HI LPRC03 SERIES
LOAD POINT ASSEMBLIES
OPERATION AND INSTALLATION
MANUAL
Corporate Headquarters
9440 Carroll Park Drive Suite 150, San Diego, CA 92121
Phone: (858) 278-2900
FAX: (858) 278-6700
Web-Site: http://www.hardyinst.com
Hardy Instruments Document Number: 0596-0309-01 Rev. B
Copyright July 2008 Hardy Instrum e nts, Inc . Al l Rights Reserved. Printed in the U.S.A. (941028)
Local Field Service
Hardy has over 200 field technicians in the U.S., and more positioned
throughout the world to assist you in your support needs. We also have factory engineers who will travel to your facility anywhere in the world to help you
solve challenging applications. We're ready to support you with:
• Installation and start-up
• Routine maintenance and certification
• Plant audits and performance measurement
• Emergency troubleshooting and repair
To request Emergency Service and Troubleshooting, Start-up, Installation,
Calibration, Verification or to discuss a Maintenance Agreement please call
800-821-5831 Ext. 1757 or Emergency Service after hours (Standard Hours
6:00 AM to 6:00 PM Pacific Standard Time) and weekends
Ext. 1111.
Outside the U.S
Hardy Instruments has built a network of support throughout the globe. For
specific field service options available in your area please contact your local
sales agent or our U.S. factory at +1 858-292-2710, Ext. 1757.
1-2
Table of Contents
Table of Contents
Table of Contents - - - - - - - - - - - - - - - - - - - -Page i
General Information- - - - - - - - - - - - - - - - - - - - - - -Page 1
Unpacking - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 1
Precautions- - - - - - - - - - - - - - - - - - - - - - - - - - -Page 1
Site Preparation - - - - - - - - - - - - - - - - - - - - - - - -Page 2
Basic Engineering Principles for Positioning
Load Point Assemblie s - - - - - - - - - - - - - - - - - - - -Page 2
Typical Mounting Arrangements- - - - - - - - - - - - - - - - -Page 3
Round Vessel - 3 Load Point Assemblies - - - - - - - - - -Page 3
Round Vessel - 4 Load Point Assemblies - - - - - - - - - -Page 3
Installing a Mount Assembly - - - - - - - - - - - - - - - - - -Page 4
Installing the Load Sensor - - - - - - - - - - - - - - - - -Page 7
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - -Page 9
Physical Checks - - - - - - - - - - - - - - - - - - - - - -Page 9
Electrical Tests for Load Point Assembly Problems - - - - -Page 10
Zero Balance Test - - - - - - - - - - - - - - - - - - - - - - -Page 10
10Bridge Resistance Test- - - - - - - - - - - - - - - - - - - -Page 10
Resistance to Ground Test - - - - - - - - - - - - - - - - - - -Page 11
Electrical Termination Cable Color Codes - - - - - - - - - - - -Page 11
Model Numbers- - - - - - - - - - - - - - - - - - - - - - - - -Page 11
Specifications- - - - - - - - - - - - - - - - - - - - - - - - - -Page 12
Drawings- - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 13
Record Model Information- - - - - - - - - - - - - - - - - - - -Page 18
i
ii
CAUTION: UNPACK WITH CARE
WHEN UNPACKING, DO NOT DISCARD THE PACKING CASE OR ANY PACKING MATERIAL, UNTIL THE
CONTENTS OF THE PACKING CASE ARE
INSPECTED AND CAREFULLY COMPARED WITH
THE SHIPPING DOCUMENTS.
IF ANYTHING IS UNSATISFACTORY, PLEASE
NOTIFY HARDY INSTRUMENTS IMMEDIATELY BY
CALLING, FAXING OR E-MAILING TO:
Customer Support Department
HARDY INSTRUMENTS, INC.
9440 Carroll Park Drive, Suite 150
San Diego, CA 92121
Phone: (800) 821-5831
(858) 278-2900
FAX: (858) 278-6700
E-mail: hardysupport@hardyinst.com
Web Address: www.hardyinst.com
TO RETURN DEFECTIVE OR DAMAGED PRODUCT(S) CALL HARDY TECHNICAL SUPPORT FOR A
HARDY SERVICE TICKET NUMBER (HST#). YOUR
COMPANY NAME, ADDRESS, TELEPHONE NUMBER,
SERIAL NUMBER OF THE UNIT AND A BRIEF
DESCRIPTION OF THE PROBLEM SHOULD BE
READY WHEN CALLING. FOR ALL NON-WARRANTY REPAIRS A PURCHASE ORDER OR CREDIT
CARD IS ALSO REQUIRED. OR USE OUR ON-LINE
HST # REQUEST FORM AT WWW.HARDYINST.COM
UNDER ONLINE SUPPORT AND THEN FACTORY
REPAIR. FOLLOW THE DIRECTIONS AND THEN
SUBMIT THE REQUEST FORM. AN HST# WILL BE
ISSUED AND EMAILED
IN CASE OF DAMAGE DUE TO SHIPPING, NOTIFY
THE DELIVERING CARRIER IMMEDIATELY FOR AN
INSPECTION.
