Rice Lake EZ Mount 1 User manual

1
EZ Mount 1
Load Cell Mounting Kit
25710
Installation
Guide
Version 2.0

Copyright © 2004 Rice Lake Weighing Systems. All rights reserved.
Printed in the United States of America.
Specifications subject to change without notice.
March 2004
Contents
1. Introduction ............................................................................. 1
2. Mechanical Installation............................................................ 2
2.1 General Installation Guidelines for Tank Mounts ..........................2
2.2 Installing the EZ Mount 1 ..............................................................3
3. Load Cell Wiring & Junction Box Connections........................ 5
4. Adjustments & Calibration....................................................... 5
5. Troubleshooting....................................................................... 6
6. Maintenance and Replacement Parts ..................................... 7
7. EZ Mount 1 Limited Warranty.................................................. 8

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1. Introduction
The EZ Mount 1 Load Cell Mounting Kit provides an extremely accurate method for
weighingmediumandlarge capacity tanks andhoppersthataresubjectto large thermal
expansion/contraction or vibration forces. The design uses a double ended shear beam
load cell (700Ωbridge) and transmits the load with a sliding pin on the load-bearing
groove of the cell. This design is very effective in providing for thermal expansion/
contraction with little friction.
Inthe majorityofapplications,theassemblies areself-
checking and held captive with no need for check or
stay rods making this mount a good choice for areas
with frequent seismic activity. The sliding pin design
easesloadcellinstallationandreplacementwithoutthe
needto raisetheweighedvesselalargeamount,which
may disturb piping and other connections.
The EZ Mount 1 is available in mild steel or stainless
steel in five sizes from 5,000-250,000 lb. The mount is compatible with RL70000 and
RTI5103 mild steel load cells in capacities from 5,000 lb to 250,000 lb. The EZ Mount
1isalsoavailableinstainlesssteelwithRL70000SSandRTI9103availableincapacities
from 5,000 lb to 150,000 lb. The RL71000HE hermetically-sealed stainless steel load
cells are available in capacities from 5,000 lb to 60,000 lb.
The installation should be planned by a qualified structural engineer. Each installation
is unique, and this manual is meant to serve only as a general guideline for installation.
Thermal
Expansion
Authorized distributors and their employees can
view or download this manual from the Rice Lake
WeighingSystemsdistributorsiteatwww.rlws.com.

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2. Mechanical Installation
2.1 General Installation Guidelines for Tank Mounts
1. Themountingsurfaceforbaseandtopplatemustbelevel.Afterinstallation,thetop
andbottomplatesmustbelevelwithin±0.5°.Ifthemountingsurfacesarenotlevel,
then shims and or grout may be used to level the mount.
If possible, check that the mount is level when the vessel is fully loaded because
excessive deflections in legs and supporting structures may cause additional side
forceswhichgreatlyaffectaccuracy.Deflectionofthemount’stoporbaseplatedue
to loading should not exceed ±0.5°. Reinforcement of legs or other support
structuresmaybenecessarytocorrectthis.Vesselswithlonglegsshouldhavecross
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-
mount systems should be avoided as even weight distribution becomes extremely
difficulttoachieve.Theload on each mount assembly should vary bynomorethan
20%. Add shims where necessary to achieve correct load distribution.
3. If the actual load cells are used during installation, take extreme care to prevent
overload damage. A tank or hopper 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 horizon-
tal and flexible. If flexible piping is not used,
make sure distance from vessel to the first pipe
supportis20-30timespipediameter.Fordetails,
see the “Technical Information” section of the
RLWS Load Cell Product Selection Guide. In
smaller, lower capacity tanks and hoppers, iso-
lating resultant forces becomes extremely criti-
cal.
5. Loadcellsshouldnotbeinstalledinmountsuntilallweldingiscompleted.Theheat
generatedfromweldingcurrentpassingthroughaloadcellcandamagetheadhesive
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,connectthegroundinsuchawaythatthecurrentdoesnotflowthrough
the load cell. For example, if welding on the mount top plate, the ground must be
connectedto thevessel,nottothe mountbaseorsupportstructure. Also,protectthe
load cell and cable from weld splatter.
6. Use only “hermetically sealed” RL71000HE load cells in washdown applications.
“Environmentally protected” load cells are not suitable for such applications and
willbe damaged. If tanks and surrounding equipmentare frequentlysteamcleaned
or if the load cell is subjected to direct washdown, a protective shroud for the
weighingassembly is recommended. Proper drainageis necessarysotheweighing
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.
LEVEL±0.5°
FLEXIBLE PIPING
J-BOX

