Rice Lake RL1800 Series User manual

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RL1800 SERIES
25712
WeighModuleKit
Installation
Guide

Contents
1. Introduction........................................................................................ 1
2. Mechanical Installation..................................................................... 2
2.1 General Installation Guidelines for Weigh Modules ...................2
2.2 Installing the RL1800 Module.....................................................3
3. Load Cell Wiring ................................................................................ 5
4. Junction Box Connections, Adjustments & Calibration .................... 5
5. Troubleshooting.................................................................................. 6
6. Maintenance and Replacement Parts ............................................... 7
7. Limited Warranty................................................................................ 8
12/98
Copyright © 1998 Rice Lake Weighing Systems.All rights reserved.
Printed in the United States of America.
Specifications subject to change without notice.

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1. Introduction
The RL1800 Series Weigh Modules are designed to accommodate normal vessel
expansion in all directions while still exercising self-checking capabilities. The
center-pivoting,tensionloadingdesignincorporatessphericalwashersandaunique
pivoting trunnion that self-restores to its center position. Vessel leveling and
adjustment can easily be done with the center loading bolt, and the load cell can be
replaced without raising the vessel.
The module is available in two sizes. The small size accepts load cells with
capacities from 250lb to 5,000lb. The large size accepts load cells from 5,000lb to
10,000lb capacities. Both sizes are available in tool steel or stainless steel.
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,andthisbookletismeant
to serve only as an overview for installation of the RL1800
Series Weigh Modules.
Caution

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2. Mechanical Installation
2.1 General Installation Guidelines for Weigh Modules
In circular mounting configurations, the preferred mounting orientation is with the
long axis of the load cell pointing toward the center of the vessel, as illustrated in
Figures 1 and 2 below.
Figures 3 and 4 illustrate other mounting configurations. For rectangular vessels,
the long axis of the load cell should be parallel to the long dimension of the vessel.
In any application where a recurring force is present in one direction, such as in a
conveyorbeltorroller platform, the long axisofthe load cell should alignwiththat
force.
1. Mounting surface for base plate and top plate must be level within ±0.5°
tominimize sideloads andextraneous forces.If themountingsurfacesare
not level, then shims or grout may be used to level the module.
If possible, check level and plumb again when container is fully loaded
becausedeflectionsinlegsandsupportingstructuresmaycauseadditional
side forces which greatly affect accuracy. Reinforcement such as cross
bracing oflegsorothersupportstructuresmaybenecessarytocorrectthis.
Deflection of the module’s top or base plate due to loading should not
exceed ±0.5°.
2. The load on each module should vary by no more than 20%. During
installation, add shims where necessary to verify that the correct load
distribution is achieved on each module.
3. During installation, dummy load cells can be used to prevent overload
damage.However,iftheactualloadcellsareusedduringinstallationofthe
weigh module, extreme care must be
taken to prevent overload damage. A
tankorhopperweighingseveraltonscan
exert huge forces when dropped only a
fraction of an inch.
4. It is crucial that all piping or conduit be
horizontalandflexiblesectionsareclose
to the vessel. If flexible piping is not
used, make sure the distance from the
LEVEL ±0.5°
FLEXIBLE PIPING
J-BOX
Figure 1 Figure 2 Figure 4Figure 3

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vesseltothefirstpipesupportis20-30timesthepipediameter. Insmaller,
lower capacity tanks and hoppers, isolating the resultant forces becomes
extremely critical. When possible, flexible conduit piping should be used
close to the vessel instead of the rigid variety. For details, see our Weigh
Modules & Vessel Weighing Systems manual, PN 43918.
5. Load cells should not be installed in the modules 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,useadummyloadcellwhenweldingtomaintainfinishedheight.
If welding is unavoidable after load cell installation, ground in such a
manner as to prevent welding current from passing through the load cell.
Groundthewelderascloselyaspossibletothepointofwelding.Neverrely
on check rods or piping for grounding.
6. When possible, use only “hermetically sealed” load cells in washdown
applications. “Environmentally protected” load cells are not suitable for
such applications and will be damaged. If tanks and surrounding equip-
ment are frequently steam cleaned, or if the load cell is subjected to direct
washdown, a protective shroud for the weigh module is recommended.
Properdrainage isnecessary sothe weighmodule isnotstandinginwater.
7. Detailed instructions for installing this load cell module follow. When
installing the load cells, use the bolts provided or grade 5 or stronger
hardened bolts. Pay particular attention to the recommended torque
values.Some modulesrequirevery looselytorquedbolts toallow theload
cellsto flexeasily.Others mustbe verytightto preventthe loadcellsfrom
creeping or digging into the module.
2.2 Installing the RL1800 Module
1. Thetypeofinstallation,structureofthevesselsupports,andstrengthofthe
mounting surface govern the method of locating, attaching, and assem-
bling the RL1800 Weigh Module. Carefully consider three areas which
commonly cause accuracy problems:
TOP PLATE
LOAD CELL BOLT
LOCK
WASHER
LOAD
CELL
LOAD CELL
MOUNTING
BLOCK BASE PLATE
JAM NUT
FLAT WASHER
SHOULDER BOLT
CONCAVE WASHER
CONVEX WASHER
LOADING BOLT
UPPER SUPPORT
LOADING BLOCK

