Kistler-Morse LD3xi Load Cell User Manual

Load Disc 3xi/LD3xiC

Installation Manual

CAUTION

It is essential that all instructions in this
manual be followed precisely to ensure
proper operation of the equipment.

97-1137-02

Rev F

July 2003

NOTICE

The content of this document is the intellectual property of Kistler-Morse Corporation.
Any reproduction or translation of this document without the written authorization of a
Kistler-Morse corporate officer is prohibited.

CAUTION

Follow these rules if welding is done on the vessel after installation of the Load Disc.
The electrical current of the welder may pass through the Load Disc, causing damage to the
transducer and possibly to the signal processor. To avoid damage, follow these precautions:

1. Disconnect the Load Disc cables from the signal processor.

2. Ground the welder as close to the welding joint as possible. The welding ground must be
between the Load Disc and the weld joint to prevent the welding current from going through the
Load Disc to earth ground.

Note

High temperatures can damage the Load Disc. If you are welding in the vicinity of a
Load Disc, monitor the temperature of the metal adjacent to the Load Disc. If it becomes too hot to
touch, stop welding immediately and remove the Load Disc before continuing. Prior to reinstalling
the Load Disc, verify that no damage has occurred by referring to the measurement procedures in
Troubleshooting, Appendix C.

Table of Contents

Table of Contents

Introduction....................................................................................................i

Welcome ........................................................................................................................................................... i

About this manual ............................................................................................................................................i

Manual Conventions ................................................................................................................................. i

Specifications ................................................................................................................................................... ii

Chapter 1. Description of the Load Disc............................................... 1-1

Introduction .................................................................................................................................................. 1-1

Description of Measurement System ...................................................................................................... 1-1

Applications Descriptions ....................................................................................................................... 1-1

Installation Option Descriptions ................................................................................................................... 1-2

Universal Top Adaptor Plate ................................................................................................................. 1-2

Leveling Top Plate Adapter ................................................................................................................... 1-3

Anyadapter Plate ................................................................................................................................... 1-3

Leveling Base Adapter Plate .................................................................................................................. 1-4

LD3xiC Assembly Option ...................................................................................................................... 1-4

Chapter 2. Preparing for the Load Disc Installation ........................... 2-1

Check Shipment ............................................................................................................................................ 2-1

Load Disc Order Items ............................................................................................................................. 2-1

Visual Check ............................................................................................................................................ 2-1

Measuring Sensor Output ............................................................................................................................ 2-2

Prepare Installation Equipment ..................................................................................................................... 2-3

Installation Equipment Needed .............................................................................................................. 2-3

Vessel Preparation......................................................................................................................................... 2-3

Factors Affecting Performance ..................................................................................................................... 2-4

Chapter 3. Mounting the Load Disc ...................................................... 3-1

General Information ....................................................................................................................................... 3-1

LD3xi/LD3xiC General Installation ................................................................................................................. 3-2

Leveling and Shimming ................................................................................................................................. 3-5

Leveling/Shimming using Universal Top Adapter Plate .......................................................................... 3-5

Leveling/Shimming using Leveling Top Adapter Plate ........................................................................... 3-6

Leveling/Shimming using Leveling Base Adapter Plate .......................................................................... 3-6

Leveling/Shimming using Anyadapter Plate ........................................................................................... 3-6

Junction Box Mounting and Wiring.............................................................................................................. 3-7

Trim Box Mounting and Wiring .................................................................................................................. 3-10

Appendix A: Contact Information ................................................................................. A-1

Appendix B: System Calibration ................................................................................... B-1

Appendix C: Troubleshooting ........................................................................................ C-1

Appendix D: Technical Drawings.................................................................................. D-1

i

Table of Contents

PB

Introduction

Introduction

This chapter describes the organization, manual conventions,
and provides specification information .

Welcome

About this manual

This manual describes the installation of the Load Disc 3xi/3xiC load cell and
its various hardware options. It includes procedures for leveling and shim­ming of the vessel if it is neccessary. Instructions for wiring the load cell to
the junction boxes and wiring the junction boxes together and to the signal
processor are also included. Refer to the signal processor manual for specific
information on wiring the junction boxes to the signal processor.

