RICE LAKE RL9000 Series Weigh Module Kit Installation Guide

RICE LAKE RL9000 Series Weigh Module Kit

Product Information

The RL9000TWM/RL9000TWM-HT Series weigh module kit is designed for use in tanks, hoppers, vessels, and other applications. It is a rugged and high- precision mount that is easy to install and does not require check rods or other stabilizing hardware. The weigh module kit is made of stainless steel construction and has a welded seal, providing additional protection in wash- down areas.

Features

• Designed for tank, hopper, vessel, and other applications
• Rugged and high-precision mount
• Easy installation without the need for check rods or stabilizing hardware
• Stainless steel construction for durability
• Welded seal for added protection in wash-down areas

Product Usage Instructions

Load Cell Wiring
Refer to the manual for instructions on load cell wiring, junction box connections, adjustments, and calibration.

Troubleshooting
If you encounter any issues with the weigh module kit, refer to the troubleshooting section in the manual for guidance.

Mechanical Installation
Follow the installation guidelines provided in the manual for tank mounts and weigh module installation.

Dimensional Drawings
Refer to the dimensional drawings in the manual for assembly instructions specific to the weight range (1K to 100K, 150K to 200K, 250K to 450K).

Note:
Each installation is unique, and it is recommended to have a qualified structural engineer plan the installation.

For further information, manuals, warranties, and web-based video training, visit the Rice Lake Weighing Systems website at www.ricelake.com.

© 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.

Revision History
This section tracks and describes manual revisions for awareness of major updates.

Table i. Revision Letter History

Introduction

This manual is meant to serve only as a general guideline for installation. Each installation is unique and should be planned by a qualified structural engineer.

• Manuals are available from Rice Lake Weighing Systems at www.ricelake.com/manuals.
• Warranty information is available at www.ricelake.com/warranties.

Overview

The RL9000TWM/RL9000TWM-HT Series weigh module is ideal for use in tanks, hoppers, vessels, and many other applications. This rugged, high-precision mount is designed for easy installation and does not require check rods or other stabilizing hardware. The stainless steel construction and welded seal offer additional protection in wash-down areas. They use low-profile shear web load cells and transmit the load via a spherical washer on the load-bearing hub of the cell. The shear web design eases load cell installation and replacement without the need to raise the weighed vessel a large amount, which could disturb piping and other connections.

Features

RL9000TWM

• 350 Ω
• Capacities: 1,000 to 450,000 lb
• Very low profile design
• 3mV/V output
• Self-centering
• Self-checking assembly
• Rated temperatures: 0° to 150° F
• Offers 100% side load, 100% uplift, 150% static safe load, and 300% ultimate static overload protection
• Stainless steel construction
• Welded seal
• Weighs accurately with as much as a 3° non-parallel load
• Includes 25 ft load cell cable

RL9000TWM-HT

• 700 Ω
• Capacities: 1000-50,000 lb (higher capacities by request)
• Very low profile design
• 3mV/V output
• Self-centering
• Self-checking assembly
• Rated temperatures: 0° to 400° F
• Offers 100% side load, 100% uplift, 150% safe load, and 300% Ultimate overload protection
• Stainless steel construction
• Welded seal
• Weighs accurately with as much as a 3° on-parallel load
• Includes 25 ft of PTFE cable

Safety

Safety Definitions:

• DANGER: 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.
• WARNING: 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.
• CAUTION: Indicates a potentially hazardous situation that, if not avoided, could result in minor or moderate injury.
• IMPORTANT: 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.

WARNING
Failure to heed may result in serious injury or death.

• Before attempting to operate this unit, make sure every individual who operates or works with this unit has read and understands the following safety information.
• Do not allow minors (children) or inexperienced persons to operate this unit.
• Do not operate without all shields and guards in place.
• Do not jump up and down on the scale.
• Do not use it 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.

Load Cell Wiring

The following section provides information on the proper wiring of load cells.

1. Route the load cell cables so they will not be damaged or cut.
   IMPORTANT: Failure to heed could result in product damage.

