Wilmar International Limited

UNMANNED WEIGHBRIDGE PROJECT

2017

Hardware
Installation & Cabling Standard Guide
For Malaysia

Version 1.0

20 December 2018

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Document Control Information
Document Information

Document Name Hardware Installation & Cabling Standard Guide

Project Name Unmanned Weighbridge Project

Document Author Freddy Halim

Document Version 1.0

Document Status Final

Date Released 20 December 2018

Approval Released Hidriyal Fadly

Document Edit History

Version Date Name Department Comments

Initial Creation from Indonesia Standard
0.1 26 June 2018 Tommy M IT
Installation Guide V4.0
Revision
-. Wiring Diagram Flow

-. Power Distribution Diagram

-. Weighbridge Wiring Diagram – Data
-. Weighbridge Wiring Diagram – Controller
Board Wiring
1.0 20 Dec 2018 Freddy H MIS - HIC
Revise Diagram Electrical Panel:
- Outgoing UPS1 and UPS2
- Replace material covers

Revise Detail UWB Kiosk:

- PSU single to double output
- PSU to Android box

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 Index
I. Power Distribution Over View.
1. Wiring.
1.1. Weighbridge Wiring Diagram.
1.1.1. Power Distribution Diagram.
1.2. Weighbridge Wiring Diagram – Data.
1.3. Weighbridge Wiring Diagram – Controller Board Wiring.
1.4. Weighbridge Wiring Diagram – UWB KiosK Wiring.
1.4.1. CTRL 1 WB IN.
1.4.2. CTRL 2 MIDDLE.
1.4.3. CTRL 3 WB OUT.
1.5. UWB KiosK Detail – 1.
1.5.1. KiosK Diagram.
1.5.2. Specification of Materials.
1.5.3. UWB KiosK Detail – 2.
2. Main Panel.
2.1. Panel Over View.
2.2. Front, Side, and Inside View.
2.3. Specification of Materials.
2.4. Installation and Wiring.
2.4.1. Installation Material Main Panel.
2.4.2. Diagram Main Panel.
3. Mini Electrical Panel Registration Room.
3.1. Front, Side, and Inside View Mini Electrical Panel.
3.2. Wiring Mini Electrical Panel Registration Room.
3.3. Specification of Materials.
4. Barrier Gate.
4.1. Barrier Gate Over View.
4.2. Specification of Materials.
4.3. Installation and Wiring.
5. Traffic Light.
5.1. Traffic Light Over View.
5.2. Specification of Materials.
5.3. Installation and Wiring.
6. RFID Pole.
6.1. Single RFID Pole.
6.1.1. Single RFID Pole Over View.
6.1.2. Specification of Materials.
6.1.3. Installation and Wiring.
6.2. Top Mid Double RFID Pole.
6.2.1. Top Mid Double RFID Pole Over View.
6.2.2. Specification of Materials.
6.2.3. Installation and Wiring.
7. Running Text (OPTIONAL).
7.1. Running Text Overview.
7.1.1. Weighing Result.
7.1.2. Specification of Materials Weighing Result.
7.2. Queing List Running Text (OPTIONAL).
7.2.1. Specification of Materials Queing List Running Text.
7.2.2. Installation and Wiring.
II. Specification and Accessories Cable.
1. Specification and Accessories Cable.
III. Marking / Identification Cable.
1. Coding and Numbering.
2. Data Cable Tanging Code.

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I. Power Distribution Over View.
1. Wiring.
1.1. Weighbridge Wiring Diagram.
1.1.1. Power Distribution Diagram.

Power Distribution Diagram

Main Panel
Inside UWB KiosK: Ctrl 1 Ctrl 2 Ctrl 3 UWB

On / Off CB 1 On / Off CB 2 On / Off CB 3

Fan, Monitor LED 19" Dual PSU 12 V & 5V (1) Dual PSU 12 V & 5V (2)

Server /
Wallmount Rack
Stecker MCB 1 MCB 2 MCB 3 MCB 4 MCB 5 Android TV Box
4 Hole BG 1 BG 0 TL 1 TL 0 Ctrl 1

From UPS 6000 / 3000 / 1500 VA

From UPS 3000 / 1500 VA

Legend:
No Color Description Cable Type
1 AC Power from UPS to Terminal KiosK NYYHY 3*1.5 mm
2 AC Power from UPS to Server Rack, CB, and Android TV Box NYYHY 3*1.5 mm
3 AC Power Traffic Light NYYHY 3*1.5 mm
4 DC Power Relay Traffic Light Single Cable AWG22 (Multiple Core)
5 DC Power Alarm NYYHY 3*1.5 mm
6 AC Power Barrier Gate and Blitz Lamp NYYHY 3*1.5 mm
7 DC Power Supply CB Single Cable AWG22 (Multiple Core)

