Loadcell troubleshooting

LOAD CELL
HANDBOOK
A Comprehensive
Guide
to
Load Cell
Theory,
Construction
and Use
230 West Coleman Street • Rice Lake, Wisconsin, USA 54868 • 715-234-9171
© 2007 Rice Lake Weighing Systems, Rice Lake, WI USA. All rights reserved.
Check out our web site,
www.ricelake.com, for this
handbook and other information
on our products.

1.0 Introduction ......................................................................................................... 1
2.0 DC Circuit Theory ................................................................................................ 2
• 2.1 Electron ...........................................................................................................................................................2
• 2.2 Current and Voltage.........................................................................................................................................2
• 2.3 Resistance........................................................................................................................................................2
• 2.4 Direct Current Circuits....................................................................................................................................2
• 2.5 Conductor Size..............................................................................................................................................11
• 2.6 Strain Gauge..................................................................................................................................................11
• 2.7 Wheatstone Bridge........................................................................................................................................11
• 2.8 Load Cell.......................................................................................................................................................12
3.0 Load Cell Electrical Theory ............................................................................... 14
• 3.1 Wiring............................................................................................................................................................16
• 3.2 Calibration.....................................................................................................................................................16
• 3.3 Output............................................................................................................................................................16
4.0 Load Cell Terms ................................................................................................. 18
5.0 Troubleshooting.................................................................................................. 20
• 5.1 Physical Check..............................................................................................................................................20
• 5.2 Zero Balance .................................................................................................................................................20
• 5.3 Bridge Resistance..........................................................................................................................................21
• 5.4 Resistance to Ground ....................................................................................................................................26
6.0 Load Cell Construction....................................................................................... 27
• 6.1 Materials........................................................................................................................................................27
6.1.1 Aluminum Load Cells ....................................................................................................................27
6.1.2 Tool Steel Load Cells.....................................................................................................................27
6.1.3 Stainless Steel Load Cells..............................................................................................................27
• 6.2 Strain Gauge Protection Alternatives............................................................................................................27
6.2.1 Potted Cell......................................................................................................................................27
6.2.2 Foam Backed Plate.........................................................................................................................27
6.2.3 Neoprene Sleeve ............................................................................................................................28
6.2.4 Hermetically Sealed .......................................................................................................................28
6.2.5 Welded Seal....................................................................................................................................28
7.0 Load Cell Types .................................................................................................. 29
• 7.1 Canister .........................................................................................................................................................29
• 7.2 Single Ended Shear Beam.............................................................................................................................30
• 7.3 Double Ended Shear Beam ...........................................................................................................................31
• 7.4 Cantilever Beam............................................................................................................................................31
• 7.5 "S" Beam.......................................................................................................................................................31
• 7.6 Platform.........................................................................................................................................................32
8.0 Load Cell Mounting Assemblies ......................................................................... 33
• 8.1 Tank and Hopper Kits ...................................................................................................................................33
8.1.1 Isolated Tension Cell Mounting Assembly (ITCM).......................................................................33
8.1.2 RL50210 Mini Tank Weighing Assembly .....................................................................................33
8.1.3 RL1800 Series Mounting Assembly ..............................................................................................34
8.1.4 RL1900 Series Mounting Assembly ..............................................................................................35
8.1.5 RL1600 Series Tank Weighing Assembly......................................................................................36
8.1.6 EZ MOUNT 1 - Tank Weighing Assembly....................................................................................36
8.1.7 Paramounts™.................................................................................................................................37
• 8.2 MVS..............................................................................................................................................................40
• 8.3 PLTA - Parallel Link Truck Scale Assembly.................................................................................................40
i
Table of Contents

ii
9.0 Load Cell Selections........................................................................................... 41
• 9.1 Mechanical to Electronic Conversion...........................................................................................................41
9.1.1 Determine Scale Multiple......................................................................................................................41
9.1.2 Load Cell Size .......................................................................................................................................42
9.1.3 Microvolt Per Graduation......................................................................................................................42
• 9.2 Tank and Hopper...........................................................................................................................................43
10.0 Load Cell Trimming............................................................................................. 45
• 10.1 Excitation Trim ...........................................................................................................................................45
• 10.2 Signal Trim..................................................................................................................................................47
• 10.3 Junction Box Care.......................................................................................................................................48
Appendix A-Units of Measure................................................................................... 49

1
LOAD CELL HANDBOOK
1.0 INTRODUCTION
A load cell is a device that outputs an electrical signal which is directly proportional to the force that is applied to it.
Load cells are used extensively in electronic weighing applications. This review will concentrate on the following
subjects:
DC Circuit Theory
Load Cell Electrical Theory
Load Cell Terms
Troubleshooting
Load Cell Construction
Load Cell Types
Load Cell Selection
Trimming
Junction Boxes

