Rice Lake RL1900 Series User manual

9
SM
Installation
Guide
RL1900 SERIES
Mounting Assembly Kit
25711

Contents
1. Introduction ........................................................................... 1
2. Mechanical Installation ......................................................... 2
2.1 General Installation Guidelines for Tank Mounts.....................2
2.2 Installing the RL1900 Mount ....................................................3
3. Load Cell Wiring..................................................................... 5
4. Junction Box Connections, Adjustments & Calibration.... 6
5. Troubleshooting ..................................................................... 6
6. Maintenance and Replacement Parts................................... 7
7. Limited Warranty .................................................................... 8

1
1. Introduction
The RL1900 Series Mounting Assemblies are 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
uniquepivoting trunnion thatis self-restoringto its centerposition. Vesselleveling
andadjustmentcanbedoneeasilywiththecenterloadingbolt,andtheloadcellcan
be replaced without raising the vessel.
Themountisavailableincapacitiesfrom1,000to10,000lb.Itfeatures304stainless
steel construction with hermetically sealed load cells, making it ideal for rigorous
washdown and corrosive environments.
The installation should be planned by a qualified structural engineer to avoid
product failure. Each installation is unique, and this booklet is meant to serve only
as an overview for installation of the RL1900 Series Mounting Assembly.

2
2. Mechanical Installation
2.1 General Installation Guidelines for Tank Mounts
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.
Figures3and4illustratemountingconfigurationsforrectangularvesselswherethe
long axis of the load cell should be parallel to the long dimension of the vessel. In
anyapplication where a recurring force is present in one direction, as in a conveyor
belt or roller platform, the long axis of the load cell should align with that force.
1. Mounting surface for base plate and top plate must be level within ±.5°to
minimize side loads and extraneous forces. If the mounting surfaces are not
level, then shims or grout may be used to level the mount.
Ifpossible,checklevelandplumbagainwhencontainerisfullyloadedbecause
deflections in legs and supporting structures may cause additional side forces
that greatly effect accuracy. Reinforcement such as cross bracing of legs or
other support structures may be necessary to correct this. Deflection of the
mount’s top or base plate due to loading should not exceed ±.5°.
2. The relative load on each mount assembly should vary by no more than 20%.
During installation, add shims where necessary to verify that the correct load
distribution is achieved on each mount.
3. Duringinstallation,dummyloadcellscanbeusedtopreventoverloaddamage.
However, 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 weighing several tons can exert huge forces when dropped only a
fraction of an inch.
4. Itiscrucialthatflexiblesectionsareclosetothevesselandallpipingorconduit
be horizontal. 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. For details, see the technical infor-
mation section of the Rice Lake Weighing Sys-
temsLoadCellProductSelectionGuide.Insmaller,
lower capacity tanks and hoppers, isolating the
resultant forces becomes extremely critical. If
possible, flexible conduit piping should be used
close to the vessel instead of the rigid variety.
a
a a
a a
LEVEL ±0.5°
FLEXIBLE PIPING
J-BOX
Figure 1 Figure 2 Figure 4
Figure 3

3
5. Loadcells should not be installed in themounts 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, 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.
6. When possible, use only “hermetically sealed” load cells in washdown appli-
cations. “Environmentally protected” load cells are not suitable for such
applications and will be damaged. If tanks and surrounding equipment are
frequently steam cleaned, or if the load cell is subjected to direct washdown, a
protectiveshroudfortheweighingassemblyisrecommended.Properdrainage
is necessary so the weighing assembly is not standing in water.
7. Detailedinstructionsforinstallingthisloadcellmountfollow.Wheninstalling
theload cells,use the bolts provided or grade 5 or strongerhardened bolts.Pay
particular attention to the recommended torque values. Some mounts require
very loosely torqued bolts to allow the load cells to flex easily. Others must be
very tight to prevent the load cells from creeping or digging into the mount.
2.2 Installing the RL1900 Mount
The type of installation, structure of the vessel supports, and strength of the
mountingsurfacedeterminesthemethod of locating, attaching,andassemblingthe
RL1900 Mounting Assembly. 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 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?
LOCK WASHER
TOP PLATE
NYLON LOCK NUT
SHOULDER BOLT
CONCAVE WASHER
LOAD CELL
MOUNTING BLOCK
UPPER SUPPORT
MOUNTING BLOCK HEX HEAD LOADING BOLT
CONVEX WASHER
FLAT WASHER
BASE PLATE
LOAD CELL BOLT
LOAD CELL
CONCAVE WASHER
CONVEX WASHER

4
After considering any areas that may cause accuracy problems, follow these
installation steps.
1. Determine where to position the mount and in which direction it should be
oriented.
2. Assemble the mount and load cell according to the drawings shown at the
beginningofthis section.Forloadcellsusing1/2"mountingbolts,torqueto65
FT-LBS.Torque3/4"mountingboltsto295FT-LBS.Adjustthecenterloading
boltonallmountstogivethelowestoverallprofileheight,whileleavingatleast
a 1/8" gap between the load cell and the upper support loading block.
3. Lift and block the vessel to the same height as the assembled mounts.
4. Lift one corner or side of the vessel enough to slide that mount into place.
5. If the mount is being fitted under the leg of a vessel, verify that the leg’s center
line passes through the center of the top plate (through the center of the load
cell’s load hole).
6. Attach the top plate by bolting. Do not fully tighten because shimming may be
necessary to level.
7. Repeat steps 4, 5, and 6 for the remaining mounts. The vessel should now be
supported on the mounts alone.
8. If necessary, move the vessel to its final position. Verify that there is no initial
misalignmentbetween the baseplate and topplate by liftingthe vesselslightly
at each support point in turn. This will also indicate if the load is evenly
distributed on all mounts. Shim if necessary (this only applies to systems
utilizing more than 3 mounts).
9. Attach the base plates to the foundation using anchor bolts for concrete or by
bolting or welding to a steel structure. Verify that the base plates are no more
than ±.5°out of level. Shim as necessary.
10. Check that the top plates are no more than±.5°out of level. Shim if necessary
and fully tighten the bolts.
11. Theload distribution can be checked more accurately 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
junctionbox andindicator. Shim if necessary. The variation in load among the
cells should be no more than 20%.