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2.2 Installing the EZ Mount 1
1. The type of installation and strength of the mounting surface governs the method
of locating, attaching, and assembling the EZ Mount 1 assembly. 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 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. Determinewheretopositionthemountandinwhichdirectionitshouldbeoriented.
The EZ Mount 1 is designed to allow for lateral movement in the direction
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
perpendicularto thelongitudinalaxis. Samplemountingorientations toaccommo-
date expansion for different vessel shapes are as follows:
Top Plate
Loading Bracket Cotter Pin
Load Cell Bolt
Load Cell Cotter Pin
Base Plate
Load Pin
Locating Pin
Washer
Load Bar

 
   
 

   
 
    

 
SUBPLATE RECOMMENDE
D
1" up to 60,000 lb
1.5" up to 150,000 lb
2.0" up to 250,000 lb
3. MakenecessarypreparationstothemountingsurfacesnotingthattheLOADCELL
BOLTS protrude beyond the BASE PLATE.

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5. Lift and block the vessel to the same height as the assembled mounts.
6. Remove the block from one support point and slide that mount into position.
7. Ifthe mount is being fittedunder thelegofavessel, verify that the leg’scenter line
passes through the center of the top plate (through the center of the load cell).
8. Lower the corner or side of the vessel carefully onto the top plate. The force of a
vessel weighing several tons can damage a load cell if dropped only a fraction of
an inch.
9. Withthetop plate positioned approximately level, mark holes for attaching the top
plate to the vessel’s mounting surface. Drill holes and attach top plate loosely to
vessel with suitable fasteners.
10. Repeat steps 4-10 for the mounting assemblies at the remaining corners or sides.
11. Verify that there is no initial misalignment between the BASE PLATE and TOP
PLATE and that the LOAD CELL is in the center of the hole in the TOP PLATE
LOADING BRACKET. Relocate if necessary.
12. Attach the base plates to the foundation using suitable anchors for concrete or by
boltingor welding to a steel structure or subplate.Verify thatthe baseplates areno
more than ±0.5°out of level. Shim as necessary.
13. Check that the top plates are no more than ±.5°out or level. Shim if necessary and
fully tighten mounting bolts.
14. If dummy cells are used, replace with actual LOAD CELLS. Refer to step 4.
15. Toachieveequalloaddistribution,finalheightadjustmentscanbemadewithshims
between the TOP PLATE LOADING BRACKET and the weighing vessel. The
variationinloadamongthecellsshouldbenomorethan20%.Theloaddistribution
can be checked accurately by exciting each load cell in turn and measuring the
output with a voltmeter.
16. Check that the bolts securing the load cell to the BASE PLATE are tight. Torque
the LOAD CELL BOLTS to only 20 foot-pounds. This allows the double-ended
load cell to flex under load.
4. Assemble the mounts by inserting either a dummy load cell or the actual LOAD
CELL into the hole in the TOP PLATE LOADING BRACKET then installing the
LOAD PIN and LOCATING PIN*. The LOAD CELL BOLTS are then passed
through the ends of the LOAD CELL and LOAD BARS and threaded into the
BASE PLATE and hand tightened.
Note: The arrow on the load cell should point in the direction of the load.
*Note: The EZ Mount can accomodate several different manufacturer’s cells that are
similar to the RL70000. Some of these load cells have a larger diameter. For this
reason a smaller diameter locating pin is also included.

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2. Provide a drip loop in all cables so that water or other liquids will not run directly
downthe cablesontoeithertheload cellsorthejunctionbox. Attachloadcellcable
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. ConnectcablesforstandardRL70000,RL70000SS,RTI5103,RTI9103loadcells
orRL71000HE hermeticallysealedloadcellstothesummingboard inthejunction
boxaccording to the guide shownbelow andthelabelsonthe 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
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.
Theloadcellistemperaturecompensatedwiththesuppliedlengthofcable.Cutting
the cable will affect temperature compensation. Coil and protect excess cable so it
will not be mechanically damaged or be sitting in water.
4. Junction Box Connections, Adjustments & Calibration
1. Refer to Junction Box manual for trimming details.
2. Refer to indicator manual or “Technical Information” section in Rice Lake Weigh-
ing Systems’ Load Cell Product Selection Guide for system calibration details.

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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
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 demon-
strates non-linearity or non-repeatability, see the following chart for possible causes and
do the following checks.
1. Check load cell mount for debris restricting load cell movement or debris
between scale and structure.
2. Check that tank/vessel and mounts are plumb, level, and square at 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.
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. Disconnecteachloadcell’ssignalleadsatthejunctionboxandcheckindividualload
cell outputs with a multimeter. Then check input/output impedances for comparison
with load cell manufacturer’s specifications.
Ifafterallthesecheckstheproblemstillcannotbeisolated,reconnectallbutoneloadcell.
Replaceloadcellwithaloadcellsimulator.Alternatesothateachloadcellisindividually
disconnected and replaced with a simulator. If there is a problem with a particular load
cell,thesymptom shoulddisappearwhenthat loadcellisdisconnected and replacedwith
simulator.
Note:TheRL71000HESeriesutilizesauniquemethodofcompensationfortemperature,
hysterisis, and linearity. Because of this, power must be applied to the excitation
loads to “close” the circuit and excite the bridge. Then the load cell bridge
resistance can be checked.

