Rice Lake RL1600 User manual

11
16952
RL1600
Weigh Module Kit
Installation
Guide

Contents
1. Introduction ............................................................................ 1
2. Mechanical Installation.......................................................... 2
2.1 General Installation Guidelines for Weigh Modules....................2
2.2 Installing the RL1600..................................................................3
3. Load Cell Wiring..................................................................... 5
4. Junction Box Connections, Adjustments & Calibration..... 6
5. Troubleshooting ..................................................................... 6
6. Maintenance and Replacement Parts................................... 8
7. RL1600 Limited Warranty.................................................... 10
© 2004 Rice Lake Weighing Systems. All rights reserved.
Printed in the United States ofAmerica.
Specifications subject to change without notice.
02/04

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1. Introduction
The RL1600 Weigh Module Kit provides an extremely accurate method for
weighingmediumandlarge capacity tanks,hoppers,bins,and reactors.Thedesign
uses a double-ended shear beam load cell (700Ωbridge) and transmits the load
through a clamping load plate to the center of the load cell. This design is very
effective in providing for thermal expansion/contraction with little friction.
In the majority of applications, the modules 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.
TheRL1600isavailableincastiron,mildsteel,or
stainless steel in sizes from 1,000-75,000lb. The
module is compatible with RL75016, RL75016
StainlessSteel,RL75016HE,Sensortronics65016
and Sensortronics 65016W Stainless Steel load
cells in capacities from 1,000 lb to 75,000 lb.
Thermal
Expansion
Authorized distributors and their employees can
view or download this manual from the Rice Lake
Weighing Systems distributor site at www.rlws.com.
The installation should be planned by a qualified structural
engineer.Eachinstallationisunique,andthismanualismeant
to serve only as a general guideline for installation.
Caution

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2. Mechanical Installation
2.1 General Installation Guidelines for Weigh Modules
1. Themountingsurfaceforthebaseandtopplatemustbelevel.Afterinstallation,
the top and bottom plates must be level within ±0.5°. If the mounting surfaces
are not level, then shims and or grout may be used to level the mount.
If possible, check that the module is level when the vessel is fully loaded
because excessive deflections in legs and supporting structures may cause
additionalside forces which greatly affect accuracy. Deflectionof the mount’s
top or base plate due to loading should not exceed ±.5°. Reinforcement of legs
or other support structures may be necessary to correct this. Vessels with long
legsshouldhavecrossbracingappliedbetweenadjacentlegstokeepthemfrom
spreading under load.
2. Compression mounting systems use three, four, or more mounts. More than
eight-module systems should be avoided as even weight distribution becomes
extremelydifficulttoachieve.Theloadoneachmoduleshouldvarybynomore
than 20%. During installation, add shims where necessary to achieve correct
load distribution.
3. Iftheactualloadcellsareusedduringinstallationoftheweighmodule,extreme
care must be taken to prevent overload damage. A tank or hopper weighing
several tons can exert huge forces when dropped only a fraction of an inch.
Dummy load cells can be used during installation.
4. It is crucial that all piping or conduit be hori-
zontal and flexible. If flexible piping is not
used,makesurethedistancefromthevesselto
the first pipe support is 20-30 times the pipe
diameter.In smaller, lower capacity tanks and
hoppers,isolatingtheresultantforcesbecomes
extremely critical. For details, see our Weigh
Modules & Vessel Weighing Systems manual,
PN 43918.
5. Load cells should not be installed in the mod-
ules until all welding is completed. The heat generated from welding current
passing through a load cell can damage the adhesive holding the strain gauge
to the body. If possible, use a dummy load cell when welding to maintain
finished height. If welding is unavoidable after load cell installation, connect
the ground in such a way that the current does not flow through the load cell.
Forexample,if weldingonthe moduletopplate, thegroundmust beconnected
to the vessel, not to the mount base or support structure. Also, protect the load
cell and cable from weld splatter.
6. Whenpossible,useonly“hermeticallysealed”loadcellsinwashdownapplica-
tions. “Environmentally protected” load cells are not suitable for such
applications and will be damaged. If tanks and surrounding equipment are
LEVEL ±0.5°
FLEXIBLE PIPING
J-BOX

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frequently steam cleaned or if the load cell is subjected to direct washdown,
aprotective shroud forthe weigh moduleis recommended. Properdrainage is
necessary so the weighing assembly is not standing in water.
7. All support points should be equally stiff so that they deflect by the same
amount as the vessel is loaded.
2.2 Installing the RL1600
1. The type of installation and strength of the mounting surface governs the
methodoflocating,attaching,andassemblingtheRL1600assembly.Carefully
consider three areas that commonly cause accuracy problems:
•Are the supporting legs adequately braced so they will not spread when the
system is fully loaded?
•Does the supporting structure have the necessary strength to prevent
excessive deflection when the system is fully loaded?
•Is there attached equipment such as skirting, venting, or piping which is
likely to cause binding or lack of flexibility?
2. Determine where to position the module and in which direction it should be
oriented.TheRL1600isdesignedtoallowforlateralmovementinthedirection
perpendicular to the longitudinal axis of the load cell. These weigh modules
shouldbe oriented so that the movement dueto thermal expansion/contraction
is perpendicular to the longitudinal axis. Sample mounting orientations to
accommodate expansion for different vessel shapes are as follows:
Load Plate and Clamp
Cotter Pin
Pin
Clamp Bolt
Lockwasher
Load Cell
Tank Mount Base
Flat Washer

