Rice Lake RL1800 Series User manual

RL1800 Series
Weigh Module Kit
Installation Manual
PN 25712 Rev B
December 5, 2018

An ISO 9001 registered company
© Rice Lake Weighing Systems. All rights reserved.
Rice Lake Weighing Systems® is a registered trademark of
Rice Lake Weighing Systems.
All other brand or product names within this publication are trademarks or registered
trademarks of their respective companies.
All information contained within this publication is, to the best of our knowledge, complete and
accurate at the time of publication. Rice Lake Weighing Systems reserves the right to make
changes to the technology, features, specifications and design of the equipment without notice.
The most current version of this publication, software, firmware and all other product updates
can be found on our website:
www.ricelake.com

Contents
© Rice Lake Weighing Systems ● All Rights Reserved i
Contents
Technical training seminars are available through Rice Lake Weighing Systems.
Course descriptions and dates can be viewed at www.ricelake.com/training
or obtained by calling 715-234-9171 and asking for the training department.
1.0 Introduction ................................................................................ 1
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 Mechanical Installation.............................................................. 3
2.1 Installation Guidelines for Weigh Modules. . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Installing the RL1800 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.0 Load Cell Wiring......................................................................... 7
3.1 Junction Box Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.0 Troubleshooting......................................................................... 8
5.0 Repair Parts................................................................................ 9

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Rice Lake continually offers web-based video training on a growing selection
of product-related topics at no cost. Visit www.ricelake.com/webinars.

Introduction
© Rice Lake Weighing Systems ● All Rights Reserved 1
1.0 Introduction
The RL1800 Series Weigh Module is designed to accommodate normal vessel expansion
in all directions while still exercising self-checking capabilities. The center-pivoting,
tension-loading design incorporates spherical washers and a unique pivoting trunnion that
self-restores to its center position. Vessel leveling and adjusting can easily be done with
the center loading bolt, and the load cell can be replaced without raising the vessel.
Manuals can be viewed or downloaded from the Rice Lake Weighing
Systems website at www.ricelake.com/manuals
Warranty information can be found at www.ricelake.com/warranties
1.1 Overview
The module is available in two sizes:
• Small – accepts load cells with capacities from 250 lb to 5,000 lb SE (small envelope
load cells)
• Large – accepts load cells with capacities from 5,000 lb to 10,000 lb
Both sizes are available in tool steel or stainless steel.
Standard Features of the RL1800 Series Weigh Module include:
• Capacities (per module): 250-10,000 lb (113.4-4,535.9 kg)
• NTEP Certified cells in 1,000-10,000 lb (453.6-4,535.9 kg) capacities
• Zinc-plated mild steel construction
• Center-pivoted, tension-loading design
• Self-checking, multi-directional movement
• Load is suspended on high-strength bolt instead of wire rope
• Design incorporates spherical washers for self-centering

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1.2 Safety
Safety Signal Definitions:
Indicates an imminently hazardous situation that, if not avoided, will
result in death or serious injury. Includes hazards that are exposed when
guards are removed.
Indicates a potentially hazardous situation that, if not avoided could
result in serious injury or death. Includes hazards that are exposed when
guards are removed.
Indicates a potentially hazardous situation that, if not avoided, could
result in minor or moderate injury.
Indicates information about procedures that, if not observed, could
result in damage to equipment or corruption to and loss of data.
General Safety
Do not operate or work on this equipment unless this manual has been
read and all instructions are understood. Contact any Rice Lake Weighing
Systems dealer for replacement manuals.
Failure to heed may result in serious injury or death.
Do not allow minors or inexperienced persons to install this unit.
Do not use for purposes other than weight taking.
Do not place fingers into slots or possible pinch points.
Do not use any load bearing component that is worn beyond 5% of the original dimension.
Do not use this product if any of the components are cracked.
Do not exceed the rated load limit of the unit.
Do not make alterations or modifications to the unit.
Do not remove or obscure warning labels.
Keep hands, feet and loose clothing away from moving parts.
DANGER
WARNING
CAUTION
IMPORTANT
WARNING