2.0 DC CIRCUIT THEORY
OBJECTIVE: Familiarization with DC circuits, Wheatstone bridge and strain gauges.
2.1 Electron
An electron is a negatively charged particle that is a part of all atoms. Electrons form orbits around the atom. Elec-
trons found in orbits closer to the atom’s center, or nucleus, are held into the atomic structure more closely than those
electrons in the outermost orbit. Conductors such as gold, copper and silver have one electron in their outer orbit, also
called the valence shell. These valence electrons can easily escape their atom and move randomly to another atom.
These electrons are called free electrons. Free electrons bump into other valence electrons, causing more free electrons.
Conductors have many free electrons randomly moving from atom to atom.
Insulators are opposite of conductors. Their valence shells contain many electrons which are tightly held to their atoms.
Insulators have few free electrons and are very poor conductors of electricity.
2.2 Current and Voltage
Electrical current is the orderly flow of electrons. When electrons flow past a given point at the rate of 6.24 x 1018
(6, 240,000,000,000,000,000) electrons per second, one ampere of current is present. The name given to the number
6.24 x 1018
is a coulomb. So we can say one ampere (Amp) of current is equal to one coulomb passing a given point
in one second. The symbol used in electronics for current is A.
In order to move electrons in a conductor to produce current flow, a force must be exerted on the conductor. In electri-
cal circuits this force is a difference in electrical potential between two points and is called voltage. So, current is the
actual electron flow and the voltage is the force that causes the electrons to flow. The symbol used in electronics for
current is I, and the symbol for voltage is E.
2.3 Resistance
Current flowing through a conductor encounters opposition from the conductor. This opposition to current flow is
called resistance. The symbol used to denote resistance is R. The unit of measure for resistance is called the ohm.
The symbol used to denote ohms is Ω.
2.4 Direct Current Circuits
A German physicist named G.S. Ohm developed a definite relationship between voltage, current and resistance in a
closed circuit. A circuit consists of a voltage source and a complete path for current flow. The path must start at one
side of the voltage source and end at the other side. This gives the circuit a complete, uninterrupted path and also estab-
lishes a potential difference between ends of the path since one side of the source has a positive potential and the other
side has a negative potential. Mr. Ohm stated, “Current is directly proportional to voltage and inversely proportional
to resistance.” This relationship is known as Ohm’s Law.
As a formula, Ohm’s Law looks like this:
Current (in amperes) = Voltage (in volts)
Resistance (in ohms)
Using the symbols for current, voltage and resistance, this relationship is shown as I = E/R. More commonly, Ohm’s
Law is referred to in the form E = IR, or voltage equals current times resistance.
2

DC CIRCUIT THEORY CONT.
-
+
Resistor
Battery Noticethereisavoltagesource(bat-
tery), a conductor and opposition to
the current (resistance). The path
is also closed to allow current flow
through the circuit.
The resistance is the load or what is being acted upon by the current. It could be a light bulb, heating element or any
other type of resistive electrical component, such as a load cell.
Let’s take a closer look at Ohm’s Law, I = E/R. Since voltage and current are directly proportional, if we increase the
battery voltage of our circuit we will also increase the current flow. Also decreasing the resistance will increase current
flow as current and resistance are indirectly proportional.
Series Resistive Circuit
A series circuit contains a power source, one or more resistances and only one path for current flow. Let’s look at a
series circuit with two resistors.
To symbolize a direct current circuit we use the symbol to represent the battery which is the power source. The
symbol for resistance is . The diagram of a simple direct current circuit is shown below.
-
+
10V
R2
= 300Ω
R1
= 100Ω
As we look at the circuit we find a 10V power source. There are two resistors in the circuit and only one path for cur-
rent to flow. So in a series circuit we can say the current in the circuit is constant. No matter where you measure the
current in the circuit it will be the same.
The total resistance (RT
) in the circuit is the sum of all resistances. (RT
= R1
+ R2
...). The total resistance of our circuit
is 400Ω. Using Ohm’s Law we can find the total current flowing in the circuit: IT
= ET
/RT
, IT
= 10V/400Ω = .025 amps
or 25 milliamps (mA). Since we know the total current flow we know the current flow through R1
and R2
(IR1
, IR2
).
Current flow is constant in a series circuit so IT
= IR1
= IR2
. The sum of the voltage drops in a series circuit are equal
to the applied voltage. What is the voltage drop across R1
? Using Ohm’s Law the voltage drop across R1
(ER1
) equals
the current flowing through R1
(IR1
) times the resistance of R1
.
3

In a formula it looks like this: ER1
= IR1
R1
ER1
= .025A (100Ω) = 2.5 volts
ER2
= .025A (300Ω) = 7.5 volts
ET
= ER1
+ ER2
ET
= 2.5V + 7.5V = 10V
Let’s look at another example.
R3
R1
2KΩ
ET
= 120V
RT
= 6KΩ
R2
= 1KΩ
Find:
ER1
ER 2
ER 3
The problem asks to find the voltage drops across each of the resistors. We first need to find the total circuit current,
which also equals the current through each of the resistors. Using Ohm’s Law:
IT
= ET
/RT
IT
= 120V/6000Ω
IT
= 20 mA
We also know that RT
= R1
+ R2
+ R3
To find R3
we can say, R3
= RT
- R1
- R2
R3
= 6KΩ - 2KΩ - 1KΩ
R3
= 3KΩ
Using Ohm’s Law to find ER1
, ER2
and ER3
...
ER1
= IR1
x R1
= .020A x 2000Ω
= 40V
ER2
= IR2
x R2
= .020A x 1000Ω
= 20V
ER3
= IR3
x R3
= .020A x 3000Ω
= 60V
4

5
DC CIRCUIT THEORY
Parallel Resistive Circuit
A parallel circuit contains a power source and more than one path for current ﬂow.
200Ω
R210V
100Ω
R1
IR2
=IR1
=
In a parallel circuit the total voltage (ET
) is applied to all circuit branches. Because of this, it is said voltage in a parallel
circuit is constant. The total circuit current is the sum of all branch currents.
Total resistance in a parallel circuit is found by ﬁnding the reciprocal of the sum of the reciprocals for each resistance.
This concept in a formula looks like this:
RT
= 1
1/R1
+ 1/R2
...
For our circuit:
RT
= 1
1/100 + 1/200
RT
= 1
.015
RT
= 66.67Ω
Notice that the total resistance is lower than the lowest individual resistance. For two resistors in parallel total resistance
can also be computed by using a formula called “Product Over the Sum.” It looks like this:
RT
= (R1
)(R2
)
R1
+ R2
RT
= (100)(200)
100 + 200
RT
= 20000
300
RT
= 66.67Ω
If the parallel resistors are the same value, it can be divided by the total number of resistors. For example, if there are
5, 100 ohm resistors in parallel the total resistance would be 100Ω/5 or 20Ω.