Contact KM at 1-800-426-9010 if you have any questions regarding the
installation. For outside the USA and Canada, call 425-486-6600.

The chapters are organized in the following way:

Chapter 1: Description of the Load Disc 3xi/3xiC
Chapter 2: Preparing the Load Disc 3xi/3xiC for Installation
Chapter 3: Mounting the Load Disc 3xi/3xiC

Appendix A through D include contact info, system calibration, troubleshoot­ing charts and technical drawings (TI’s).

Manual Conventions

Three kinds of special explanations appear throughout the manual —
Warning , Caution and Note. The format and significance of each is
defined below:

WARNING

Possible danger to people. Injury may result if this information is
ignored.

CAUTION

Possible risk to the product. The Load Disc or other equipment may be
damaged if this information is ignored.

Note

Contains additional information about a step or feature critical to the
installation or operation of the Load Disc.

i

Specifications

Introduction

LD3xi

Mechanical

Compression: 3 x rated load

Tension: 1 x rated load

Shear (capacity 220 lbs -2200 lbs): 0.5 x rated load

(capacity 5500 lbs): 0.25 x rated load

Functional Integrity: 1.5x rated load (compression)

Electrical

Excitation Voltage - Operating Range: 5-15 VDC

Recommended Supply Voltage: 10 VDC

Maximum Current: 16mA @ 10 VDC excitation (0o F)

Output Resistance: 700 ohms +/- 2%

Output

Non-linearity/Hysteresis combined: 0.03% standardized output

Return to Zero over 30 min: 0.026% standardized output

Creep over 30 min: 0.028% standardized output

Creep over 20 and 30 min: 0.008% standardized output

Zero Balance: 1% standardized output

Rated Output: 2 mV/V +/-0.1%

LD3xiC/LD3xiMJ

Mechanical

Compression: 3 x rated load

Tension: 1 x rated load

Shear: 0.5 x rated load

Functional Integrity: 1.5x rated load (compression)

Electrical

Excitation Voltage - Operating Range: 5-15 VDC

Recommended Supply Voltage: 10 VDC

Maximum Current: 16mA @ 10 VDC excitation (0

Output Resistance: 700 ohms +/- 2%

Output

Non-linearity/Hysteresis combined: 0.03% rated output

Return to Zero over 30 min: 0.026% rated output

Creep over 30 min: 0.028% rated output

Creep over 20 and 30 min: 0.008% rated output

Zero Balance: 1% rated output

Rated Output: 2 mV/V +/-0.1%

o

F)

Environmental

Temperature Range - Standard: 14o to 104o F (-10o to 40o C)

Temperature Zero Shift: 0.0013%/

Temperature Sensitivity Change: 0.00094% /

Storage Temp Range: -4

o

to 176o F (-20

o

F (0.0024%/oC)

o

F (0.0017% /o C)

o

C to 80oC)

Humidity: 100%

Physical

Construction: 17-4 PH 900 stainless steel

Connector (optional): 6P rated sealed 5-conductor,

12mm male receptacle

Cable Length: 16ft. (5 m) with tinned pigtail termination

Rating: IP68

Shipping Weight: 5 lbs (2.3 kg)

(100h at 1m water column)

Environmental

Temperature Range - Standard: 14o to 104o F (-10o to 40o C)

Temperature Zero Shift: 0.0013%/

Temperature Sensitivity Change: 0.00094% /

Storage Temp Range: -4

o

to 176o F (-20

o

F (0.0024%/oC)

o

F (0.0017% /o C)

o

C to 80oC)

Humidity: 100%

Physical

Construction:

sensor: 17-4 PH 900 stainless steel

cage: 304 stainless steel

Cable Length: 16ft. (5 m) with tinned pigtail termination

Rating: IP68 (100h at 1m water column)

Shipping Weight: 18.7 lbs (8.5 kg)

Approvals: CE, OIML R60

ii

Chapter 1. Description

Chapter 1:
Description of the Load Disc

This chapter describes the Load Disc 3xi/3xiC/3xiMJ
Compression Load Cell and its installation options.