OPERATION AND INSTALLATION MANUAL
General Information The Hardy Instruments (HI) LPRC03 Low Profile
Series, with self-aligning load points, is designed for
applications in hoppers, tanks and silos. The HI
LPRC03 Advantage Loadpoint consists of a hermeti-
cally sealed, stainless steel load sensor (gauge area
and cable entry), with Enhanced C2
®
Second Generation Calibration, and a matched mV/V and mV/V/
Ohm and a 1/4 inch conduit adapter and mount.
The HI LPRC03 mount eliminates the effects of
unwanted forces, which makes it well suited for hi gh
capacity vessels. Its performance exceeds IP68 and
NEMA 6 Standards for Wash Down Resistance,
ensuring accurate output even for th e most demanding
applications.
The mount comes preassembled, with the top plate
centered to the bottom of the unit using two heavy
bolts to hold the parts together. Each load point is fitted with a grounding strap. The mounti ng hardwa re is
available in either stainless or zinc plated steel.
Unpacking The load sensor is shipped in a separate container. Do
not remove it from it’s packaging until just before
installation. Although the load sensor is designed for
harsh environments, it is a precision instrument and
should be treated as such.
Precautions • Always treat the Load Sensor as a precision
instrument. Leave the assembly in its packaging
until it is time for installation.
• NEVER CARRY OR SWING THE LOAD SEN-
SORS BY THEIR CABLE.
• Never let moisture get into any interconnections.
• Inspect the box, packing, and lo ad point assembly
for any signs of damage. Since most load point
assemblies are shipped F.O.B. our factory, such
damage is normally the responsibility of the carrier and should be reported to them.
Page 1
HI HLPRC03 SERIES LOAD POINT ASSEMBLY
LOAD SENSOR CERTIFICATION SHEETS ARE
AVAILABLE 24 HOURS A DAY AT OUR WEB SITE: http://www.hardinst.com. Go to “Products” or
“Support,” click Advantage Load Sensor Tool/Certification, then follow directions.
Note the serial number(s) for reference when talking
to Hardy Customer Service. Store this information in
a safe location for future reference.
Site Preparation As foundations for the load point assemblies, use a
metal base plate that will not be deformed when you
weld it to the bottom plate of the load point.
• Check the I/I diagrams that come with this document for th e assembly ’s dimensions. (Th ey are
also available on the Hardy Instruments Web Site
(http://www.hardyinst.com ).
• All mounting surfaces for the base and loading
plate must be level. Load Point Assemblies must
be level to within 0.4/100 for legal or trade applications or 0.8/100 for general applications.
• Complete all welding before installing the load
sensor.
Basic Engineering Principles for Positioning Load Point Assemblies
Page 2
Note the following requirements when positioning the
Load Point.
• Position the Load Point Assemblies to distribute
the load (weight) as evenly as possible between
each load point assembly in the scale.
• When the installation does not allow even load
distribution, select higher capacity load point
assemblies.
• All load point assemblies must have the same
capacity when used in one scale.
Typical Mounting Arrangements
Round Vessel - 3 Load Point Assemblies
OPERATION AND INSTALLATION MANUAL
FIG. 1: ROUND VESSEL TANK - 3 LOAD
CELLS
Round Vessel - 4 Load Point Assemblies
FIG. 2: ROUND VESSEL TANK - 4 LOAD
POINT ASSEMBLIES
Page 3
HI HLPRC03 SERIES LOAD POINT ASSEMBLY
Installing a Mount Assembly
Step 1. Read the Operation and Installation Manual
first to familiarize yourself with the installa-
tion process.
Step 2. Unpack the mount.
Step 3. The load sensor is separaely crated. Set it
aside in a safe location to be installed after
all the welding has been completed.
Step 4. Place the mount on the foundation plates.
Step 5. Level each mount top plate. Note that all
load points should be within +/- 0.5
o
of each
other . Use shim sto ck and p lace it under the
bottom plate to adjust the height for each
mount.
Step 6. When the assemblies are within tolerance of
each other. Position the preassembled
mount on to a foundation plate, and either
weld or bolt the unit into place.
Page 4
FIG. 3: WELDING ON MOUNTING PLATE
FIG. 4: BOLTING ONTO MOUNTING PLATE
OPERATION AND INSTALLATION MANUAL
Step 7. Weld or bolt the top plate to the load carrier .