5
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 (66 °C). Do not shorten any
load cell cable.The load cell is temperature compensated with the supplied
length of cable. Cutting the cable will affect temperature compensation. 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. Connectcablesforstandard RTI SSBandHBMSB3loadcellstothesumming
boardinthejunctionboxaccordingtotheguideshownbelowandthelabelson
the terminal strips of the junction box. To verify the wiring scheme, see the
certification shipped with each load cell.
5. If the wiring from the junction box to the indicator is longer than 25 feet, use
positive and negative remote sense lines for better performance.
LOAD CELL WIRE COLOR FUNCTION
Black
-SIGRed
- EXC
Green +EXC
White +SIG
SHIELDGray or Bare
a
a a
a a a a
aa a
aa
aaa
a a
a
a a
a a aa a a
aa
a a a
a
a a
a
aa
a a
a a aa
a a a a
a a
a
a a a a
a a
a a
aa a
a
a a
a
a a
a
DRIP LOOP

6
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
4. Junction Box Connections, Adjustments & Calibration
• Refer to Junction Box manual for trimming details.
• Refertotheindicatormanualand/orthe“TechnicalInformation”sectioninthe
Load Cell Product Selection Guide for system calibration guidelines.
5. Troubleshooting
Ifthesystempowersupandgivessometypeofstabledigitalreadoutthatvarieswith
the load on the system, the system problems are probably caused by factors other
than the load cells. All too often, the load cells are blamed for a malfunctioning
system; 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. Check load cell mount for debris restricting load cell movement or debris
between scale and structure. Check any overload stops for proper clearance.
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.
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.

7
6. Maintenance and Replacement Parts
RL1900 STAINLESS STEEL MOUNTS
No. Description No. Req. Replacement Part Numbers
1,000lb-5,000lb 10,000lb
1 Base Plate ..................................... 1 ............ 18254 ......................... 18280
2 Load Cell Mounting Block ...........1 ............ 18253 .........................18281
3 Flat Washer .................................. 1 ............ 15175 .........................15180
4 Load Cell Bolt .............................. 2 ............ 14767 .........................14790
5 Lock Washer ................................ 2 ............ 15168 .........................15182
6 Upper Support/Top Plate.............. 1 ............ 22293 .........................18282
7 Nylon Lock Nut............................ 1 ............ 14666 .........................14689
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 ............ 14763 .........................14789
12 Upper Support Mounting Block ...1 ............ 22738 .........................22744
13 Load Cell ...................................... 1 ............ See Load Cell Selection Guide
3
6
7
8
9
2
12 11 10
5
1
4
13

8
7. Limited Warranty
RiceLakeWeighingSystems(RLWS)warrantsthatallRLWSequipmentandsystems
properly installed by a Distributor or Original Equipment Manufacturer (OEM) will
operate per written specifications as confirmed by the Distributor/OEM and accepted
byRLWS.Allsystemsandcomponentsarewarrantedagainstdefectsinmaterialsand
workmanshipfortwo (2) yearsaftersystem start-up. Thetwo-yearwarranty obligation
is contingent upon clear documentation which establishes the start-up date. In the
absence of irrefutable documentation establishing the system start-up date, the two-
year warranty coverage will commence upon the date of shipment of equipment from
Rice Lake Weighing Systems.
RLWS warrants that the equipment sold hereunder will conform to the current written
specifications authorized by RLWS. RLWS warrants the equipment against 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:
1. Upon discovery by Buyer of such nonconformity, RLWS will be given prompt written
notice with a detailed explanation of the alleged deficiencies.
2. AttheoptionofRLWS,theequipmentwillbereturnedtoRLWSattheexpenseofthe
Buyer.
3. Examination of such equipment by RLWS confirms that the nonconformity actually
exists, and was not caused by accident, misuse, neglect, alteration, improper
installation, improper repair or improper testing; RLWS shall be the sole judge of all
alleged non-conformities.
4. Suchequipmenthasnotbeenmodified,altered,orchangedbyanypersonotherthan
RLWS or its duly authorized repair agents.
5. RLWSwillhaveareasonabletimetorepairorreplacethedefectiveequipment.Buyer
is responsible for shipping charges both ways.
6. 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.
THESEWARRANTIESEXCLUDEALLOTHERWARRANTIES,EXPRESSEDORIMPLIED,
INCLUDINGWITHOUTLIMITATIONWARRANTIESOFMERCHANTABILITYORFITNESS
FOR A PARTICULAR PURPOSE. NEITHER RLWS NOR DISTRIBUTOR WILL, IN ANY
EVENT, BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
RLWS AND BUYER AGREE THAT RLWS’S SOLE AND EXCLUSIVE LIABILITY HEREUN-
DER IS LIMITED TO REPAIR OR REPLACEMENT OF SUCH GOODS. IN ACCEPTING
THISWARRANTY,THEBUYERWAIVESANYANDALLOTHERCLAIMSTOWARRANTY.
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.
© 1995 Rice Lake Weighing Systems, Inc. Rice Lake, WI USA. All Rights Reserved. Rice
Lake Weighing Systems • 230 West Coleman St. • Rice Lake, Wisconsin 54868 • USA •