Introduction

The Load Disc 3xi/3xiC/3xiMJ is a low profile load cell that is bolted to both
the support surface and the vessel supports, and is used to measure the
weight of materials in vessels and tanks. The sealed, stainless steel construc­tion--IP68 rated unit with an optional NEMA-6P watertight cable system and
cable entry–makes the LD3xi/3xiC/3xiMJ ideal for use in high-pressure wash

Figure 1-1:
LD3xi Compression Load Cell
with optional NEMA-6P cable
system

down and occasionally submerged environments. The LD3xi/LD3xiC/3xiMJ
offers system performance accuracy of 0.03%.

The low-profile design for low clearance installations also keeps the vessel’s
center of gravity low and stable. Vessel tipping, walking or overturning while
agitating is eliminated. Installation and setup is simplified with less hardware.
No external vessel hold-downs are necessary, even in areas of high wind or
seismic activity. There are no moving parts that can wear out or require
replacement.

weight/4

weight/4

LD3xi/
LD3xiC
(x4)

junction box

signal
processor

weight/4

weight/4

Signal
transmission/
Serial Output

Setpoints for
signaling a
change in staus,
such as high and
low alarms

Figure 1-2:
General installation layout for LD3xi/
LD3xiC using a junction box.

In bakery, pasta, confectionary and spice processing to resins, concrete/
aggregate, sand, pulp, minerals and other dry-to-wet operating conditions,
the LD3xiC offers very specific advantages not available in most higher
priced load cells. Standards include a tough “cage” mounting fixture into
which the 17-4 stainless steel LD3xiC cell securely locks in place. Since the
LD3xiC cell can be loaded before or after the tank is installed onto the “cage”
fixture, you have more flexibility in mounting procedures. If ever the cell
needs to be replaced, it can be unloaded without having to remove the
“cage” fixture itself. The LD3xiC is available in virtually all popular weight
capacities from 220 lbs to 22,000 lbs. and is easy to specify due to identical
dimensions and price.

General Description of Measurement System

The deflection of the load cell by the vessel weight is measured by the foil
gage sensor, which is entirely sealed within the watertight cavity of the
transducer. The sensor converts the deflection into an electrical signal which is
directly proportional to the increase or decrease of the vessel contents.
Material movement and changes in material repose will not affect the accuracy
of the system. Accurate weight information is then sent to a signal processor
for display, information transmission and storage (See Figure 1-2).

Applications Description

The watertight design of the load cell makes it ideal for measuring bulk
material in the sanitary and clean-in-place environments. It is particularly
suitable for use on mixing and blending vessels, surge hoppers, and agitated
vessels. Rugged, solid, bolt-in-place mounting assures vessel stability in
outdoor storage vessels with gussets or legs used in all process industries.

1-1

Installation Option Descriptions

Chapter 1. Description

This section will briefly describe the following hardware options:

Universal Top Plate Adapter, Leveling Top Plate Adapter,
Anyadapter Plate and Leveling Base Adapter Plate.

As well as the LD3xiC Load Cell configuration.

See Chapter 2 and 3 for more specific installation instructions and
refer to the TI drawings located in Appendix D.

Universal Top Adapter Plate

This option consists of the Universal Top Adapter Plate, spring washer and a
hex head bolt. The adapter plate attaches to the load disc with the bolt and
washer. The adapter plate then bolts to a vessel gusset or a flat plate welded
to the vessel leg, using customer-supplied hardware.

Note: Accomodates up to three
degrees of tilt in the floor or
vessel legs.

1-2

Chapter 1. Description

Leveling Top Plate Adapter

This option consists of the Universal Top Adapter Plate, a hex head bolt,
spherical washer set and jam nuts. The adapter plate attaches to the load disc
with the hex bolt and hardware. The adapter plate then bolts to a vessel gusset or
a flat plate welded to the vessel leg, using customer-supplied hardware.

