The wide variety of weigh modules we manufacture and distribute may leave you wondering what the differences are between certain models and, most importantly, which modules are best suited for your needs. We’ve broken down our weigh module selection into three application categories. Most operations can be classified into one of these:
Truck Scale Weighing
Complete Mounting Kits
Complete mounting kits are available with our weigh modules, simplifying the selection and installation processes. Each kit comes with a detailed installation manual and an analog junction box with cable assembly, eliminating the need to order separate parts. All standard weigh module kits include the required load cell(s), junction box, mounting hardware and cable, but can be customized to meet your exact needs.
More information on this topic and more can be found in the Load Cell and Weigh Module Handbook or Load Cell and Weigh Module Selection Guide.
With the largest selection of quality load cells available in stock, nobody offers faster, more reliable service. Whether you need a replacement load cell or a load cell for a unique application, we’ve got a solution to fit any need. Our knowledgeable customer service representatives can answer your questions and help you select the best load cell for any application from tank and hopper weighing, to bulk material management, to mechanical scale conversions.
Load cells can be categorized into the following types:
Here are some easy-to-follow steps to help you troubleshoot potential load cell problems. Before you begin you will need a good quality digital multimeter, at least a 4½ digit ohm meter. The tests are: physical inspection, zero balance, bridge resistance and resistance to ground.
How does it look? If it is covered with rust, corroded or badly oxidized, chances are the corrosion has worked its way into the strain gauge area as well. If the general and physical condition appear good, then you need to look at specifics: sealing areas, the element itself, and the cable.
Other items to look for: metal distortion or cracks, metal rippling, cracks in the weld, or abrasions in the metal. It may be necessary to remove the load cell and check it for physical distortion against a straight edge.
No inspection would be complete without thoroughly inspecting the cable. Cable should be free of cuts, crimps and abrasions. If your cable is cut and in a wet environment, water or chemicals can "wick" up the cable into the strain gauge area, causing load cell failure. If your physical inspection fails to uncover any identifiable damage, a more detailed evaluation is required.
This test is effective in determining if the load cell has been subjected to a physical distortion, possibly caused by overload, shock load or metal fatigue. Before beginning the test, the load cell must be in a "no load" condition. That is, the cell should be removed from the scale or the dead load must be counterbalanced.
Now that the cell is not under any load, disconnect the signal leads and measure the voltage across the negative signal and positive signal. The color code for determining negative- and positive-signal leads is provided on the calibration certification with each load cell. The output should be within the manufacturer’s specifications for zero balance, usually ± 1% of full scale output. During the test, the excitation leads should remain connected with the excitation voltage supplied by the digital weight indicator. Be certain to use exactly the same indicator that is used in the cell’s daily operation to get a reading accurate to the application.
The usual value for a 1% shift in zero balance is 0.3mV, assuming 10 volts excitation on a 3 mV/V output load cell. To determine your application’s zero shift, multiply the excitation volts supplied by your indicator by the mV/V rating of your load cell. When performing your field test, remember that load cells can shift up to 10% of full scale and still function correctly. If your test cell displays a shift under 10%, you may have another problem with your suspect cell, and further testing is required. If the test cell displays a shift greater than 10%, it has probably been physically distorted and should be replaced.
Before testing bridge resistance, disconnect the load cell from the digital weight indicator. Find the positive and negative excitation leads and measure across them with a multimeter to find the input resistance. Don’t be alarmed if the reading exceeds the rated output for the load cell. It is not uncommon for readings as high as 375Ω for a 350Ω load cell. The difference is caused by compensating resistors built into the input lines to balance out differences caused by temperature or manufacturing imperfections. However, if the multimeter shows an input resistance greater than 110% of the stated output value (385Ω for a 350Ω cell or 770Ω for a 700Ω cell), the cell may have been damaged and should be inspected further.
If the excitation resistance check is within specs, test the output resistance across the positive and negative Signal leads. This is a more delicate reading, and you should get 350Ω ±1% (350Ω cell). Readings outside the 1% tolerance usually indicate a damaged cell.