   • The cable should not be routed near heat sources greater than 150°F.
   • Do not shorten the load cell cable. Cutting the cable affects temperature compensation.
   • Coil and protect excess cable to avoid damage or 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.
   Load Cell Wire Colors (RL9000TWM Only)

   Wire Color| Function Positive Reading
   Green| + EXC
   Black| – EXC
   Red| – SIG
   White| + SIG
   Gray or Bare| Shield

Table 2-1. Wire Function

3. If conduit protection is needed against mechanical or rodent damage to the load cell cables, use flexible conduit and conduit adapters (20K to 450K only) at the load cells.
4. Connect cables for load cells 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.

Junction Box Connections, Adjustments, and Calibration

• Refer to the junction box manual for trimming details.
• Refer to the indicator manual for system calibration details.

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 the 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 possible causes and do the following checks.

cells; may have lost system calibration
Non-linearity| Thermal expansion or deflection under load causing binding or side load
Non-repeatability| Loosen 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 the junction box, cables or load cell; mechanical binding

Table 3-1. Possible Causes

1. Check the load cell mount for debris restricting load cell movement or debris between scale and structure.
2. Check that the tank/vessel and mounts are plumb, level, and square at critical areas.
3. Check all piping and conduit for connections that restrict vessel movement.
4. If check rods are used, loosen all connections to the 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 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 the individual load cell outputs with a multimeter. Then check input/output impedances for comparison with the load cell manufacturer’s specifications.

If after all these checks the problem still cannot be isolated, reconnect all but one load cell. 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 disconnected and replaced with the simulator.

Mechanical Installation

Installation Guidelines for Tank Mounts

• Mounting surfaces for plates must be level. After installation, the top and bottom plates must be level within ±0.5°. If the mounting surfaces are not level, use shims and/or grout to level the mount.
• Check that the mount is level when the vessel is fully loaded, if possible, excessive deflections in legs and supporting structures can cause additional side forces which affect accuracy. Deflection of the mount top or base plate due to loading must not exceed ±0.5°. 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.
• Compression mounting systems use three, four, or more mounts. More than eight-mount systems should be avoided as even weight distribution becomes extremely difficult to achieve. The load on each mounting assembly should vary by no more than 20%. Add shims as needed, to achieve correct load distribution.
• Take extreme care to prevent overload damage. A tank or hopper can exert huge forces when dropped only a fraction of an inch.
• It is crucial that all piping or conduit be horizontal and flexible. 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 resultant forces becomes extremely critical. See the Load Cell and Weigh Module Handbook manual (PN 22054) for more information.
• The weigh module assemblies should not be installed 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 mount when welding to maintain the 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. Protect the load cell and cable from weld splatter.

Example:
if welding on the mount top plate, the ground must be connected to the vessel, not to the mount base or support structure.

RL9000 Series Weigh Module Kit

• Use only hermetically sealed load cells in wash-down applications. 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 wash down, a protective shroud for the weighing assembly is recommended. Proper drainage is necessary so the weighing assembly is not standing in water.
• All support points should be equally stiff so that they deflect by the same amount as the vessel is loaded.

Weigh Module Installation

The type of installation and strength of the mounting surface governs the method of locating, attaching, and installing the mount assembly. Three areas which commonly cause accuracy problems to consider:

• 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 that could cause binding or lack of flexibility?

Use the following steps to install the weigh module assembly:

1. Position a mount in every vessel leg location.
   NOTE: The modules are designed to allow for lateral movement in any direction. Figure 4.1 illustrates sample mounting orientations to accommodate different vessel shapes.

2. Make necessary preparations for the mounting surfaces.
   NOTE: A 1-inch subplate can be used to ensure a good mounting surface.
   If using a top plate or mounting directly to the load cell, apply an anti- seize product to the fastener threads to prevent gall.

3. Lift and block the vessel to the same height as assembled mounts.

4. Slide a mount into position.

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).