This hardware arrangement allows 360 degree movement of the top plate and
angular misalignment of up to 3 degrees. Additionally, there is a leveling feature
that allows vertical height adjustments. This arrangement also incorporates a
locking-jam nut to insure the height remains unchanged.

Anyadapter Plate

This option consists of the unique Anydapter Plate which has a
universal bolt pattern (to fit a variety of vessel leg flanges), and a hex
head bolt. The plate attaches to the load disc with the bolt and washers.
The Anyadapter plate then bolts to a vessel gusset or a flat plate
welded to the vessel leg, using customer-supplied hardware.

This hardware arrangement allows 360 degree movement
of the top plate and angular misalignment of up to 3
degrees. Additionally, there is a leveling feature that
allows vertical height adjustments. This arrangement
also incorporates a locking-jam nut to insure that the
height remains unchanged.

1-3

Note:
Adapter plate not shown in
illustrationat right.

This kit requires an adapter
plate for proper installation.

Chapter 1. Description

Leveling Base Adapter Plate

This kit consists of a Leveling Base Adapter Plate and four hex bolts, four flat
washers, and four lock washers. The LD360S bolts onto the leveling base
adapter plate. This plate rests on four leveling nuts and washers screwed onto
anchor bolts installed in the foundation. By turning the leveling nuts, the height
of the load discs and thus the vessel, can be adjusted for proper load distribution.

LD3xiC/3xiMJ Load Cell Assembly

This unit consists of the LD3xiC/3xiMJ load cell assembly (load cell and installed
set screws) and a cage assembly. The load cell has the loading head on top and
they both slide into the cage assembly. They are held in place with three set
screws. The set screws are pre-installed into the load cell at the factory. The load
cell assembly slips down into the holes of the cage assembly. (The LD3xiC
assembly does not include jacking bolts, the LD3xiMJ does include jacking
bolts.)

1-4

Chapter 2. Pre-Installation

Chapter 2:

Preparing for the Load Disc Installation

This chapter describes the pre-check procedures for the LD3xi/LD3xiC.
Checking the load discs before installation will ensure properly
working equipment that will provide accurate monitoring of
vessel contents.

Check Shipment

Perform the following prior to installing the Load Disc:

Check Load Disc Order Items

The following items are included with a typical order for each vessel
(quantities dependent on application):

LD3xi/LD3xiC Load Cell

Junction Boxes or molded junctions

Top or Bottom Hardware (LD3xi only)

If any items are needed, contact KM before proceeding. Substituting
parts without KM approval may cause system problems and will void
the warranty.

Visual Check

Visually inspect all equipment in the order — including Load Discs,
junction boxes, and signal processors — to verify they have not been
damaged during shipment. If any item has been damaged, contact KM
for a replacement.

2-1

Chapter 2. Pre-Installation

Measuring Sensor Output

To measure the output of the LD3xi/LD3xiC, the sensor needs to
have an excitation voltage applied to it from a signal processor, a DC
voltage generator, or a KM test meter.

To use the excitation from the KM Test Meter, put the switch in
the simulate position and wire the positive to the red position
and the negative to the black position.

Turck Option

The excitation would be applied to the excitation wires or the quick
disconnect cable, brown (positive) and black (negative). The
millivolt signal would be measured with a multimeter on the output
wires, white (positive) and blue (negative).

Standard Fixed Cable

The excitation would be applied to the excitation wires of the
standard fixed cable, red (positive) and black (negative). The
millivolt signal can be measured on the output wires, white (positive)
and Yellow (negative).

2-2

Prepare Installation
Equipment

(Customer Supplied)

Chapter 2. Pre-Installation

The following equipment is needed to install Load Discs:

Lifting equipment

Tape measure

Level

Pry bar

Marking pen

Wrenches

ASTM A-325 bolts or anchor bolts (or equivalent
strength), lock washers, and flat washers to
secure Load Disc to vessel support or
foundation (if applicable)*

Signal processor

Shims (if applicable)

Grout (if applicable)

Note: KM recommends the use

of a trim box for applications

which need to be “certified for

trade”.