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 1.2. Weighbridge Wiring Diagram – Data.
Weighbridge Wiring Diagram - Data

LAN Surge
Protector
Wallmount /
Server Rack
LAN Surge
Protector
Android TV
Box LAN Surge
Protector

CB 1 CB 2 CB 3

USR USR
TCPIP TCPIP

UPS 1 UPS 2

Legend:
No Color Description Cable Type
01. Controller Board Cable to Switch/Hub UTP CAT 6
02. CCTV Cable to Switch/Hub UTP CAT 6
03. Serial Cable UPS to USR/TCP Converter RS232 Serial Cable
04. Android TV Box to Switch/Hub UTP CAT 6
05. USR/TCP Converter to Switch/Hub UTP CAT 6
06. Lan Surge Protector to Grounding NYYHY 1*1.5 mm

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 1.3. Weighbridge Wiring Diagram – Controller Board Wiring.
Weighbridge Wiring Diagram - Controller Board Wiring

Ctrl 1 Ctrl 2 Ctrl 3

Input 1 Output 1 Input 1 Output 1 Input 1 Output 1

Input 2 Output 2 Input 2 Output 2 Input 2 Output 2
Input 3 Output 3 Input 3 Output 3 Input 3 Output 3

WG 1 WG 1 WG 1
WG 2 WG 2 WG 2

Legend:
No Color Description Cable Type
01. Barrier Gate Open/Close Status Signal Cable AWG22 (Multiple Core)
02. Infrared Sensor Signal Cable AWG22 (Multiple Core)
03. Barrier Gate Open Trigger Signal Cable AWG22 (Multiple Core)
04. Traffic Light Relay Control (Red/Green Light) Signal Cable AWG22 (Multiple Core)
05. Alarm Signal Cable AWG22 (Multiple Core)
06. Wiegand Reader Signal Cable AWG22 (Multiple Core)

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 1.4. Weighbridge Wiring Diagram – UWB KiosK Wiring.
1.4.1. CTRL 1 WB IN.

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 [Back]
1.4.2. CTRL 2 MIDDLE.

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 1.4.3. CTRL 3 WB OUT.

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 1.5. UWB KiosK Detail – 1.
1.5.1. KiosK Diagram.

1.5.2. Specification of Materials.

No Des Materials Volume Brand
01. UWB Box. 1 Pcs Custom
02. IP Camera. 1 Pcs
03. Logitech Z120 2.0 Stereo Speaker. 1 Pcs Logitech
04. Alarm/Mini Siren. 1 Pcs JYACAM
05 Monitor LED LG 19 Inch 19M38H HDMI Wide Screen. 1 Pcs LG
06. X96 Mini Android TV Box. 1 Pcs China
07. RFID Reader – KR 201M. 1 Pcs ZKTeco
08. Push Button. 1 Pcs
09. UWB Controller Board. 3 Pcs UWB
10. PSU Dual Output 25A (5V 3-10A - 12V 10-15A). 2 Pcs Custom
11. MCB 4A. 5 Pcs Schneider
12. Surge Protector 3 Holes. 1 Pcs
13. Switch ON OFF. 3 Pcs
14. Duct/Tray cable Size 25x25mm. 2 Pcs
15. HDMI Cable. 1 Pcs
Note: See Capture #1 for Wiring and part number 14 (Switch On/Off).

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 1.5.3. UWB KiosK Detail – 2.

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 2. Main Panel.
2.1. Panel Over View.

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 2.2. Front, Side, and Inside View.