In our example circuit we can find total current by using Ohm’s Law:
IT
= ET
RT
IT
= 10V
66.67Ω
IT
= 150 mA
Use Ohm’s Law to find IR1
and IR2
.
IR1
= ER1
R1
= 10V
100Ω
= 100 mA
IR2
= ER2
R2
= 10
200Ω
= 50 mA
By adding IR1
and IR2
we find the total circuit current is 150 mA just as we calculated with Ohm’s Law.
Let’s look at another example.
RT
= 28.57KΩ
R2
= 100KΩ
IR3
1mA
R1
Find:
ET
R1
R3
IR1
Let’s start by finding ET
. We know that ET
is the same as the voltage applied to each branch. Since we know R2
and
IR2
we can use Ohm’s Law to find ER2
which is the same as ET
.
ER1
= R1
x IR1
= 100,000Ω (.002A)
= 200V
IR2
= 2mA
6

7
Since we know ET
we can find R3
.
R3
= ET
IR3
= 200V
.001A
= 200KΩ
We know ET
and RT
is given. Use Ohm’s Law to figure out IT
.
IT
= ET
RT
= 200V
28.57KΩ
= 7 mA
Since IT
= IR1
+ IR2
+ IR3
we can figure out the current through branch resistor IR1
.
IR1
= IT
- IR3
- IR2
IR1
= 7mA - 1mA - 2mA
IR1
= 4mA
Since we know ET
and IR1
we can find R1
using Ohm’s Law.
R1
= ET
IR1
R1
= 200V
.004A
R1
= 50KΩ
Series-Parallel Circuit
A series-parallel circuit has at least two parallel branches in addition to at least one resistor through which total circuit
current flows. The resistor through which all circuit current flows is called the series resistor.
Below is an example of a series-parallel circuit.
10V
R1
50Ω
R2
100Ω R3
150Ω
Find:
RT
IT
ER1
ER2
ER3

To find total circuit resistance, find the equivalent resistance of R2
and R3
in parallel.
Req = 1
1/R2
+ 1/R3
= 1
1/100 + 1/150
= 60Ω
The equivalent series circuit is shown below.
R1
= 50Ω
10V
ET
Req = 60Ω
Req = Equivalent Resis-
To find RT
add the series resistances. RT
= R1
+ Req
RT
= 50Ω + 60Ω
RT
= 110Ω
To find total current in the circuit use Ohm’s Law.
IT
= ET
RT
IT
= 10V
110Ω
IT
= .091A or 91mA
Since total circuit current flows through R1
we can say IT
= IR1
. Using Ohm’s Law we can figure the voltage drop
across R1
.
ER1
= IR1
R1
ER1
= .091A (50Ω)
ER1
= 4.55 volts
Since R1
drops or uses 4.55 volts, that leaves 10V - 4.45V or 5.45 volts to be dropped across the parallel network of
R2
and R3
. Using Ohm’s Law we can determine the current flow through R2
and R3
. The total current in the circuit
will divide proportionately between R2
and R3
. In other words, the total current in the circuit will be the sum of the
branch currents IR2
and IR3
.
8

IR2
= ER2
R2
= 5.45V
100Ω
= .0545A or 54.5 mA
IR3
= ER3
R3
= 5.45V
150Ω
= .0363A or 36.3 mA
IT
= IR2
+ IR3
IT
= 54.5 mA + 36.3 mA
= 90.8 mA
Rounding off the 90.8 mA to the nearest whole number, we get 91 mA just as we calculated earlier.
Remember that a series-parallel circuit has to have at least one component through which total circuit current passes.
The following type of circuit is sometimes erroneously referred to as a series-parallel circuit.
R1
1.5KΩ
R2
4.5KΩ
ET
= 6V
R3
2KΩ
Using our definition of series-parallel circuits, we can see that total circuit current does not flow through any of the
components. This circuit is actually a parallel circuit.
To determine the current flow through R1
+ R2
we need to add these resistances for a total branch resistance of 6KΩ.
Using Ohm’s Law we can find the current through branch R1
+ R2
.
IR1+R2
= ER1
+ R2
R1
+ R2
= 6V
6,000Ω
= 1 mA
R4
10KΩ
9

OR
RT
= (6000)(12000)
6000 + 12000
RT
= 72,000,000
18000
RT
= 4,000Ω or 4KΩ
To determine the current flow through R3
+ R4
we add their resistances for a total of 12KΩ. Use Ohm’s Law to cal-
culate total current.
IR3 + R4
=ER3
+ R4
R3
+ R4
= 6V
12,000Ω
= .5 mA or 500 μA
Total circuit current is the sum of the currents through both branches or IT
= IR3 + R4
+ IR1 + R2
or 1 mA + .5 mA = 1.5
mA.
To calculate total circuit resistance we can use Ohm’s Law again.
RT
= ET
IT
= 6V
.0015A
= 4,000Ω or 4KΩ
We can also calculate total resistance by using the “reciprocal of the sum of the reciprocals” formula or the “product
over the sum” formula. We know the R1
+ R2
branch resistance is 6.0KΩ and the R2
+ R4
branch resistance is 12KΩ.
RT
= 1
1 1
R1
+ R2
+ R3
+ R4
RT
= 1
1/6000 + 1/12000
= 1
3/12000
= 1
1/4000
= 4,000Ω or 4KΩ
If we want to know the voltage drop across each resistor we can also use Ohm’s Law. Let’s use R1
. We know that the
current flowing through R1
equals the current flowing through R2
and the branch made up of R1
+ R2
, because these
two resistances are in series with each other. Using Ohm’s Law we can multiply the resistance of R1
times the current
flow through R1
(IR1
) to find ER1
(voltage drop across R1
).
ER1
= R1
IR1
= 1,500Ω (.001A)
= 1.5V
Ohm’s Law can also be used to find voltage drops throughout the rest of the circuit.
This circuit is the foundation for building a Wheatstone bridge circuit which is the circuit used in load cells. We will
explore this circuit in the next section.
10