Vessel Preparation

Digital Multimeter (FLUKE™ or equivalent)

* See TI drawings in Appendix D for the appropriate bolt size.

There are two aspects to successful use of Load Discs — properly
functioning Load Discs and appropriate vessel support
characteristics. Review the following list of error sources, and make
the recommended corrections before you install the Load Discs:

• An inadequate vessel foundation can allow excessive
movement. Ensure the foundation is concrete or steel.

• Hidden load-bearing structures, such as discharge chutes
or plumbing supported by the floor, can reduce loads on
the vessel supports. Install flexible couplings to minmize
this problem.

• Cross-connecting structures, such as catwalks and
manifolds, can transfer loads from adjacent vessels.
Install slip joint or flex couplings to minimize this
problem.

• Shock loads can damage the Load Disc. Install protective
barriers or stops to prevent vehicles from hitting the
vessel supports.

2-3

Chapter 2. Pre-Installation

Factors that affect Performance

An independent, isolated vessel with no connection to any other vessel
or adjacent structure provides the most accurate results for a weight
measurement system. Examples of this type of application are floor scales
and truck scales. Connections to other vessels or structures affect
accuracy because the transducers interpret strain changes caused by the
connecting structures as being caused by changes in the material weight.

No horizontal run

No horizontal run

Flex coupling

Horizontal run too short for cross­sectional area of pipe

Horizontal run length is ok for
cross-sectional area of pipe

Flex

Some typical causes of error related to
connecting structures and, where applicable,
methods for reducing the errors follow:

• Catwalk

• Hidden load bearing members

• Vessel goes through roof

• Tripper conveyors or deck plating

• Rigid piping connection between vessel and

another adjacent structure

• Poor Foundation

• Flexible Structure

• Uneven Loading

Figure 2-1:
Examples of typical causes of error.

2-4

Chapter 3. LD3xi/LD3xiC Mounting

Chapter 3: Mounting the Load Disc

This chapter describes installation and wiring of the
LD3xi/LD3xiC and junction boxes. Follow all instructions
carefully to ensure proper operation of the system.

General Information

The load disc has a variety of mounting hardware options that
accommodate almost all possible applications. These general require­ments apply to all applications:

• Ensure the surfaces where the baseplates bolt down onto are
clean, smooth, flat, and level, with less than 1° of slope in any
direction.

• Ensure vessel legs/gussets are clean, smooth, flat, and level,
with less than 1° of slope in any direction.

CAUTION: If you
need to raise the
vessel or one vessel
leg after installation,
loosen the bolts on all
Load Discs to prevent
overloading.

• Position load disc so the cable cannot be snagged or chafed and
can be easily routed to the junction box.

• When raising the vessel for load disc installation, use proper
support to prevent the vessel from tipping or falling.

• During installation, carefully distribute the load to ALL load
discs evenly. PLACING THE LOAD ON ANY ONE LOAD DISC
MAY CAUSE DAMAGE.

• Hardware and Bolts —

1. All bolts and hardware to attach the Load Disc to the vessel

and to the foundation are customer-supplied,
ASTM A-325 or equivalent. (See TI drawings Appendix D)

2. Use specified hardware and bolt sizes. Using other than the

specified hardware can either reduce strength or overstress
the load disc during installation, voiding the warranty.

3. All bolts are kept loose until shimming and leveling is

complete.

• Securing LD3xi/LD3xiC after Leveling/Shimming —
Once the weight distribution criteria has been satisfied
through leveling and/or shimming, complete the installation by
tightening the required bolts for your application.

3-1

Chapter 3. LD3xi/LD3xiC Mounting

LD3xi/LD3xiC
General Installation

This section describes the installation procedures for the following
hardware options:

Universal Top Plate Adapter, Leveling Top Plate Adapter, Anyadapter
Plate, Leveling Base Adapter Plate as well as the LD3xiC.