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6. Maintenance and Replacement Parts
EZ Mount 1 Mild Steel Mounts
No. Description Reqd. Replacement Part Numbers
A* B* C* D* E*
1Top Plate Loading Bracket 1 ..... 18273... 18274 ... 18275 ...29014.... 26061
2Load Cell Bolt..................... 2 ..... 14773... 14795 ... 14797 ...14797.... 26071
3Washer................................ 2 ..... 15177... 15184 ... 15184 ...15184.... 26070
4Double-Ended
Shear Beam Load Cell ..... 1 ..... See Load Cell Selection Guide
5Load Bar ............................. 2 ..... 18267... 18268 ... 18269 ...18269.... 26073
6Base Plate .......................... 1 ..... 18264... 18265 ... 81266 ...82166.... 26074
7Load Pin.............................. 1 ..... 18270... 18271 ... 18272 ...18272.... 26067
8Locating Pin ....................... 1 ..... 18261... 18262 ... 18263 ...18263.... 26076
9Cotter Pins.......................... 2..... 15229... 15251 ... 15257 ...15257.... 26069
EZ Mount 1 Stainless Steel Mounts
No. Description Reqd. Replacement Part Numbers
A* B* C* D*
1Top Plate Loading Bracket 1 .............18376 .....18377 ... 18378 .... 29013
2Load Cell Bolt..................... 2 .............14774 ..... 14796 ... 14798 .... 14798
3Washer................................ 2 .............15178 .....15187 ... 15187 .... 15187
4Double-Ended
Shear Beam Load Cell ..... 1.............See Load Cell Selection Guide
5Load Bar ............................. 2 .............18267 .....18268 ... 18269 .... 18269
6Base Plate .......................... 1 .............18370 ..... 18371 ... 18372 .... 18372
7Load Pin.............................. 1 .............18270 .....18271 ... 18272 .... 18272
8Locating Pin ....................... 1 .............18373 .....18374 ... 18375 .... 18375
9Cotter Pins.......................... 2.............15230 .....15252 ... 15258 .... 15258
*A-size mounts use load cells with capacities from 5,000-20,000 lb.
*B-size mounts use load cells with capacities from 30,000-60,000 lb.
*C-size mounts use load cells with a capacity of 100,000 lb.
*D-size mounts use load cells with a capacity of 150,000 lb.
*E-size mounts use load cells with a capacity of 200,000 lb. and 250,000 lb.
1
2
3
4
5
6
7
8
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7. EZ Mount 1 Limited Warranty
Rice Lake Weighing Systems (RLWS) warrants that all RLWS brand load cells properly
installed by a Distributor or Original Equipment Manufacturer (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 written
specificationsauthorizedbyRLWS.RLWSwarrantstheequipmentagainstfaultyworkman-
ship 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:
•Upondiscoveryby Buyer of such non-conformity, RLWSwillbe given prompt written
notice with a detailed explanation of the alleged deficiencies.
•Examination of such equipment by RLWS confirms that the non-conformity actually
exists,andwasnotcausedbyaccident,misuse,neglect,alteration,improperinstallation,
improper repair or improper testing; RLWS shall be the 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 equipment. Buyer
is responsible for shipping charges both ways.
•In no event will RLWS be responsible for travel time or on-location repairs, including
assembly or disassembly of equipment, nor will RLWS be liable for the cost of any
repairs made by others.
THESE WARRANTIES EXCLUDE ALL OTHER WARRANTIES, EXPRESSED OR
IMPLIED, INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANT-
ABILITY OR FITNESS FOR A PARTICULAR PURPOSE. NEITHER RLWS NOR
DISTRIBUTOR WILL, IN ANY EVENT, BE LIABLE FOR INCIDENTAL OR CONSE-
QUENTIAL DAMAGES.
RLWS AND BUYER AGREE THAT RLWS’S SOLE AND EXCLUSIVE LIABILITY
HEREUNDER IS LIMITED TO REPAIR OR REPLACEMENT OF SUCH GOODS. IN
ACCEPTING THIS WARRANTY, THE BUYER WAIVES ANY AND ALL OTHER
CLAIMS TO WARRANTY.
SHOULD THE SELLER BE OTHER THAN RLWS, THE BUYER AGREES TO LOOK
ONLY TO THE SELLER FOR WARRANTY CLAIMS.
No terms, conditions, understanding, or agreements purporting to modify the terms of this
warranty shall have any legal effect unless made in writing and signed by a corporate officer
of RLWS and the Buyer.
© 2004 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