11
BALANCED WHEATSTONE BRIDGE
Figure 2
NOTE: All resistors are
equal.
A is a symbol for an am-
meter,
2.5 Conductor Size
A conductor or wire has a certain amount of resistance depending on its diameter. The larger the diameter, the lower
the resistance. If we stretch the wire we have decreased its diameter, or cross-sectional area, thus increasing its re-
sistance. The opposite is also true. If we compress the wire, its diameter is increased and its resistance is decreased.
Since it takes a force to act upon the wire to compress or stretch it, the wire can be configured to measure force. This
configuration of wire is called a strain gauge.
2.6 Strain Gauge
A strain gauge consists of a very fine length of wire that is woven back and forth in a grid and laid on a piece of paper
or plastic called its base. A common wire used is a copper-nickel alloy with a diameter of about one thousandth of an
inch (.001”). The wire is zig-zagged to form a grid so to increase the effective length of the wire that comes under the
influence of the force applied to it. Leads are attached to the ends of the gauge. Strain gauges can be made very small,
sometimes as small as 1/64”. These gauges are cemented to a strong metal object, commonly referred to as the load
receiving element, to make up a load cell. The gauges are configured into a circuit called a Wheatstone bridge.
2.7 Wheatstone Bridge
The type of resistive circuit used in load cells is a Wheatstone bridge.
STRAIN GAUGE
Figure 1

When power is applied to this bridge the current flowing in the R1
/R3
branch is equal to the current flowing in the R2
/R4
branch. This is true because all resistors are equal. Since there is no voltage difference between points 1 and 2 there
is no current flow through the ammeter. This bridge is in a balanced condition.
Now let’s increase the resistance of R1
and R4
to 350.5 ohms, and decrease the resistance of R2
and R3
to 349.5
ohms.
UNBALANCED
WHEATSTONE BRIDGE
Figure 3
As you can see, the bridge becomes unbalanced. There is actually three paths for current flow in this circuit.
Path 1 Negative battery terminal through R2
and R4
back to the positive battery terminal.
and R3
back to the positive battery terminal.
, the ammeter, R3
and back to the positive
battery terminal.
Notice this time there is current flow through the ammeter. This current flow is a result of a potential difference between
points 1 and 2. The larger the potential difference the larger the current flow through the ammeter.
2.8 Load Cell
We can take our strain gauge and Wheatstone bridge theories and use them to construct a load cell. We will use a col-
umn of steel and glue a strain gauge on each of the four sides of the column. As weight is placed on top of the column,
the length of the column would decrease. The column also would become “fatter,” or bulge out. Two strain gauges
are placed opposite of each other to respond proportionately to the change in length.
Two other gauges are placed on opposite sides of the column and respond to the change in the column’s bulge. Since
one pair of strain gauges become shorter their wire diameters become larger and their resistance decreases. The other
pair of strain gauges are positioned so their wires lengthen, thus decreasing their diameter and increasing their resis-
tance. If we hung the same weight from the bottom of the column instead of compressing the column we would be
placing tension on it. The column and strain gauges would act in the opposite direction but still stretch and compress
the wires by the same amount. See Figure 4 - Strain Gauge on page 13.
12

12
LOAD CELL
Figure 5
We can wire our strain gauges into a Wheatstone bridge conﬁguration. We can calibrate the ammeter to read in pounds
instead of amps. In effect, we actually have a scale. Of course this is a crude, very inaccurate scale. It is intended to
show the basic load cell principle. Load cells are made in different shapes and conﬁgurations. The strain gauges are
strategically placed for peak performance. See Figure 5.
STRAIN GAUGE
Figure 4
13

13
3.0 LOAD CELL ELECTRICAL THEORY
OBJECTIVE: Familiarization with load cell electrical theory.
The Wheatstone bridge configured above is a simple diagram of a load cell. The resistors marked T1
and T2
represent
strain gauges that are placed in tension when load is applied to the cell. The resistors marked C1
and C2
represent strain
gauges which are placed in compression when load is applied.
The +In and -In leads are referred to as the +Excitation (+Exc) and -Excitation (-Exc) leads. The power is applied to
the load cell from the weight indicator through these leads. The most common excitation voltages are 10 VDC, and
15 VDC depending on the indicator and load cells used. The +Out and -Out leads are referred to as the +Signal (+Sig)
and -Signal (-Sig) leads. The signal obtained from the load cell is sent to the signal inputs of the weight indicator to
be processed and represented as a weight value on the indicator’s digital display.
As weight is applied to the load cell, gauges C1
and C2
compress. The gauge wire becomes shorter and its diameter
increases. This decreases the resistances of C1
and C2
. Simultaneously, gauges T1
and T2
are stretched. This lengthens
and decreased the diameter of T1
and T2
, increasing their resistances. These changes in resistances causes more current
to flow through C1
and C2
and less current to flow through T1
and T2
. Now a potential difference is felt between the
output or signal leads of the load cell.
Let’s trace the current flow through the load cell. Current is supplied by the indicator through the -In lead. Current
flows from -In through C1
and through -Out to the indicator. From the indicator current flows through the +Out lead,
through C2
and back to the indicator at +In. In order to have a complete circuit we needed to get current from the -In
side of the power source (Indicator) to the +In side. You can see we accomplished that. We also needed to pass current
through the indicator’s signal reading circuitry. We accomplished that as the current passed from the -Out lead through
the indicator and back to the load cell through the +Out lead. Because of the high internal impedance (resistance) of
the indicator, very little current flows between -Out and +Out.
Since there is a potential difference between the -In and +In leads, there is still current flow from -In through T2
and
C2
back to +In, and from -In through C1
and T1
back to +In. The majority of current flow in the circuit is through
these parallel paths. Resistors are added in series with the input lines. These resistors compensate the load cell for
temperature, correct zero and linearity.
Let’s look at a load cell bridge circuit in mathematical terms to help you understand the bridge circuit in both a balanced
and unbalanced condition. Our Wheatstone bridge can either be drawn in a conventional diamond shape or as shown
in the diagram on the following page. Either way, it is the same circuit.
14