1. Prior to installing the load cell, verify that they are the correct
capacity for your application by reviewing the information on
the label.

2. Measure the load cell voltage output. With no-load,
the meter should read 0mV. (This measurement range is used
only to verify the condition of the Load Disc.)
If the reading is significantly outside of this range, consult the
factory before continuing the installation.

(If you have the LD3xiC, go to Step 5.)

3. Place bolt through center hole of adapter plate and install
hardware for your application (See Appendix D: TI Drawings)

a. For Universal Top Plate Adapter, install bolt and

plate to LD3xi, tightening bolt to 5-10 ft-lbs.

Note: Concrete founda­tion and grouting shown
for reference only. The
concepts apply to all
foundation types.

Anchor bolts supplied by
customer.

b. For Leveling and Anyadapter, install washers and

nuts to the bolt and plate, making sure the washers/
nuts are loosely tightened against plate. Install the
plate assembly to the LD3xi, tightening bolt to 5-10
ft-lbs.

4. For Leveling and Anyadapter applications, adjust plate to
lowest position by lowering jam nut to top of LD3xi and
tighten. Then lower leveling nut to the jam nut.

Figure 3-1: Angular misalignment

3-2

Chapter 3. LD3xi/LD3xiC Mounting

5. Raise the vessel.

6. Inspect the foundation and vessel mounting surfaces that
will mate to the LD3xi/LD3xiC plates.

a. Check the mounting hole locations and size on both

the foundation base and the vessel foot pad. (Refer
to the TI drawings, Appendix D.)

b. Also check the surfaces for flatness and angular

misalignment. A baseplate with leveling nuts is
recommended. (See Figure 3-1)

7. Mount the LD3xi/LD3xiC assembly to the foundation. (See TI drawings,

Appendix D)

a. Lower the LD3xi/LD3xiC to the foundation. Take

care to align the mounting holes with the foundation
mounting holes/studs.

b. Install the bolts and nuts as required. DO NOT fully

tighten the bolts at this time. Leave a 1/4-inch gap
between the nut and the washer to allow for positioning
of the Load Discs. (See Figure 3-2.)

c. Repeat Steps 7a and 7b for the remaining Load Discs.

8. Record the voltage output at “no-load”condition now that it is in

position.

a. Assign a number (1, 2, 3, etc.) to the load disc and make a

note of it.

b. Measure the output of load cell..

c. Repeat steps a and b for all the Load Discs.

Figure 3-2: Leave 1/4-inch gap for positioning

Load Disc # No-Load Output Dead Weight Output Output Change (mV)

(mV) (mV) (Dead Weight Output - No-Load Output)

1

2

3

4

Figure 3-3: Weight Distribution Chart: Record YOUR system’s Load Outputs

3-3

Figure 3-4: Lower vessel onto
top plate.

Note: All output changes should
be positive! If you observe a
negative output change, check
wiring polarity and vessel load
shifting.

Chapter 3. LD3xi/LD3xiC Mounting

9. Mount the vessel to the LD3xi/LD3xiC.

a. Lower the vessel gently onto the Load Discs.

(Alignment pins may be used to help guide and
position the vessel.) (See Figure 3-4)

b. Center the Load Disc top mounting holes with the

vessel mounting holes, using the clearance
available from the bottom mounting holes.

Note: If the vessel hole pattern does NOT match up with
the Load Disc hole pattern, modify the mounting holes on
the vessel. DO NOT hammer or force the Load Disc into
position by tightening the mounting bolts. The vessel holes
will need to be resized or relocated.

c. Place the four top bolts (customer supplied)

through the vessel and the Load Disc mounting
holes. The bolts must be able to pass freely
through the holes without interference.

d. Tighten the bolts, leaving a 1/4-inch gap for

positioning. (See Figure 3-2)

11. Check dead weight output.

a. Record the dead weight output on your Weight

Distribution Chart that was started on page 3-3.

b. Calculate the Output Change. (Change should be

positive.)

3-4