Rice Lake SURVIVOR 2100HE User manual

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Contents
1.0 Introduction........................................................................................ 1
2.0 Mechanical Installation..................................................................... 2
2.1 General Installation Guidelines for Tank Mounts ........................2
2.2 Installing the 2100HE ................................................................3
3.0 Load Cell Wiring ................................................................................ 5
4.0 Junction Box Connections, Adjustments & Calibration ....................6
5.0 Troubleshooting..................................................................................6
6.0 Maintenance and Replacement Parts ............................................... 8
Limited Warranty ......................................................................................9
Copyright © 1997 Rice Lake Weighing Systems.
All rights reserved. Printed in the United States of America. Specifications subject to change without notice.
December 1997

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1.0 Introduction
The 2100HE Weigh Module Kit provides an extremely accurate method for
weighing medium and large capacity tanks and hoppers that are subject to harsh,
hostile environments. The design uses a double-ended shear beam load cell (700Ω
bridge) and transmits the load with a sliding pin on the load bearing groove of the
cell. This design allows thermal expansion/contraction with little friction.
In the majority of applications, the assemblies are
self-checking and held captive with no need for
check or stay rods. The sliding pin design eases load
cell installation and replacement without the need to
raise the weighed vessel a large amount, which may
disturb piping and other connections.
The2100HEmodule isavailablein stainlesssteelin twosizesin capacitiesranging
from20,000-100,000lb.ThemountiscompatiblewithRL75060andSensortronics
65103 load cells.
The installation should be planned by a qualified structural engineer. Each instal-
lation is unique, and this manual is meant to serve only as a general guideline for
installation.
Thermal
Expansion

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2.0 Mechanical Installation
2.1 General Installation Guidelines for Tank Mounts
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.
Ifpossible,checkthatthemountislevelwhenthevesselisfullyloadedbecause
excessive deflections in legs and supporting structures may cause additional
sideforceswhichgreatlyaffectaccuracy.Deflectionofthemount’stoporbase
plate due to loading should not exceed ±.5°. Reinforcement of legs or other
support structures may be necessary to correct this. Vessels with long legs
should have cross bracing applied between adjacent legs to keep them from
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
extremely difficult to achieve. The load on each mount assembly should vary
by no more than 20%. During installation, add shims where necessary to
achieve correct load distribution.
3. If the actual load cells are used during installation of the weighing assembly,
extreme care must be taken to prevent overload damage. A tank or hopper
weighingseveraltonscanexerthugeforces whendroppedonlyafractionofan
inch. Dummy load cells can be used during installation.
4. Itiscrucialthatallpipingorconduitbehorizontaland
flexible. If flexible piping is not used, make sure the
distancefromthe vesseltothe firstpipesupport is20-
30timesthe pipediameter.Fordetails, seethetechni-
cal information section of the RLWS Load Cell Prod-
uct Selection Guide. In smaller, lower capacity tanks
and hoppers, isolating the resultant forces becomes
extremely critical.
5. Load cells should not be installed in the mounts 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. For example, if welding on the
mount top plate, the ground must be connected to the vessel, not to the mount
base or support structure. Also, protect the load cell and cable from weld
splatter.
Note: The arrow on the load cell should point in the direction of the load.
6. All support points should be equally stiff so that they deflect by the same
amount as the vessel is loaded.
LEVEL±0.5°
FLEXIBLE PIPING
J-BOX

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2.2 Installing the 2100HE
1. The type of installation and strength of the mounting surface governs the
method of locating, attaching, and assembling the 2100HE module. Carefully
consider three areas that commonly cause accuracy problems:
• Arethesupportinglegsadequatelybracedsotheywillnotspreadwhenthe
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 that is
likely to cause binding or lack of flexibility?
2. Determine where to position the mount and in which direction it should be
oriented.The2100HEisdesignedtoallowforlateralmovementinthedirection
perpendicular to the longitudinal axis of the load cell. These tank weighing
units should be oriented so that the movement due to thermal expansion/
contraction is perpendicular to the longitudinal axis. Sample mounting orien-
tations to accommodate expansion for different vessel shapes are as follows:
Top plate
Load cell bolt
Load cell
Retaining bolt
Base plate
Retaining plate
Bushing
Load pin

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3. Assemble the mounts by inserting the LOAD PIN into the TOP PLATE. The
RETAINING BOLTS are passed through the RETAINING PLATE and
BUSHINGS and threaded into the TOP PLATE. Insert the LOAD CELL into
this assembly so that the load pin sits in the groove at the center of the cell and
tighten bolts to approximately 50ft.lb. Set the top plate/load cell assemble in
position on the BASEPLATE. Pass the LOAD CELL BOLTS through the
LOAD CELL and thread into the BASEPLATE. Leave loose for now.
4. Lift and block the vessel to the same height as the assembled mounts.
5. Remove the block from one support point and slide that mount into position.
6. If the mount is being fitted under the leg of a vessel, verify that the leg’s center
linepassesthroughthecenteroftheTOPPLATE(throughthecenteroftheload
cell).
7. LowerthecornerorsideofthevesselcarefullyontotheTOPPLATE.Theforce
of a vessel weighing several tons can damage a load cell if dropped only a
fraction of an inch.
8. WiththeTOPPLATEpositionedapproximatelylevel,markholesforattaching
the TOP PLATE to the vessel’s mounting surface. Make holes and attach the
TOP PLATE loosely to the vessel with suitable fasteners.
9. Repeatsteps4-8forthemountingassemblies attheremainingcornersorsides.
10. Verify that there is no initial misalignment between the BASE PLATE and
TOP PLATE and that the LOAD PIN is centered in the groove of the LOAD
CELL. Relocate if necessary.
11. Attach the BASE PLATES to the foundation using suitable anchors for
concreteorbyboltingorweldingtoasteelstructureorsubplate.Verifythatthe
BASE PLATES 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. If dummy cells were used, replace with the LOAD CELLS.
14. To achieve equal load distribution, final height adjustments can be made with
shimsbetweentheTOPPLATEandtheweighingvessel. Thevariationinload
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.
15. TightentheboltssecuringtheloadcelltotheBASEPLATE.TorquetheLOAD
CELL BOLTS to only 20 foot-pounds. This allows the double-ended load cell
to flex under load.

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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 400°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. Connect cables for standard RL75060 or Sensortronics 65103 cells to the
summingboardinthejunctionboxaccordingtotheguideshownbelowandthe
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.
LOAD CELL WIRE COLOR FUNCTION
Black
+EXCRed
- EXC
Green +SIG
White - SIG
SHIELDGray or Bare
Drip Loop
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4.0 Junction Box Connections, Adjustments & Calibration
1. Refer to the Junction Box manual for trimming details.
2. Refertotheindicatormanualorthe“TechnicalInformation”sectionintheRice
Lake Weighing Systems’ Load Cell Product Selection Guide for system
calibration details.
5.0 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 the majority 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. Checkloadcell mountfordebrisrestricting loadcellmovement or debris
between scale and structure.
2. Check that tank/vessel and mounts 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.
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