14
LOAD CELL ELECTRICAL THEORY CONT.
Notice that the individual branch resistances still total 700Ω so there is still 14.3 mA of current flowing in each branch
of our circuit.
We have replaced the ammeter with a voltmeter which will represent the display on our weight indicator. Also, the
leads connected to our indicator are designated +Sig and -Sig. These represent our positive and negative signal leads.
The 10 volt battery represents our indicator’s power supply that provides the precise voltage to excite or power the
load cell. The resistance values represent our four strain gauges which make up our load cell.
Since there is no load on our cell, all strain gauge resistances are the same. Using Ohm’s Law we can figure the voltage
drops at points 1 and 2. Each branch contains 350Ω + 350Ω = 700Ω of resistance. The current flow in the branch is
the branch voltage divided by the branch resistance.
IR1 + R2
= ER1 + R2
R1
+ R2
= 10V
700Ω
= 14.3 mA
To figure the voltage at point 1 we can use Ohm’s Law.
ER3
= IR3
R3
= 14.3 mA x 350Ω
= 5V
Since all resistances are equal, the voltage at point 2 is also 5V. There is no voltage difference between points 1 and
2 thus a zero reading is displayed on our indicator.
Now let’s place a force on our load cell. Our force caused R1
and R4
to go into tension, which increased their resis-
tances. R2
and R3
went into compression, which decreased their resistances. These changes are depicted in the fol-
lowing diagram.
IR3 + R4
= ER3 + R4
R3
+ R4
= 10V
700Ω
= 14.3 mA
15

15
However, there is a potential difference between points 1 and 2, thus a reading is displayed on our indicator. Let’s
calculate the potential difference.
To find the voltage at point 1 we will calculate the voltage drop across R3
. We know the current flow through R3
is
14.3 mA.
ER3
= IR3
(R3
)
= 0.0143A (349.5Ω)
= 4.9979V
To find the voltage at point 2 we will calculate the voltage drop across R1
. Again, we know the current flow through
R1
is 14.3 mA.
ER1
= IR1
(R1
)
= 0.0143A (350.5Ω)
= 5.0122V
To find the potential difference between points 1 and 2 we subtract ER3
from ER1
and find the difference to be .0143V
or 14.3 mv.
We see that our bridge has become unbalanced and the potential difference across the bridge is 14.3 mV. The indica-
tor is calibrated so a certain millivolt reading would correspond to a certain weight measurement. As we previously
stated the indicator draws current. But its internal resistance is so high that the current it draws is negligible and has
no affect on load cell operation.
3.1 Wiring
A load cell may have a cable with four or six wires. A six-wire load cell, beside having + and - signal and + and
- excitation lines, also has + and - sense lines. These sense lines are connected to the sense connections of the indicator.
These lines tell the indicator what the actual voltage is at the load cell. Sometimes there is a voltage drop between the
indicator and load cell. The sense lines feed information back to the indicator. The indicator either adjusts its voltage
to make up for the loss of voltage, or amplifies the return signal to compensate for the loss of power to the cell.
Load cell wires are color coded to help with proper connections. The load cell calibration data sheet for each load cell
contains the color code information for that cell. Rice Lake Weighing Systems also provides a load cell wiring color
guide on the back cover of our Load Cell Product Selection Guide.
3.2 Calibration Data
Each load cell is furnished with a calibration data sheet or calibration certificate. This sheet gives you pertinent data
about your load cell. The data sheet is matched to the load cell by model number, serial number and capacity. Other
information found on a typical calibration data sheet is output expressed in mV/V, excitation voltage, non-linearity,
hysteresis, zero balance, input resistance, output resistance, temperature effect on both the output and zero balance,
insulation resistance and cable length. The wiring color code is also included on the calibration data sheet. See a
sample calibration data sheet on page 17.
3.3 Output
A load cell’s output is not only determined by the weight applied, but also by the strength of the excitation voltage, and
its rated mV/V full scale output sensitivity. A typical full scale output for a load cell is 3 millivolts/volt (mV/V). This
means that for each volt of excitation voltage applied at full scale there will be 3 millivolts of signal output. If we have
100 lbs applied to a 100 lb load cell with 10 volts excitation applied the load cell signal strength will be 30 mV. That
is 10V x 3 mV/V= 30 mV. Now let’s apply only 50 lbs to the cell, keeping our excitation voltage at 10 volts. Since
50 lbs is 50% or one half of full load, the cell signal strength would be 15 mV.
16

Rice Lake Weighing Systems
Calibration Certiﬁcate
1. Model No. 50210-25
2. Serial No. 37647
3. Capacity 25 lbs
4. Output 3.0678 mV/V
5. Excitation 10 Volts
6. Non-Linearity < 0.010 % FSO
7. Hysteresis < 0.010 % FSO
8. Zero Balance -0.0230 mV/V
9. Input Resistance 375 Ohms Nominal
10. Output Resistance 350 Ohms
11. Temperature Effect
Output < 0.0005 % /F
Zero < 0.0010 % /F
Insulation Resistance 5000 Mega Ohms at 50 VDC
Cable Length 20 ft
NTEP Certiﬁcate No. ****
Minimum Dead Load (lb) ****
Class ****
V min ****
n Maximum ****
Load Cell Usage ****
Safe Load Limit (lb) ****
Wiring
Red + Input
Green + Output
White - Output
Black - Input
Shield
17