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• Arethesupportinglegsadequatelybracedsotheywillnotspreadwhenthe
system is fully loaded?
• Does the supporting structure have the necessary strength to prevent
flexing 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.
3. Assemblethemoduleandloadcellaccordingtothedrawingsshownatthe
beginning of this section. For load cells using 1/2" mounting bolts, torque
to 65 FT-LBS. Torque 3/4" mounting bolts to 295 FT-LBS. Adjust the
centerloadingboltonallmodulestogivethelowestoverallprofileheight,
whileleavingatleasta1/8"gapbetweentheloadcellandtheuppersupport
loading block.
4. Lift and block the vessel to the same height as the assembled modules.
5. Liftone corneror sideof thevessel enoughtoslidethatmoduleintoplace.
6. If the module is being fitted under the leg of a vessel, verify that the leg’s
centerlinepasses through thecenterof the top plate(throughthe center of
the load cell’s load hole).
7. Attachthetopplatebybolting.Donotfullytightenbecauseshimmingmay
be necessary to level.
8. Repeatsteps5,6,and7fortheremainingmodules.The vesselshouldnow
be supported on the modules alone.
9. If necessary, move the vessel to its final position. Verify that there is no
initial misalignment between the base plate and top plate by lifting the
vessel slightly at each support point in turn. This will also indicate if the
load is evenly distributed on all modules. Shim if necessary (this only
applies to systems utilizing more than 3 modules).
10. Attach the base plates to the foundation using anchor bolts for concrete or
byboltingor weldingtoa steelstructure.Verify that thebase plates areno
more than ±0.5°out of level. Shim as necessary.
11. Check that the top plates are no more than ±0.5°out of level. Shim if
necessary and fully tighten the bolts.
12. The load distribution can be more accurately checked by connecting each
loadcellto thejunctionboxandindicatorinturnandmeasuringtheoutput
withavoltmeter.To verify wiring scheme, checktheinstallation manuals
for the junction box and indicator. The variation in load among the cells
should be no more than 20%. Shim if necessary.

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3. Load Cell Wiring
1. Routetheloadcellcablessotheywillnotbedamagedorcut.Cableshould
notberoutednearheatsourcesgreaterthan150°F(66°C). Donotshorten
any load cell cable.The load cell is temperature compensated with the
suppliedlengthofcable.Cuttingthecablewillaffecttemperaturecompen-
sation. Coil excess cable and protect it 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. Connectcablesfor standardRL30000,RL39123, and RL35083loadcells
to the summing board in the junction box according to the guide shown
below and the labels on the terminal strips of the junction box. To verify
the wiring scheme, see the certification shipped with each load cell.
5. Forbetter performance,use positiveand negativeremote senselinesifthe
wiring run from the junction box to the indicator is longer than 25 feet.
LOAD CELL WIRE COLOR FUNCTION
Black
+EXCRed
- EXC
Green +SIG
White - SIG
SHIELDGray or Bare
a
a a
a a a a
aa a
aa
aaa
a a
a
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a a aa a a
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a a a
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DRIP LOOP
4. Junction Box Connections, Adjustments & Calibration
• Refer to junction box manual for trimming details.
• Refer to indicator manual for system calibration guidelines.

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5. Troubleshooting
If system powers up and gives some type of stable digital readout that varies with
the load on the system, system problems are probably caused by factors other than
theloadcells.Alltoooften,loadcellsareblamedforamalfunctioningsystem;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
demonstratesnon-linearityornon-repeatability,seethefollowingchartforpossible
causes and refer to the following list of checks.
1. Checkloadcellmodulefordebrisrestrictingloadcellmovementordebris
between scale and structure. Check overload stops for proper clearance.
2. Checkthattank/vesselandmodulesareplumb,level,andsquareatcritical
areas.
3. Check all piping and conduit for connections that restrict vessel move-
ment.
4. If check rods are used, loosen all connections to finger tight for testing.
5. Check load cell cables for physical or water damage.
6. Check all electrical connections, especially in the junction box.
If the problem still is not found:
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.
Possible Cause
No return to zero Mechanical binding or debris in seals or under load cells; may have lost system
calibration
Non-linearity Thermal expansion or deflection under load causing binding or side load
Non-repeatability Loose load cell mount; drifting caused by moisture, load cell overload or shock
damage; mechanical binding
Lost calibration Out of level or plumb; moisture problem; mechanical binding
Drifting readout Moisture in junction box, cables, or load cell; mechanical binding
Symptom