2.3. Specification of Materials.

No Description Materials Quantity Brand Remark
Digital V-A-Hz Meter 3 in 1
-. Volt Meter 80-300V
01 3 Pcs Din Rail
-. Ammeter 0-100 Ampere.
-. Frequency Hertz (Hz) model MCB
02 MCB - 2 Phase 25 A 1 Pcs Schneider Power In
03 MCB - 1 Phase 10 A 2 Pcs Schneider For UPS
04 Fuse Link 10*38 10A 1 Pcs CIC
05 Fuse Link 10*38 6A 1 Pcs CIC
06 Arrester V25-B/1-2P 1 Pcs Schneider
07 ELCB - 6A 1 Phase - 30mA 4 Pcs Schneider Power Out
08 Selector Switch - XB4BD33 2 Pcs Schneider
Pilot Lamp CL-523R 22mm Red 230
09 1 Pcs Schneider
VAC
Pilot Lamp CL-523G 22mm Green
10 4 Pcs Schneider
230 VAC
11 Name Plate 1 Lot
Accessories (Busbar N+G, Cable Lug,
12 1 Lot
Cable Tray)
Panel Box (H*W*D): 600*400*200
13 1 Pcs
mm
Acrylic color same
14 Cover Acrylic 1 Pcs Custom
with panel Box

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 2.4 Installation and Wiring.
2.4.1. Installation Material Main Panel.

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 2.4.2. Diagram Main Panel.

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 3. Mini Electrical Panel Registration Room.
3.1. Front, Side, and Inside View Mini Electrical Panel.

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 3.2. Diagram Mini Panel.

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 3.3. Wiring Mini Electrical Panel Registration Room.

3.4. Specification of Materials.

No Description Materials Quantity Brand Remark
Digital V-A-Hz Meter 3 in 1.
-. Volt Meter 80-300V.
01 2 Pcs Din Rail
-. Ammeter 0-100 Ampere.
-. Frequency Hertz (Hz) model MCB.
02 Arrester V25-B/1-2P. 1 Pcs Schneider
03 Fuse Link 10*38 6A. 1 Pcs CIC
04 Fuse Link 10*38 10A. 1 Pcs CIC
05 MCB 25A 2P 30MA. 1 Pcs Schneider Power In
06 MCB - 1 Phase 10 A. 1 Pcs Schneider For UPS
07 ELCB - 6A. 2 Pcs Schneider Power Out
08 Pilot Lamp CL-523R 22mm Red 230 VAC. 1 Pcs Schneider
Pilot Lamp CL-523G 22mm Green 230
09 2 Pcs Schneider
VAC.
10 Selector Switch - XB4BD33. 1 Pcs Schneider
11 Name Plate. 1 Lot
Accessories (Busbar N+G, Cable Lug, Cable
12 1 Lot
Tray).
13 Panel Box (H*W*D): 400*300*200 mm. 1 Pcs
Acrylic color same
14 Cover Acrylic. 1 Pcs Custom
with panel Box

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 4. Barrier Gate.
4.1. Barrier Gate Over View.

4.2. Specification of Materials.

No. Des. Materials Volume Brand
01. Barrier Gate 1 Pcs BS-3306AC
02. Duct/Tray cable Size 25*25mm 1 Pcs
03. Railing Device Size 35*150mm 1 Pcs
04. Hard Switch 6 Pins 1 Pcs Rocket Switch
05. VLD-12/24 Loop Detector 1 Pcs JUTAI/LD-100

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 4.3. Installation and Wiring.

Power Motor output1 output2 LIGHT Limit PROTECT Button

L N L1 com L2 no1 com nc1 no2 com nc2 dc+ dc- com light light OL com CL PT INFRD GN STP opn cls psh v+
1 2 1 2 1

L
12 +V
N
Output 1
M GND

Controller Board
Open Limit Status Close Limit Status

PE COM OUTPUT 1 (CB)

12V SMPS

Switch Button
INPUT 2
Controller
Board
VLD
1 2 6
5
7
4
3 4 8
L N 3
9
5 6 2
10
N 1 11
L

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 5. Traffic Light.
5.1. Traffic Light Over View.

5.2. Specification of Materials.

No. Des. Materials Volume Brand
INDOTRAFIC Traffic Light LED Red
01. 1 Pcs INDOTRAFIC
+Green
02. Relay 12VDC/10A + Socket 1 Pcs Omron
03. Terminal Block Krustin Type (White) 1 Pcs Krustin
04. Diode IN4002-2A 1 Pcs

5.3. Installation and Wiring.

MCB KIOSK

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 6. RFID Pole.
6.1. Single RFID Pole.
6.1.1. Single RFID Pole Over View.

6.1.2. Specification of Materials.

No. Des. Materials Volume Brand
01. RFID Pole 165cm. 1 Pcs Custom.
Camera HikVision DS-2CD2B25FWD-
02. 1 Pcs HIKVISION.
IZX.
03. Alarm Siren. 1 Pcs JYACAM.
04. RFID Reader KR. 1 Pcs Zkteco.
05. Push button 2 Pin SPST. 1 Pcs Local Custom.