19
4.0 LOAD CELL TERMS
OBJECTIVE: Familiarization with load cell terminology.
We know that a load cell is an electromechanical device. It can be called a transducer as it converts one form of energy
to another — mechanical force or stress to electrical energy. Aload cell has various characteristics that are measurable.
These characteristics are determined by the type of metal used, shape of the load cell and how well it is protected from
its environment. To understand load cells better there are terms that you need to become familiar with so you can better
match the load cell to your application.
CALIBRATION - The comparison of load cell outputs against standard test loads.
COMBINED ERROR - (Nonlinearity and hysteresis) - The maximum deviation from the straight line drawn between
the original no load and rated load outputs expressed as a percentage of the rated output and measure on both increas-
ing and decreasing loads.
CREEP - The change in load cell output occurring over time, while loaded, and with all environmental conditions
and other variables remaining constant.
CREEP RECOVERY - The change in no load output, occurring with time, after removal of a load which had been
applied for a speciﬁc period of time.
DRIFT - A random change in output under constant load conditions.
ECCENTRIC LOAD - Any load applied parallel to, but not concentric with, the primary axis.
ERROR - The algebraic difference between the indicated and true value of the load being measured.
EXCITATION - The voltage applied to the input terminals of a load cell. Most load cells have a rated excitation
voltage of 10 VDC. There are load cells available that are rated at 15, 20 and 25 VDC and also some that have both
AC and DC excitation ratings.
HYSTERESIS - The maximum difference between load cell output readings for the same applied load. One reading
is obtained by increasing the load from zero, and the other reading is obtained by decreasing the load from rated load.
Hysteresis is measured as percentage of the full scale rated output (% F.S.). Common load cell hysteresis values are
.02% F.S., .03% F.S. and .05% F.S.
INPUT BRIDGE RESISTANCE - The input resistance of the load cell. It is measured by placing an ohmmeter
across the input or excitation leads. It is usually higher than the output bridge resistance because of the presence of
compensating resistors in the excitation circuit.
INSULATION RESISTANCE - The DC resistance measured between the load cell circuit and the load cell struc-
ture.
NON-LINEARITY - The maximum deviation of the calibration curve from a straight line drawn between the no load
and rated load outputs. It is expressed as a percentage of the full-scale rated output. It is measured on an increasing
load only. Common non-linearity values are .02% F.S. and .03% F.S.
OUTPUT - The signal produced by the load cell where the output is directly proportional to excitation and the load
applied. The signal must be in terms such as millivolts per volt (mV/V) or volts per ampere (V/A).
OUTPUT BRIDGE RESISTANCE - The output resistance of the cell. It is measured by placing an ohmmeter
between the signal or output leads. Common bridge resistances are 350Ω, 480Ω, 700Ω, 750Ω and 1000Ω.
18

20
LOAD CELL TERMS CONT.
OUTPUT, RATED - The algebraic difference between the output at no load and the output at rated load.
REPEATABILITY - The maximum difference between load cell output readings for repeated loadings under identi-
cal loading and environmental conditions.
RESOLUTION - The smallest change in mechanical input which produces a detectable change in the output sig-
nal.
SAFE OVERLOAD RATING - The maximum load, in percent of rated capacity, which can be applied without
producing a permanent shift in performance characteristics beyond those specified. A common safe overload rating
is 150% F.S.
SENSITIVITY - The ratio of the change in output to the change in mechanical input.
SHOCK LOAD - A sudden increase in load usually caused by dropping weight onto the scale. Can cause permanent
load cell damage.
SIDE LOAD - Any load acting 90° to the primary axis at the point of axial load application.
TEMPERATURE EFFECT ON RATED OUTPUT - The change in rated output due to a change in ambient tem-
perature. It is usually expressed as the percentage change in rated output per 100°F change in ambient temperature.
TEMPERATURE EFFECT ON ZERO BALANCE - The change in zero balance due to a change in ambient
temperature. It is usually expressed as the change in zero balance in percent of rated output per 100°F change in am-
bient temperature.
TEMPERATURE RANGE, COMPENSATED - The range of temperature over which the load cell is compensated
to maintain rated output and zero balance within specified limits.
TOLERANCE - A magnitude fixing the limit of allowable error or departure from true performance or value.
ULTIMATE OVERLOAD RATING - The maximum load, in percent of rated capacity, which can be applied to a
load cell, without producing a structural failure.
ZERO BALANCE - The output signal of the load cell with rated excitation and with no load applied, usually ex-
pressed in percent of rated output.
19

5.0 TROUBLESHOOTING
OBJECTIVE: Perform physical, zero balance and bridge resistance checks.
Load cells fail in a variety of ways for a variety of reasons. These reasons may be mechanical, environmental, or
electrical. We will discuss these reasons and make physical and electrical load cell inspections. Most load cell failures
are caused by incorrect applications or abuse.
Mechanical Failure
The load cell may fail mechanically or physically. If the cell is too small for the application, the excessive weight
will cause the cell to distort and not return to its no load shape, thus keeping the strain gauges either in compression
or tension. The total weight of the weigh structure (platform, hopper, vessel) plus the weight of the material being
weighed must be considered. The number of structural support points also plays a role in load cell weight distribution.
Normally the total weight of the structure is divided equally between all the load cells.
Shock loading also can cause mechanical failure. Shock loading occurs when the weight is dropped suddenly onto the
scale, which can cause permanent distortion of the load cell. Observe the operators when they are loading the scale.
If they are shock loading the scale, the operators require training on proper scale operation and/or larger capacity cells
need to be used. Be careful as too large of a cell capacity can decrease load cell sensitivity or output below minimum
indicator sensitivity requirements. Non-axial or side loading can also cause mechanical failure besides measurement in-
accuracies. Side load can be minimized through proper use of various types of mounting hardware (See Section 8).
Environmental Effects
Most load cells are compensated to operate within a speciﬁed temperature range, usually 0° to 150°F. The load cell
may operate properly outside these limits. However, the calibration data supplied with the load cell is only valid when
the cell is operated within its compensated range.
Moisture has a very negative effect on load cell operation. Moisture can cause no output, overload indications, or
most commonly, continuous drift and erratic scale operation. Moisture enters a load cell through cut cables or through
pressure. If a non-hermetically sealed load cell is used in a high pressure washdown application, water will be forced
in the load cell.
Chemicals can cause corrosion of the load cell. Corrosion can work its way into the strain gauges, especially if the
material used to protect against the environment has worn away. A stainless steel load cell may be required to keep
the cell from corroding, but may not prevent the penetration of moisture. Some chemicals such as chlorine can even
corrode stainless steel.
5.1 Physical Check
The ﬁrst step to take when troubleshooting a load cell is to check for distortion, cracks or rippling of the metal. All
welds should be free of cracks or deep pox marks. Look for crimps, cuts and excessive abrasions on the load cell cable.
Moisture can enter anywhere the cable is cut. The moisture will wick its way to the load cell and cause problems such
as unstable readings.
5.2 Zero Balance
As given in our Load Cell Terms section, zero balance is the output signal of the load cell with rated excitation and no
load applied. It is expressed in percent of rated output. Zero balance changes usually occur if the load cell has been
mechanically overloaded.
With no load on the cell and the cell connected to the indicator, use a millivoltmeter to check the load cell output voltage.
At 10 volts excitation a 3 mV/V load cell will output 30 mV at full load. At a 1% tolerance the load cell with no load
applied should output less than .3 mV or 300 μV. (.01 x 30 mV = .3 mV). A zero tolerance of greater than 1% may be
cause to condemn your load cell. Regauging may be impractical as a mechanical overload usually causes permanent
structural damage. Some load cells may operate properly with a shift of up to 10%.
20