Mechanical Installation
© Rice Lake Weighing Systems ● All Rights Reserved 3
2.0 Mechanical Installation
The installation should be planned by a qualified structural engineer.
Each installation is unique, and this booklet is meant to serve only as an
overview for installation of the RL1800 Series Weigh Modules.
2.1 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.
Figure 2-1. Circular Mounting
For rectangular vessels, the long axis of the load cell should be parallel to the long
dimension of the vessel.
Figure 2-2. Rectangular Mounting
In any application where a recurring force is present in one direction, such as in a
conveyor belt or roller platform, the long axis of the load cell should align with that force.
Mounting surface for base plate and top plate must be level within ± 0.5to minimize side
loads and extraneous forces.
• If the mounting surfaces are not level, shims or grout may be used to level the
module.
• If possible, check level and plumb again when container is fully loaded; the
deflections in legs and supporting structures may cause additional side forces
which greatly affect accuracy.
• Reinforcement, such as cross bracing of legs or other support structures, may be
needed to correct this.
• Deflections of modules top or base plate due to loading should not exceed ± 0.5
CAUTION

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The load on each module should not more than 20%. During installation, add shims where
needed to verify the correct load distribution is achieved on each module.
During installation, dummy load cells can be used to prevent overload damage.
If the actual load cells are used during installation of the weigh module,
extreme care must be taken to prevent overload damage. A tank or
hopper weighing several tons can exert extreme forces when dropped
only a fraction of an inch.
All piping or conduit must be horizontal and flexible sections close to the vessel.
• If flexible piping is not used, make sure the distance from the vessel to the first
pipe support is 20-30 times the pipe diameter.
• In smaller, lower capacity tanks and hoppers, isolating the resultant forces
becomes extremely critical.
• If possible, use flexible conduit piping close to the vessel instead of the rigid
variety.
• See the Weigh Modules & Vessel Weighing Systems manual (PN 22054) for more
information.
Figure 2-3. Piping and Conduit
Load cells should not be installed in modules until 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, ground in such a manner as to
prevent welding current from passing through the load cell.
• Ground the welder as closely as possible to the point of welding.
Never rely on check rods or piping for grounding.
When possible, use hermetically sealed load cells in washdown applications.
• Environmentally protected load cells are not suitable for such applications and will
be damaged.
IMPORTANT
Flexible Piping
Junction Box
Level ± 0.5°
IMPORTANT
IMPORTANT

Mechanical Installation
© Rice Lake Weighing Systems ● All Rights Reserved 5
• If tanks and surrounding equipment are frequently steam cleaned, or if the load
cell is subjected to direct washdown, a protective shroud for the weigh module is
recommended.
• Proper drainage is necessary so the weigh module is not standing in water.
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 modules require very loosely torqued bolts to allow the load cells to flex
easily.
• Some modules must be very tight to prevent the load cells from creeping or
digging into the module.
Figure 2-4. Parts of the RL1800 Module
2.2 Installing the RL1800 Module
The type of installation, structure of the vessel supports, and strength of the mounting
surface govern the method of locating, attaching, and assembling the RL1800 Weigh
Module. Carefully consider three areas which 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 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?
To install the load cells, use the following directions:
1. Determine where to position the module and which direction it should be oriented.
2. Assemble the module and load cell (Figure 2-4).
• Torque 1/2'' mounting bolts to 65 ft-lb
• Torque 3/4'' mounting bolts to 175 ft-lb
3. Adjust center loading bolt on all modules to give the lowest overall profile height,
leaving at least 1/8'' gap between the load cell and the upper support loading block.
Top Plate
Load Cell Bolt and Lock
Washer
Load Cell
Load Cell
Mounting Block
Base Plate
Loading Bolt
Flat Washer
Upper Support
Loading Block
Convex
Washer
Concave
Washer
Shoulder
Bolt
Jam Nut

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4. Lift and block the vessel to the same height as the assembled modules.
5. Lift one corner or side of the vessel enough to slide that module into place.
6. If the module is being fitted under the leg of a vessel, verify the leg’s center line
passes through the center of the top plate (and center of the load cell’s load hole).
7. Secure top plate by bolting, do not fully tighten, shimming may be needed to level.
8. Repeat steps 5, 6 and 7 for the remaining modules. The vessel is now supported on
the modules only.
9. Move the vessel to its final position, if necessary.
10. 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 also indicates if the load
is evenly distributed on all modules.
11. Shim as needed (this only applies to systems utilizing more than 3 modules).
12. Attach the base plates to the foundation using anchor bolts for concrete or by
bolting or welding to a steel structure.
13. Verify that the base plates are no more than ±0.5out of level. Shim if needed.
14. Check that the top plates are no more than ±0.5out of level. Shim if needed.
15. Tighten the bolts.
16. Check the load distribution by connecting each load cell to the junction box and
indicator in turn and measuring the output with a voltmeter. To verify wiring scheme,
check the installation manuals for the junction box and indicator. The variation in
load among the cells should be no more than 20%. Shim if needed.