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6. Maintenance and Replacement Parts
RL1800 Tool Steel Modules
No. Description No. Req. Replacement Part Numbers
250lb-5,000lb 5,000lb-10,000lb
1 Base Plate ....................................1............ 22723 ..................... 22728
2 Load Cell Mounting Block ............1............ 22724 ..................... 22729
3 Lock Washer ................................2............ 15167 ..................... 15181
4 Load Cell Bolt...............................2............ 14765 ..................... 14788
5 Upper Support .............................1............ 22725 ..................... 22730
6 Jam Nut........................................1............ 14664 ..................... 14687
7 Flat Washer ..................................1............ 15173 ..................... 15179
8 Shoulder Bolt................................2............ 22726 ..................... 22726
9,10 Spherical Washer Set ...................1............ 15198 ..................... 15120
11 Hex Head Loading Bolt ................1............ 14759 ..................... 14786
12 Upper Support Mounting Block....1............ 22727 ..................... 22731
13 Load Cell ......................................1............ See Load Cell Selection Guide
RL1800 Stainless Steel Modules
No. Description No. Req. Replacement Part Numbers
1,000lb-4,000lb 5,000lb-10,000lb
1 Base Plate ....................................1............ 22732 ..................... 22739
2 Load Cell Mounting Block ............1............ 22733 ..................... 22740
3 Lock Washer ................................2............ 15168 ..................... 15182
4 Load Cell Bolt...............................2............ 14766 ..................... 14789
5 Upper Support .............................1............ 22734 ..................... 22741
6 Jam Nut........................................1............ 14766 ..................... 14688
7 Flat Washer ..................................1............ 15175 ..................... 15180
8 Shoulder Bolt................................2............ 22735 ..................... 22735
9 Concave Washer ..........................2............ 22736 ..................... 22742
10 Convex Washer Set......................2............ 22737 ..................... 22743
11 Hex Head Loading Bolt ................1............ 14760 ..................... 14787
12 Upper Support Mounting Block....1............ 22738 ..................... 22738
13 Load Cell ......................................1............ See Load Cell Selection Guide
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3
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1
5
6
7
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10
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7. RL1800 Limited Warranty
Rice Lake Weighing Systems (RLWS) warrants that all RLWS brand load cells
properlyinstalledbyaDistributororOriginalEquipmentManufacturer(OEM)will
operate per written specifications. All load cell products are warranted against
defects in materials and workmanship for two (2) years. Products marked as
“waterproof” are warranted against defects in materials and workmanship relating
to moisture ingress.
RLWS warrants that the equipment sold hereunder will conform to the current
writtenspecificationsauthorizedbyRLWS.RLWSwarrantstheequipmentagainst
faulty workmanship and defective materials. If any equipment fails to conform to
these warranties, RLWS will, at its option, repair or replace such goods returned
within the warranty period subject to the following conditions:
•UpondiscoverybyBuyerofsuchnonconformity,RLWSwillbegivenprompt
written notice with a detailed explanation of the alleged deficiencies.
•Examination of such equipment by RLWS confirms that the nonconformity
actually exists, and was not caused by accident, misuse, neglect, alteration,
improperinstallation,improper repairorimproper testing;RLWSshall bethe
sole judge of all alleged non-conformities.
•Such equipment has not been modified, altered, or changed by any person
other than RLWS or its duly authorized repair agents.
•RLWS will have a reasonable time to repair or replace the defective equip-
ment. Buyer is responsible for shipping charges both ways.
•In no event will RLWS be responsible for travel time or on-location repairs,
includingassemblyordisassembly ofequipment,norwillRLWSbe liablefor
the cost of any repairs made by others.
THESEWARRANTIESEXCLUDEALLOTHERWARRANTIES,EXPRESSED
OR IMPLIED, INCLUDING WITHOUT LIMITATION WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. NEI-
THER RLWS NOR DISTRIBUTOR WILL, IN ANY EVENT, BE LIABLE FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES.
RLWS AND BUYER AGREE THAT RLWS’S SOLE AND EXCLUSIVE LI-
ABILITY HEREUNDER IS LIMITED TO REPAIR OR REPLACEMENT OF
SUCH GOODS. IN ACCEPTING THIS WARRANTY, THE BUYER WAIVES
ANY AND ALL OTHER CLAIMS TO WARRANTY.
SHOULDTHESELLERBEOTHERTHANRLWS,THEBUYERAGREESTO
LOOK ONLY TO THE SELLER FOR WARRANTY CLAIMS.
No terms, conditions, understanding, or agreements purporting to modify the terms of
thiswarrantyshallhaveanylegaleffectunlessmadeinwritingandsignedbyacorporate
officer of RLWS and the Buyer.
©1998 Rice Lake Weighing Systems, Inc. Rice Lake, WI USA. All Rights Reserved.
RICE LAKE WEIGHING SYSTEMS
230 WEST COLEMAN STREET • RICE LAKE, WISCONSIN 54868 • USA