TROUBLESHOOTING CONT.
Another balance check may be made which compares one half of the bridge circuit to the other half. With the load cell
leads disconnected and no load applied to the cell, perform the following steps.
Short the signal leads together. This action will yield a circuit that looks like Figure 6.
Measure and record the resistance between the signal leads and the -Exc lead (measures parallel
combination R1
/R3
in series with -Excitation compensation resistors).
Measure and record the resistance between the signal leads and the +Exc lead (measures parallel
combination R2
/R4
in series with +Excitation compensation resistors).
The difference between the above two readings should be zero ohms.
5.3 Bridge Resistance
The bridge input resistance is measured by placing an ohmmeter between the +Exc and -Exc leads. The bridge output
resistance is measured by placing an ohmmeter between the +Sig and -Sig leads. The normal resistance readings are
found on the load cell calibration data sheet. Your measured readings should be within 1% of the values stated on the
calibration data sheet.
You can also take measurements between the following parts of the bridge:
+Exc to +Sig +Exc to -Sig
- Exc to +Sig - Exc to -Sig
The -Exc to +Sig measurement and the -Exc to -Sig measurement should be identical. This is also true of the +Exc to
+Sig measurement and the +Exc to -Sig measurement. Any differences in readings indicate damage to the load cell.
Let’s take a look at some load cell resistance readings and determine if these readings represent a functional load cell
or one that is damaged. Figure 7 (on page 22) will represent the type of load cell we are testing.
LOAD CELL CIRCUIT
Figure 6
-
+
21

23
Normal -Sig -Exc +Exc +Exc -Exc -Exc
Output to to to to to to
Resistance +Sig +Exc +Sig -Sig +Sig -Sig
LOAD CELL A 350Ω 350Ω 410Ω 292Ω 292Ω 292Ω 292Ω
LOAD CELL B 350Ω 350Ω 410Ω 292Ω 292Ω 295Ω 295Ω
LOAD CELL C 350Ω 350Ω 410Ω 289Ω 295Ω 289Ω 295Ω
LOAD CELL D 350Ω ∞ 410Ω 292Ω ∞ 292Ω ∞
LOAD CELL E 350Ω 700Ω 760Ω 380Ω 1080Ω 380Ω 380Ω
NOTE: An ohmmeter reading of ∞ is an inﬁnity or open reading.
Figure 8
In example A of Figure 8, we see that the input resistance (-Exc to +Exc) is 410Ω. This is the sum of the 350Ω bridge
and the equivalent resistance of the resistors placed in the excitation leads. The output resistance is 350Ω. All other
resistances are identical. This is a good load cell. Let’s examine how the 292Ω was obtained for the bridge resistances.
We know that these four resistors are 350Ω resistors. We will look at the equivalent circuit that is being measured
when we place our ohmmeter across the -Exc and -Sig leads.
R
LOAD CELL RESISTANCE READINGS
Figure 7
22

We now simplify the circuit.
R3
, R4
, and R2
are in series as are R7
and the equivalent R5
/R6
parallel combination. We can add these series resistors
and simplify our circuit to the following.
The 350Ω and 1050Ω resistors are in parallel. To ﬁnd the equivalent resistance we will use the formula R1
R2
R1
+
R2
.
350Ω (1050)
350Ω + 1050
367500
1400
262Ω
We now add the 30Ω series resistance for a total circuit resistance of 292Ω. The other resistances are calculated in
the same manner.
In example B, the +Exc to +Sig and +Exc to -Sig readings are identical as are the -Exc to +Sig and -Exc to -Sig read-
ings. Even though all the bridge resistance values are NOT the same, this load cell will operate properly. Both sides
of the bridge are still balanced.
Referring to example C we see that the +Exc to +Sig and +Exc to -Sig readings differ from each other as do the -Exc
to +Sig and -Exc to -Sig readings. This load cell is a damaged cell. It was probably mechanically overstressed and
failed to fully return to its no load position. This cell should be condemned.
RT
=
RT
=
=
=
23

In example D we have some open readings. All the open readings occur whenever we are taking a measurement in-
volving the -Sig lead. In this case the -Sig lead is open or became detached from the strain gauge. Depending upon
the cost of the cell, it may be advantageous to have this cell repaired. We will look in depth at the strange readings
found in example E. First of all, the problem is an open gauge. In this case it is R2
.
Our -Sig to +Sig measurement is represented by the following diagram (with R2
open).
Total resistance is 700Ω (R1
+ R3
)
-Exc to +Exc measurement:
Since R2
is open there is no path to complete our measurement through it. Our ohmmeter will read the sum of all
resistances except R1
and R2
for a total of 760Ω.
+Exc to +Sig measurement:
24
Since R2
is open
RT
= R10
+R8
/R9
+ R4
RT
= 10Ω + 20Ω + 350Ω
RT
= 380Ω
350Ω
350Ω