Load Cell Wiring
© Rice Lake Weighing Systems ● All Rights Reserved 7
3.0 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 (66C).
Do not shorten any load cell cable.
* The load cell is temperature compensated with the supplied length of cable.
* Cutting the cable affects temperature compensation.
* Coil excess cable and protect it so it does not be mechanically damaged or
sitting in water.
* Cutting the coil voids the warranty.
Figure 3-1. Drip Loop
2. Provide a dip loop in all cables so water or other liquids will not run directly down
the cables onto the load cells or the junction box.
3. Attach load cell cable to the dead structure, not the vessel.
4. 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.
5. Connect cables for the load cells to the summing board in the junction box
according to the junction box manual. To verify the wiring scheme, see the
certification shipped with each load cell.
6. For better performance, use positive and negative remote sense lines if the
wiring run from the junction box to the indicator is longer than 25'.
3.1 Junction Box Connection
Refer to the junction box manual for connections, adjustments and calibration. It also
contains the trimming details.
Refer to indicator manual for system calibration guidelines.
IMPORTANT

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4.0 Troubleshooting
If system powers up and displays some type of stable digital readout that varies with the
load on the system, system problems are most likely caused by factors other than the load
cells. Load cells are usually blamed for a malfunctioning system, however, 90% of the
time the problem is mechanical.
If system can be calibrated but does not return to zero, loses calibration or demonstrates
non-linearity or non-repeatability, see Table 4-1 for possible causes and refer to the
following list of checks.
1. Check load cell module for debris restricting load cell movement or debris
between scale and structure.
2. Check overload stops for proper clearance.
3. Ensure tank/vessel and modules are plumb, level, and square at critical areas.
4. Check all piping and conduit for connections that restrict vessel movement.
5. If check rods are used, loosen all connections to finger-tight for testing.
6. Check load cell cables for physical or water damage.
7. Check all electrical connections, especially in the junction box.
If the problem is not found:
1. Check possible indicator malfunction by using a load cell simulator to input a
known good signal into the indicator.
2. Disconnect each load cell’s signal leads at the junction box and check individual
load cell outputs with a multimeter.
3. Check input/output impedances for comparison with load cell manufacturer’s
specifications.
If a problem still cannot be isolated:
1. Reconnect all but one load cell.
2. Replace the load cell with a load cell simulator. Alternate so that each load cell
is individually disconnected and replaced with a simulator. If there is a problem
with a particular load cell, the symptom should disappear when that load cell is
not to the simulator.
Symptom 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
Table 4-1. Troubleshooting

Repair Parts
© Rice Lake Weighing Systems ● All Rights Reserved 9
5.0 Repair Parts
Figure 5-1. RL1800 Parts Illustration
Item
No. Description QTY Replacement Part Numbers
250 - 5,000 lb 5,000 - 10,000 lb
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 15200
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
Table 5-1. RL1800 Tool Steel Replacement Parts
2
3
4
1
5
6
7
8
9
10
11
12
13

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Figure 5-2. RL1800 Parts Illustration
Item
No. Description Qty. Replacement Part Numbers
1,000 - 5,000SE lb 5,000LE - 10,000 lb
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 1 22736 22742
10 Convex Washer 1 22737 22743
11 Hex Head Loading Bolt 1 14760 14787
12 Upper Support Mounting Block 1 22738 22744
13 Load Cell 1 See Load Cell Selection Guide
Table 5-2. RL1800 Stainless Steel Replacement Parts
2
3
4
1
5
6
7
8
9
10
11
12
13

230 W. Coleman St. • Rice Lake, WI 54868 • USA
U.S. 800-472-6703 • Canada/Mexico 800-321-6703 • International 715-234-9171 • Europe [phone]
Rice Lake Weighing Systems is an ISO 9001 registered company.
© Rice Lake Weighing Systems Specifications subject to change without notice.
www.ricelake.com
December 5, 2018 PN 25712 Rev B