With the multimeter, we tested each leg and got the following readings:
•T1(–Sig, +Exc) = 282Ω
•C1(–Sig, –Exc) = 278Ω
•T2(+Sig, –Exc) = 282Ω
•C2(+Sig, +Exc) = 278Ω
NOTE: When testing leg resistance, a reading of 0Ω or ∞ means a broken wire or loose connection within the cell. In a good load cell in a “no load” condition, all legs need not have exactly equal resistance, but the following relationships must hold true:
3.(C1 + T1) = (T2 + C2)
In this damaged load cell, both tension legs read 4Ω higher than their corresponding compression legs. The equal damage mimics a balanced bridge in the output resistance test (3 above), but the individual leg tests (1, 2 above) show that the cell must be replaced.
NOTE: On multiple-cell applications for matched millivolt output, excitation resistance values may be higher than 110%.
Resistance to Ground
If the load cell has passed all tests so far but is still not performing to specifications, check for electrical leakage or shorts. Leakage is nearly always caused by water contamination within the load cell or cable, or by a damaged or cut cable. Electrical shorting caused by water is usually first detected in an indicator readout that is always unstable, as if the scale were constantly "in motion." The wrong cell in the wrong place is the leading cause of water contamination. Almost always, these leaking cells are "environmentally-protected" models designed for normal non-washdown, not the "hermetically sealed" models that would have stood up to washdown and other tough applications.
Another cause is loose or broken solder connections. Loose or broken solder connections give an unstable readout only when the cell is bumped or moves enough so the loose wire contacts the load cell body. When the loaded scale is at rest, the reading is stable.
To really nail down electrical leakage problems though, test resistance to ground with a low-voltage megohm-meter. Use caution; a high-voltage meter that puts more than 50VDC into the cell may damage the strain gauges. If the shield is tied to the case, twist all four leads together and test between them and the load cell metal body. If the shield is not tied to the case, twist all four leads and the shield wire together and test between them and the body. If the result is not over 5000MΩ, current is leaking to the body somewhere.
If the cell fails this test, remove the shield wire and test with only the four live leads to the metal body. If this tests correctly (over 5000MΩ), you can be reasonably sure current is not leaking through a break in the cable insulation or inside the gauge cavity.
Minor water infiltration problems can sometimes be solved outside the factory. If you are sure that water contamination has occurred and if you are sure that the cable entrance seal is the entry point, try this remedy: remove the cell to a warm, dry location for a few days, allowing the strain gauge potting to dry. Before putting the cell back into service, seal with silicone around the cable entry point in the load cell body. This prevents the reentry of water vapor into the cell.
More information on this topic and more can be found in the Load Cell and Weigh Module Handbook or Load Cell and Weigh Module Selection Guide.
What kind of torture do your load cells have to withstand?
Load cells are critical components in all weighing systems where they sense the weight of material in weigh hoppers, other vessels, or processing equipment. In some applications, a load cell may be exposed to a hostile environment with corrosive chemicals, heavy dust, high temperatures, or excessive moisture from washing down equipment with large amounts of liquid. Or the load cell may be exposed to high vibration, unequal loads, or other harsh operating conditions. Such conditions can lead to weighing errors or can even damage the load cell if it hasn’t been chosen correctly. To select the right load cell for a demanding application, you need a solid understanding of your environment and operating conditions and what load cell features are best for handling them.
What makes a tough application
Take a close look at the environment surrounding your weighing system and what operating conditions the system must
• Will the area be extremely dusty?
• Will the weighing system be exposed to temperatures higher than 150°F
• What are the chemical properties of the material being weighed?
• Will the system be washed down with water or another cleaning liquid? If cleaning chemicals are to be used to wash down the equipment, what are their characteristics?
• Will your wash down method expose the load cell to excessive moisture? Will the liquid be sprayed at high pressure? Will the load cell ever be immersed in liquid during wash down?
• Will the load cells be loaded unequally because of material buildup or other conditions?
• Will the system be subject to shock loading (sudden large loads)?
• Will the weighing system’s dead load (the vessel or equipment containing the material) be large in proportion to the live load (the material)?
• Will the system be subject to high vibration from passing vehicles or nearby processing or handling equipment?
• If the weighing system is for processing equipment, will the system be subject to high torque forces from the equipment’s motor?
Once you know the conditions your weighing system will face, you’re ready to choose a load cell with the right features to not only withstand these conditions but to operate reliably over the long term.