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3. Assemble the modules by attaching the load cell to the load plate and clamp
usingthelockwashersandclampscrews. Then,inserttheloadpinsthrough the
base plate and load cell. Secure the load pins with washers and cotter pins.
Note: The arrow on the load cell should point in the direction of the load.
4. Lift and block the vessel to the same height as the assembled modules.
5. Remove the block from one support point and slide that module into position.
6. As the module is being fitted under the leg of the vessel, verify that the leg’s
centerline passesthrough the centerof the loadplate (through the center ofthe
load cell).
7. Lower the corner or side of the vessel carefully onto the load plate.
8. With the load plate positioned approximately level, mark holes for attaching
the load plate to the vessel’s mounting surface. Make holes and attach the load
plate loosely to vessel with suitable fasteners.
9. Repeat steps 5-8 for the weigh modules at the remaining corners or sides.
10. Verify that there is no initial misalignment between the tank mount base and
load plate and clamp and that the load plate and clamp is centered with respect
to the load cell. Also, verify that the load cell, clamp, and load cell assembly is
centered in the base plate. Relocate if necessary.
11. Attach the base plates to the foundation using suitable anchors for concrete or
byboltingorwelding toasteelstructure orsubplate.Verify that thebaseplates
are no more than ±.5°out of level. Shim as necessary.
12. Check that the top plates are no more than ±.5°out or level. Shim if necessary
and fully tighten mounting bolts.
13. IMPORTANT: Check that each pin of each module has approximately equal
weightapplied. Ifa pin isloose, shim betweenthe baseplate and foundationas
necessary.
14. If dummy cells are used, replace with the load cells. Refer to step 3.
15. To achieve equal load distribution, final height adjustments can be made with
shims between the load plate and clamp and the vessel. The variation in load
among the cells should be no more than 20%. The load distribution can be
checked accurately by exciting each load cell in turn and measuring the output
with a voltmeter.
Caution
Use extreme care when lowering the vessel. The
force of a vessel weighing several tons can dam-
agea load cellif dropped only a fraction of an inch.

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3. Load Cell Wiring
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.Cuttingthecablewillaffecttemperaturecompensation.Coil andprotect
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. Attach
load cell cable to the dead structure, not the vessel.
3. 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.
4. ConnectcablesforstandardRL75016,RL75016StainlessSteel,RL75016HE,
Sensortronics 65016 and Sensortronics 65016W Stainless Steel load cells to
thesummingboardinthejunctionboxaccordingtotheguideshownbelowand
the labels on the terminal strips of the junction box. To verify the wiring
scheme, see the certification shipped with each load cell.
5. For better performance, use positive and negative remote sense lines if the
wiring running from the junction box to the indicator is longer than 25 feet.
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4. Junction Box Connections, Adjustments & Calibration
1. Refer to the Junction Box manual for trimming details.
2. Refer to the indicator manual for system calibration details.
5. Troubleshooting
If the system powers up and gives some type of stable digital readout that varies
with the load on the system, any system problems are probably caused by factors
other than the load cells. The load cells are often blamed for a malfunctioning
system, but 90% of the time, the problem lies elsewhere. Look for mechanical
causes for your problem first.
If the system can be calibrated but doesn’t return to zero, loses calibration, or
demonstrates non-linearity or non-repeatability, see the following chart for pos-
sible causes and do the following checks.
1. Check weigh module for debris restricting load cell movement or debris
between scale and structure.
2. Check that tank/vessel and modules are plumb, level, and square at the
critical areas.
3. Check all piping and conduit for connections which restrict vessel
movement.
4. If check rods are used, loosen all connections to finger tight only for
testing.
5. Check load cell cables for physical or water damage.
6. Check all electrical connections, especially in the junction box.
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7. Check possible indicator malfunction by using a load cell simulator to
input a known good signal into the indicator.
8. 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 after all these checks the problem still cannot be isolated, reconnect all but one
loadcell.Replacetheloadcellwithaloadcellsimulator.Alternatesothateachload
cellisindividuallydisconnectedandreplacedwithasimulator.Ifthereisaproblem
with a particular load cell, the symptom should disappear when that load cell is
disconnected and replaced with the simulator.

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6. Maintenance and Replacement Parts
RL1600 CAST IRON MODULES
No. Description Reqd. Replacement Part Numbers
A* B*
1... Weigh Module Base ................... 1 ............ 18439......... 18441
2... Washer ....................................... 4 ............ 15165......... 15179
3... Load Plate and Clamp................ 1 ............ 18443......... 18445
4... Cotter Pin.................................... 4 ............ 15232......... 15237
5... Pin............................................... 2 ............ 18449......... 18448
6... Lock Washer............................... 2 ............ 15167......... 15181
7... Clamp Bolt .................................. 2 ............ 15080......... 15099
8... Load Cell .................................... see Load Cell Product Selection Guide
*A-size mounts use load cells with capacities from 1,000-5,000 lb.
*B-size mounts use load cells with capacities from 10,000-25,000 lb.
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