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 6.1.3. Installation and Wiring.

6.2. Top Mid Double RFID Pole.

6.2.1. Top Mid Double RFID Pole Over View.

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 6.2.2. Specification of Materials.
No. Des. Materials Volume Brand
01. RFID Pole 190 cm. 1 Pcs Custom.
Camera HikVision DS-2CD2B25FWD-
02. 1 Pcs HIKVISION.
IZX.
03. Alarm Siren. 1 Pcs JYACAM.
04. RFID Reader KR. 2 Pcs Zkteco.
05. Push button 2 Pin SPST. 1 Pcs Local Custom.

6.2.3. Installation and Wiring.

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 7. Running Text (OPTIONAL).
7.1. Running Text Overview.
7.1.1. Weighing Result.

Unbox:

7.1.2. Specification of Materials Weighing Result.

No. Des. Materials Volume Brand

01. 16x32 (3*1 Plat) Led Running Text. 3 Units Runwell
02. Running text Control board. 1 Unit Runwell
Aluminium Composite Panel Box Mat.
03. 1 Pcs
Aluminium.

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 7.2. Queing List Running Text (OPTIONAL).

7.2.1. Specification of Materials Queing List Running Text.

No. Des. Materials Volume Brand
01. 16*32 (3*1 Plat) Led Running Text. 5 Units Runwell
02. Running text Control board. 1 Unit Runwell
Aluminium Composite Panel Box Mat.
03. 1 Pcs
Aluminium.

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 7.2.2. Installation and Wiring.

PSU 5V 20A
V+ CONTROLER
To LED
Display
RT 1 V-
A B A B
V+ V- gnd N L

PSU 5V 20A
V+ CONTROLER
To LED
Display
RT 2 V-
A B A B
V+ V- gnd N L

PSU 5V 20A
V+ CONTROLER
To LED
Display
RT 3 V-
A B A B
V+ V- gnd N L

PSU 5V 20A
V+ CONTROLER
To LED
Display
RT 4 V-
A B A B
V+ V- gnd N L

PSU 5V 20A
V+ CONTROLER
To LED
Display
RT 5 V-
A B A B
V+ V- gnd N L

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II. Specification and Accessories Cable.
1. Cable and Accessories Over View.
Cable Single Phase Outgoing

Cable PSU and RS Data

Cable VLD

Specification:Model:JTHT-11 size: 0.5m*2 Temperature:-65~+200℃ One roll length: 305m Material: Silicone rubber and stranded silver plated

copper wire Color: Red and Black Characters：It has excellent corrosion resistance,oil resistance, strong acid, strong alkali resistance, strong

oxidant, etc; With excellent electrical insulation properties, resistant to high voltage, small loss at high frequency, no mo isture absorption,

insulation resistance; It has excellent flame resistance, aging resistance, long service life.

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Data Cable

Busbar

Cable Lug

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III. Marking / Identification Cable.
1. Coding and Numbering.
CODE
NAMING DESCRIPTION
UPS : Uninterruptible Power Supply (UPS)
KS : UWB KIOSK
DP : TCS Dispencer Box (Controller Panel Box for Traffic Control)
BGI : Barrier Gate In (Entry Gate)
BGO : Barrier Gate Out (Exit Gate)
TLI : Traffic Light In (Entry Gate)
TLO : Traffic Light Out (Exit Gate)
PSU : Power Supply
SVR : Server Rack/Wall mount Rack
CTRL : Controller Board

CODE NUMBERING
1 : Device Number 1
2 : Device Number 2
3 : Device Number 3
4 : Device Number 4
5 : Device Number 5
6 : Device Number 6
Etc
Example :

UPS1-KS1
Fist Code means from source device, Second code means to destination device
the code it's read: "From UPS Number 1 To UWB Kiosk Number 1"

2. Data Cable Tanging Code:

CODE Description
CTRL : Controller Board
C : IP Camera

First code means device source, second code means Weight bridge number, third code means device number

Example :
CTRL-WB1-C1 : Controller Weighbridge 1 for entry gate
CTRL-WB1-C2 : Controller Weighbridge 1 for Kiosk
CTRL-WB1-C3 : Controller Weighbridge 1 for exit gate
C-WB1-01 : Camera Weighbridge 1 for entry gate
C-WB1-02 : Camera Weighbridge 1 for Kiosk
C-WB1-03 : Camera Weighbridge 1 for exit gate

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