Learn more about this topic by retriving the White Paper: Choosing Load Cells For Tough Applications.
A load cell’s resolution will determine what sensitivity (or readability) it can attain for a given capacity. That is, the resolution of the weighing system (whether it has one or multiple points) equals the system capacity divided by its sensitivity. Simply put, the higher the capacity system, the lower the resolution and sensitivity. Consider for instance a 5,000 pound system divided by 1 pound would be a 1:5000 system. That same 5000 pound scale displaying the weight in 0.5 pound increments would change to 1:10,000 (5,000 pounds divided by 0.5 pound.
Understanding this is important, because as a scale’s resolution gets higher, the actual millivolt output per increment gets smaller. The smaller each millivolt reading, the more difficult it is to detect small weight changes. This makes it more difficult for the load cell to deliver accurate weighing results and the digital indicator to display stable readings.
To learn more visit the White Paper: Opereration, Capacity Versus Resolution, and Common Types of Load Cells.
Aluminum Load Cells
Aluminum load cell elements are used primarily in single point, low capacity applications. The alloy of choice is 2023 because of its low creep and hysteresis characteristics. Aluminum load cells have relatively thick web sections compared to tool steel cells of comparable capacities. This is necessary to provide the proper amount of deflection in the element at capacity. Machining costs are usually lower on aluminum elements due to the softness of the material. Single point designs can be gauged for costs similar to those of bending beams.
Tool Steel Load Cells
Load cells manufactured from tool steel elements are by far the most popular cells in use today. The cost to performance ratio is better for tool steel elements compared to either aluminum or stainless steel designs. The most popular alloy are 4330 or 4340 because they have low creep and low hysteresis characteristics.
This type of steel can be manufactured to spec consistently, which means that minute load cell design changes don’t have to be made every time a new lot or new steel vendor is selected.
Stainless Steel Load Cells
Stainless steel load cells are made from 17-4ph, which is the alloy having the best overall performance qualities of any of the stainless derivatives. Stainless steel cells are more expensive than tool steel load cells. They are sometimes fitted with hermetically sealed web cavities which makes them an ideal choice for corrosive, high moisture applications. Stainless steel load cells that are not hermetically sealed have little advantage over comparable cells constructed of tool steel, other than a higher resistance to corrosion.
More information on this topic and more can be found in the Load Cell and Weigh Module Handbook.
It may be necessary to trim the load cell outputs as a first step before starting the calibration process. Trimming is performed at the junction box to equalize the weight reading from all cells in a system. This ensures that the scale weighs correctly regardless of where the load is applied to the scale.
Trimming is necessary if:
1. It is a legal-for-trade weighing application.
*2. The location of the center of gravity of the contents is not fixed, e.g., powder material which may accumulate on one side.
*3. A high-accuracy weighing system is required.
Trimming is not necessary if:
4. Matched output load cells are used (as in the Paramounts).
5. Weighing self-leveling materials (liquids).
6. The vessel is partially supported on flexures.
*Assume that the vessel’s center of gravity (see 2 and 3 above) rises along the same vertical line as the vessel is filled. Each load cell is always subjected to the same percentage of the weight.
Trimming involves placing the same weight over each load cell in turn, and adjusting the corresponding trim pot in the junction box until the indicator reads the same for all cells. To further illustrate load cell trimming, please review the following examples of signal trim and excitation trimming procedures.
Load Cell Trimming
Many weighing systems use multiple load cells and therefore require a summing junction box to tie or "sum" the load cell signals together, allowing a digital weight indicator to read a single "system" signal. The summing process actually wires multiple load cells so that all their signal lines and excitation lines are in parallel, providing instantaneous electronic summing of the signals.
Load cell summing is necessary because:
•Weight distribution in multiple load cell systems is not equal at each load cell. The vessel loading process, presence of agitators, and the characteristics of the material and many other factors affect weight distribution on the load cells.
•It is virtually impossible to make each load cell exactly alike. Load cell manufacturing process tolerances allow for some variance in individual cell specifications. This variance, if unchecked, would not allow for the kinds of accuracy required in modern process applications.
There are two summing methods; Excitation trim and Signal trim.
Excitation Trimming Load Cells
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