FIG. 5: WELD OR BOLT THE TOP PLATE
Step 8. If you bolt the plate, fasten the left two bolts
snugly, but the right two bolts loosly.
FIG. 6: BOLTING ADVICE
NOTE: The basic mount serves as a construction block. Do
not install the load sensor until al welding has been
completed.
Page 5
HI HLPRC03 SERIES LOAD POINT ASSEMBLY
Step 9. Unpackage the load sensor and place the
Top and Bottom Load Sensor Housings on
the Load Sensor.
FIG. 7: LOAD SENSOR
Page 6
Step 10. Apply a layer of grease to th e O-rings i nside
the loading cups and assemble cups with the
load sensor.
Step 11. Slide the load sensor assembly with cups
between the bottom and top plate into position with the loading cups facing as shown.
FIG. 8: LOAD SENSOR
OPERATION AND INSTALLATION MANUAL
Step 12. Be sure to line up the horizontal anti-rota-
tion notch.
Step 13. Mount the lower clamp and tighten the
screws. When you mount the upper clamp,
tighten screws loosely for now.
FIG. 9: FASTEN CLAMPS
Step 14. Remove the bolts holding the parts together,
then tighten the two bolts that were left
loose in step eight.
Installing the Load Sensor
FIG. 10: REMOVE BOLTS
Step 15. Place a hydraulic jack between the top and
bottom plates. Apply just enough lift to
remove the spacers.
FIG. 11: REMOVE SPACERS
Step 16. Use the jack to lower the load carrier onto
the load sensor
Page 7
HI HLPRC03 SERIES LOAD POINT ASSEMBLY
Step 17. Remove the jack, then tighten the upper
clamp bolts that were left loose in Step 13.
Step 18. Set lift off gap to about 1.5-3 mm and
secure it with the locking screw.
FIG. 12: SET GAP
CAUTION:
DO NOT REINSTALL THE SHIPPING BOLT
WHICH IS USED FOR ALIGNMENT ONLY. IF
REINSTALLED, IT WILL YIELD IMPROPER
WEIGHT READINGS.
Step 19. Use primer paint on the zinc-plated load
point assemblies and then a finish coat on
and around the welds to protect them from
iron oxide formation.
Step 20. Repeat the installation process for each of
the load point assemblies in the system.
Step 21. When finished the load point assembly
should look like the figure below.
FIG. 13: FINISHED LOAD POINT ASSEMBLY
WITH STANDARD LOAD SENSOR
Page 8
OPERATION AND INSTALLATION MANUAL
NOTE: For additional help with the load point installation,
contact your local Hardy Instruments Representative
or either Application Engineering or Customer Support at the Hardy Instruments company.
Troubleshooting
Physical Checks Follow these steps before runing any electrical tests:
Step 1. Visually inspect each load point assembly
for physical damage. If you find any problems, replace the part that is damaged.
• Look for distortions or cracks in all
metal parts. Make sure that any welds
are not cracked and do not have deep
pot marks.
• Check all cables for cracks, cuts or
crimping. Check for any abrasions on
the cables.
• Look for structural changes in the scale
or supporting structures.
• Look for binding of any k ind on the lo ad
point assembly.
Step 2. In the Troubleshooting section of the Hardy
Manual for the weighing instrument, look
for information on how to troubleshoot
using Integrated Tech nician. (See also the
support page of the Hardy Web site at: http:/
/www.hardyinst.com.)
Step 3. Get the Load Sensor certification sheets for
referencing while troubles hooting. They are
also available 24 hours a day at our Web
Site: http://www.hardyinst.com.
Page 9
HI HLPRC03 SERIES LOAD POINT ASSEMBLY
Electrical Tests for Load Point Assembly Problems
Zero Balance Test
NOTE: Output sensitivity can shift up to about 10% of their
Bridge Resistance Test
Problem: Changes in the Zero Balance.
Cause: Load Cell has been overloaded.
Remedy:
Step 1. Use a millivolt meter or the Integrated
Technician feature of the weighing instrument and measure the signal output under
“no load” conditions. The reading should be
less than 1% of the full scale output.
full scale and still function correctly.
Step 2. If the output has shifted more than 10%,
replace the sensor.
Assumption: A 5VDC excitation on a sensor with a
3mV/V output sensitivity, a 1% shift in zero balance
will yield a .1mV/V change from the specification.
Problem: Changes in Bridge Resistance
Cause: Failure of a compensating element, or by a
broken or burned bridge wire. Often caused by an
electrical transient such as lightning or welding.
Page 10
Remedy:
Step 1. Use an Ohmmeter and measure the resis-
tance between the EXC + and EXC- leads.
The value for the EXC leads should be 1106
ohms +/- 50 ohms.
Step 2. Use an Ohmmeter and measure the resis-
tance between the SIG + and SIG - leads.