6. Lower the corner or side of the vessel carefully onto the top plate.
   IMPORTANT: The force of a vessel weighing several tons can damage a load cell if dropped only a fraction of an inch.

7. With the top plate positioned approximately level, mark holes for attaching the top plate to the vessel’s mounting surface.

8. Drill holes and attach the top plate loosely to the vessel with suitable fasteners.

9. Verify that there is no initial misalignment between the base plate and the top plate.

10. Attach the base plates to the foundation using suitable anchors for concrete or by bolting or welding to a steel structure or sub-plate. Verify that the base plates are as level as possible.
    NOTE: Base plates should be fully supported. Shimming is not recommended.

11. Check that the top plates are no more than ±.5° out or level. Shim if necessary and fully tighten mounting bolts.

12. Repeat steps 4-11 for the mounting assemblies at the remaining corners or sides.

NOTE:
To achieve equal load distribution, final height adjustments can be made with shims between the top plate loading bracket and the weighing vessel. The variation in load 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. Consider using a bead of flexible caulk between the load cell and the base on lighter capacity assemblies. This will prevent debris from lodging between the load cell and the base and cause repeatability or accuracy problems.

Weigh modules are assembled, with Locktite®, at the factory and should not require adjustment.

If the weigh modules have been disassembled for any reason, perform the following:

1. Remove the large center screw.
2. Align the convex load disc and the load cell with the center hole in the base plate.
3. Apply Locktite and install the large screw and continue to turn until the rubber o-ring just contacts the convex load disc.
4. Back the screw off 1/4 turn.

IMPORTANT:
Do not attempt to adjust the center bolt unless removing the load cell for replacement purposes. This bolt is factory adjusted and any attempt to loosen or tighten this bolt will void the warranty. It is normal for there to be movement between the load cell and the center bolt. The screw provides lateral restraint and lift-off protection. Never remove it or back it off more than the suggested amount.

Dimensional Drawings

1K to 100K Assembly

Dimensions (Inches)

Rated Capacity|

A

|

B1

|

C

|

D

|

E

|

F

|

G

|

H

|

I

| Conduit Adapter
1K-10K| 4.0| 2.0| 3.25| 3.5| 0.4| 3/8-16| 1.35| 0.375| 0.75| N/A
15K| 4.0| 2.0| 3.25| 3.5| 0.4| 3/8-16| 1.60| 0.625| 0.75| N/A
20-50K| 7.0| 3.75| 5.50| 6.0| 0.63| 1/2-13| 2.48| 0.75| 1.3| 1/2-14 NPT
60K-100K| 8.0| 4.25| 6.50| 7.0| 0.81| 3/4-16| 2.50| 1.0| 1.3| 1/2-14 NPT

Table 5-1. 1-100K Assembly

150K to 200K Assembly

Dimensions (Inches)

Rated Capacity|

A

|

B2

|

C

|

D

|

E

|

F

|

G

|

H

|

I

| Conduit Adapter
150K-200K| 10.0| 7.825| 8.0| 9.0| 1.1| 1-14| 4.75| 2.0| 1.7| 1/2-14 NPT

Table 5-2. 150-200K Assembly

RL9000 Series Weigh Module Kit

250K to 450K Assembly

Dimensions (Inches)

Rated Capacity|

A

|

B2

|

C

|

D

|

E

|

F

|

G

|

H

|

I

| Conduit Adapter
250K-450K| 11.0| 7.75| 9.0| 9.0| 1.3| 7/8-14| 6.42| 3.0| 2.25| 1/2-14 NPT

Table 5-3. 250-450K Assembly

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© Rice Lake Weighing Systems

Content is subject to change without notice.
230 W. Coleman St. • Rice Lake, WI 54868 • USA USA: 800-472-6703 • International: +1-715-234-9171
www.ricelake.com.

References

• Rice Lake Weighing Systems
• Rice Lake Weighing Systems
• Videos and Webinars | Rice Lake Weighing Systems
• Rice Lake Weighing Systems
• Videos and Webinars | Rice Lake Weighing Systems

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