and Material

Safety Data Sheet (MSDS)

Rust-inhibiting silicone grease

OPTIONAL

Insulation and insulation hardware (if best

performance is required for an outdoor

installation on column legs)

If any items are missing from the order, contact

Kistler-Morse® before proceeding. Substituting

parts without Kistler-Morse® approval may cause

system problems and will void the warranty.

Note

A signal processor and its manual are required

to calibrate the system. If using an existing

signal processor, this will not be included in

the order.

MICROCELL™ INSTALLATION EQUIPMENT

Tape measure

Marking pen

Kistler-Morse® Test Meter

Kistler-Morse® Microcell™ Sensor Drill Template

Drill motor

Tapping uid

Tap handle

Disk grinder, 4½” (114 mm) or larger, or belt

grinder

Sandpaper (coarse and ne)

Degreaser (isopropyl alcohol or acetone)

Level

Caulking gun

9/64” hex T-handle driver

Digital Multimeter (DMM)

Tape (electrical or masking)

Note

If the Microcell™ sets will be install by

Kistler-Morse®, the service technician provided

by Kistler-Morse® will bring this equipment on

site with the tool kit. If the Microcell™ sets will

be installed by the customer, the purchase

of a Kistler-Morse® Test Meter is highly

recommended to simplify the installation.

JUNCTION BOX AND FIELD WIRING

EQUIPMENT

Drill motor

#29 drill bit

#8-32, 2-ute, spiral-point tap

Tap handle

Tapping uid

9/64” Allen wrench

#8-32 socket head cap screws

#8 at washers (3/16” inner diameter, 7/16” outer

diameter)

Belden™ 8791, 18 gauge, 3-conductor shielded

interconnect cable or equivalent (for up to

1,000 ft (305m) length)

Belden™ 8618, 16 gauge, 3-conductor shielded

interconnect cable or equivalent (for 1,000 ft

to 2,000 ft (305m to 610m) length)

Conduit and ttings or cable tray

Caulking gun

Sikaex 1A polyurethane sealant or Dow

Corning RTV 738 or RTV 739

CAUTION

Only use Sikaex 1A polyurethane 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 damaged during shipment. If any

item was damaged, contact Kistler-Morse®

immediately for a replacement.

FUNCTIONAL CHECK

Perform a functional check of the Microcells™

before installation to verify they were not damaged

during shipment. Two methods of performing the

check are described below.

TESTING WITH A KISTLER-MORSE®

TEST METER

The Kistler-Morse® Test Meter (Figure 2-1) is

designed specically to test Kistler-Morse®

sensors. If you do not have a test meter,

disregard this section and proceed to TESTING

WITH A DIGITAL MULTIMETER (DMM).

Note

The test meter display indicates a low battery or

behaves erratically when the batteries are weak.

When this occurs, replace the batteries before

testing.

1. See Figure 2-1. Connect the Microcell™

red, white, and black wires to the

corresponding test meter terminals. Place

the Microcell™ on a stable surface.

2. Turn on the power to the test meter and set

the Simulate/Test Switch to the Test

position. Verify the no-load output is

between +25mV and -25mV.

3. Repeat Steps 1 and 2 for each Microcell™.

If the no-load output for any Microcell™ is

outside these specications:

A. Proceed to TESTING WITH A DIGITAL

MULTIMETER (DMM) to determine the

resistance values for that Microcell™, and

B. Contact Kistler-Morse® for assistance

after determining the resistance values

and before proceeding with installation.

CAUTION

Replace Micrcells™ in packing tubes until ready

to install.

Figure 2-1. Kistler-Morse® Test Meter.

TESTING WITH A DIGITAL MULTIMETER (DMM)

Follow this procedure to test the Microcell™ sets

if you do not have a Kistler-Morse® Test Meter or

the readings using the Test Meter were outside the

specications:

1. Set the DMM resistance scale to

accommodate a measured range up to

20,000Ω.

2. Put one 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 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

4. Repeat Steps 2 and 3 for each Microcell™. If

either reading for any Microcell™ is outside

these specications, contact Kistler-Morse® for

assistance before proceeding with installation.

CAUTION

Replace Micrcells™ in packing tubes until ready

to install.

CHAPTER 3. MICROCELL™ INSTALLATION

ON VERTICAL COLUMN LEGS

INTRODUCTION

Follow the instructions in this chapter only if

installing Microcells™ on vertical column legs.

This chapter describes the mounting locations,

installation details, and wiring details for

Microcells™ and junction boxes. Follow all

instructions carefully to ensure proper system

operation.

Note

Do not mix different types of Microcells™ on

one vessel. The three types (3” standardized,

3” non-standardized, and 2” standardized) are

not interchangeable.

MOUNTING LOCATIONS

Follow the procedures below to determine and

mark Microcell™ mounting locations prior to

beginning installation. Following these procedures

will ensure optimal system performance. Consult

Kistler-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” conguration. A Microcell™ set

consists of two rosette arrays (four Microcells™

total) mounted on opposite sides of a support leg,

at the same elevation.

Note

Best performance cannot be achieved if:

1. The leg is too narrow for the horizontal

Microcell™ and its environmental cover, or

2. Installation is on round legs.

See STANDARD PERFORMANCE.

Figure 3-1. Microcell™ Rosette Array for

Best Performance.

STANDARD PERFORMANCE

For standard performance, Microcells™ are

mounted vertically. A Microcell™ set consists of

two (2) Microcells™ mounted on opposite sides of

a support leg, at the same elevation.

Figure 3-2. Vertical Microcell™ for

Standard Performance.

Figure 3-3. Microcell™ Mounting Arrangements on Legs.

HORIZONTAL DISTRIBUTION OF

MICROCELL™ SETS

Microcell™ sets are placed on each support leg.

Refer to Figure 3-3 for the mounting locations for

each shape.

VERTICAL LOCATION OF MICROCELL™

SETS

Note

Microcell™ locations may be adjusted up to

12 in (305mm) vertically to avoid obstacles. If

adjusting locations, maintain the conguration

of the Microcell™ set (i.e., if one Microcell™ in

the set is moved from its ideal location, move

the other(s) as well).

COLUMN LEGS WITHOUT X-BRACES

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. Vertical Location of Microcell™

Sets for Legs Without X-Braces.

COLUMN LEGS WITH X-BRACES

See Figure 3-5.

If the free leg distance is 12 in (305mm) or more, mount

the Microcell™ sets at mid-height of the free leg.

Measure the free leg between the bottom of the bottom

X-brace or horizontal brace and the top of the

foundation.

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