The value for the SIG leads should be 1 ,000
ohms +/- 10 ohm.
Step 3. Readings that exceed the ranges indicated
suggest damage, and the load cell should be
throroughly inspected or replaced.
OPERATION AND INSTALLATION MANUAL
Resistance to Ground Test
NOTE: Be careful NOT to include the two C2 wires.
WARNING WHEN USING A MEGGER DO NOT EXCEED
Problem:Electrical leakage is creating an unstable
output from the instrument.
Cause:Water contamination in the load sensors or
cables.
Remedy:
Step 1. Tie together the load sensor excitation (2),
signal (2) and ground (1) wires.
Step 2. Use a megohmmeter and measure the resis-
tance between all five wires tied together
and the load cell metal body. The measured
value should be 5,000 megohms or more.
Step 3. Replace the load cell if the cell fails both
tests.
50 VOLT RANGE.
If the sensor fails this test, remove the ground wire
and test with only the four live leads.
Replace the load cell if the cell fails both tests.
If the sensor passes the test, an insulation problem in
the cable is most likely.
Electrical Termination Cable Color Codes
Model Numbers
NOTE: The -43 indicates a stainless steel Load Sensor with
The cable is 6 conductor, shielded (floating) and 30
feet in length.
EXC+Red EXC -Black
SIG +Green SIG -White
C2+Gray C2-Violet
SHIELDYellow
stainless steel mounting hardware. For zinc plated
mounting hardware use -45.
Page 11
HI HLPRC03 SERIES LOAD POINT ASSEMBLY
Capacity Model # Model #
LBS MT Fixed Assembly Spare Load Sensor
66K 30 HI LPRC03-66K-45C HI RCH03-66K
110K 50 HI LPRC03-110K-45C HI RCH03-110K
200K 90 HI LPRBc03-200K-45C HI RCH03-200K
TABLE 1: MODEL NUMBERS & CAPACITIES
Specifications Operating Specifications
• Rated Output (F.S.)2+-0.002mv/v
• Non-Linearity+-0.012% R.O.
• Hysteresis<+-0.025% R.O.
• Zero Balance<+-1.0% R.O.
• Creep @ 5 Min.<+-0.010% R.O.
• Temp Effect Output<+-0.0014% R.O./C (.0011
on RCHO3)
• Temp Effect Sensitivity<+-0.0010% R.O./C
(.0005 on RCHO3)
• Input Resistance1050 to 1200 ohms +/- 50
• Output Resistance1000 +- 1 ohm +/- 10
• Insulation Resistance >5000 megohms
• Excitation 5-15VDC
• Safe Load Limit 200% Emax
• Ultimate Load 300% Emax
• Safe Side Load 100% Emax
Page 12
Environmental Specifications
• Operating TemperatureMinus 40
o
C to +80o C)
F (-40
• Compensated Temperature14
(Minus 10
o
C to Plus 40o C)
o
F to Plus176o
o
F to 104o F
OPERATION AND INSTALLATION MANUAL
• Load Sensor Material17-4 Martensitic (Magnetic) Stainless Steel
• Load Sensor Fittings Coated Tool Steel
• Top Plate & Base Plate Material 316 Stainless
Steel or Zinc Plated Steel
• Conduit Adapter. 250-18 NPT
• Hermetic Sealing
• Gauging Area Welded Cylindrical Sleeve
• Cable Entry Glass to Metal Header
Drawings See the section Installing Load Point Assembly for
installation procedures.
All data and information contained in or disclosed by
these drawings is confidential and proprietary information of Hardy Instruments Inc. and all rights
therein are expressly reserved.
Page 13
HI HLPRC03 SERIES LOAD POINT ASSEMBLY
Drawing 1: Module assembly for shipment, positioned on site, and showing the welding alternatives
Page 14
OPERATION AND INSTALLATION MANUAL
Drawing 2: Welded module installed
Page 15
HI HLPRC03 SERIES LOAD POINT ASSEMBLY
Drawing 3: Bolted module installed
Mark “F” indicates the center of the load, which
coincides with the center of the tank leg, etc.
Drawing 4: Dimensional drawing
Page 16
OPERATION AND INSTALLATION MANUAL
Drawing 5: Bolted module installed
Page 17
HI HLPRC03 SERIES LOAD POINT ASSEMBLY
Record Model Information
Please print the unit serial number and mode l number
for reference when ordering parts for the HI LPRC
Load Point Assembly
The serial number can be found on the side of the load
sensor, or by entering the SelfTest Mode of the HI
2151/30WC.
Scale Name/Location:
Model Number:
Serial Number 1:
Serial Number 2:
Page 18
Serial Number 3:
Serial Number 4:
Serial Number 5:
Serial Number 6:
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