-Exc to + Sig measurement:
-Exc to -Sig measurement:
Since R2
is open
RT
= R10
+R8
/R9
+ R4
+R3
+R1
RT
= 10Ω + 20Ω + 350Ω + 350Ω +
350Ω
RT
= 1080Ω
+Exc to - Sig measurement:
Since R2
is open
RT
= R7
+R5
/R6
+ R1
RT
= 10Ω + 20Ω + 350Ω
RT
= 380Ω
Since R2
is open
RT
= R7
+R5
/R6
+ R3
RT
= 10Ω + 20Ω + 350Ω
RT
= 380Ω
25

5.4 Resistance to Ground
Resistance to ground or electrical leakage, is often caused by water contamination within the cell or cable. An unstable
output is a good indication of water contamination. The resistance between all load cell leads tied together and the load
cell metal body should be 1000 megohms or higher. You can measure this very high resistance value with a megohm-
meter (often referred to as a “megger”). The megger should not put out over 50 volts to prevent load cell damage. If
the cell fails this test, remove the ground wire from the rest of the leads and retest with all leads except the ground wire
connected together. If the test is now good (greater than 1000 MΩ), an insulation problem in the cable is suggested.
The Wheatstone bridge configuration amplifies the effects of leakage resistance between the signal leads and ground.
A leakage resistance path of one megohm can cause an appreciable shift in zero load cell output. Leakage resistance
does not seriously affect the calibration of the instrument but it will cause the instrument to appear to have unstable
zero because leakage resistance is not steady.
!Caution:
Do not cut the load cell cable. The load cell is calibrated with a certain amount of cable attached.
If the cable is cut, the warranty and calibration data will be void. When returning load cells for
credit or evaluation, include the calibration data sheet to avoid a recalibration charge.
Whenever you are measuring the resistance of your load cell draw a diagram. It may help you see which resistors are
actually in your measurement circuit.
You may not know the value of the compensation resistors. This will not keep you from being able to evaluate your
load cell. Just remember:
The +Sig to - Sig reading is the output bridge resistance and should be within 1% of the rated
output resistance (normally 350Ω, 700Ω or 1000Ω).
The +Exc to -Exc reading (bridge input) will normally be larger that the output reading as there
are compensating resistors in the excitation circuit. See the calibration certificate for the normal
input resistance.
The -Exc to -Sig and -Exc to +Sig readings should match as should the +Exc to +Sig and +Exc
to -Sig readings.
26

6.0 LOAD CELL CONSTRUCTION
OBJECTIVE: Familiarization with load cell materials and sealing techniques.
6.1 Materials
6.1.1 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.
6.1.2 Tool Steel Load Cells
Load cells manufactured from tool steel elements are by far the most popular cells in use today. The cost to perfor-
mance ratio is better for tool steel elements compared to either aluminum or stainless steel designs. The most popular
alloy is 4330 because it has 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.
6.1.3 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 fit-
ted 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.
6.2 Strain Gauge Protection Alternatives
Environmentally Protected, Non-Washdown
6.2.1 Potted Cell
One method of environmentally protecting a load cell is potting it with a special silicon-based material. This material
feels sticky and gelatinous. It easily returns to its original shape after a force is applied to it. This is important as this
potting material must not affect the operation of the cell. A 100% silicon material is not used, as this material is very
corrosive. The potting material fills the strain gauge cavity and decreases the ability of moisture to reach the strain
gauges.
Environmental protection of a load cell is necessary to help keep out unwanted contaminants, such as moisture, which
will cause erratic cell operation. When installing load cells, run the cable so it slopes down, away from the cell. Mois-
ture in the cable will work its way to the load cell. It is also good practice to allow the conduit a way to drain moisture
out of itself. An environmentally protected cell is not suitable for high moisture, steam, or washdown applications
(see hermetically sealed on page 28).
6.2.2 Foam Backed Plate
Some load cell strain gauge cavities are protected by a foam backed plate that is secured over the cavity. This type
of protection affords some moisture and foreign object protection but does not protect the cell as well as the potting
material of a potted cell.
27

6.2.3 Neoprene Sleeve
Another type of environment protection is the use of a neoprene sleeve or boot. The boot covers the strain gauge
cavity and is secured by clamps. The strain gauge cavity is easily accessed for repair. If the boot is not lubricated, it
will crack which will, of course, allow moisture into the cell cavity. It is good practice to lubricate this sleeve during
routine inspections.
Washdown
6.2.4. Hermetically Sealed
The hermetically sealed load cell gives the best protection against moisture and other contaminants. The cavity is cov-
ered with a metal cap which is sealed by soldering it to the body. A true hermetically sealed load cell also has a welded
header where the cable terminal leads are soldered. This prevents water from wicking into the load cell body itself.
These cells are the most expensive cells but are required in high moisture and washdown environments.
6.2.5. Welded Seal
A welded seal load cell can be constructed of stainless or alloy steel. The gauge cavity is covered with a metal cap
which is sealed by soldering it to the load cell body. Unlike a true hermetically sealed load cell, a welded seal load cell
does not have a welded header where the load cell cable enters the load cell. The load cell cable should be run through
conduit for acceptable use in mild washdown environments.
LOAD CELL CONSTRUCTION CONT.
28

7.0 LOAD CELL TYPES
OBJECTIVE: Identify load cell types and their applications.
Load cells are built in various sizes and types for various applications. We will look at the different type of load
cells.
7.1 Canister
The canister cell is the earliest load cell design. It is either hermetically sealed or welded to protect the gauges. See
Figure 9-- Canister Load Cell.
CANISTER LOAD CELL
Figure 9
Canister cell popularity is waning as their cost is 2 or 3 times that of a bending beam cell. There are two types of canister
construction, single column and multiple column. Single column canisters cannot normally withstand a side load of
over 15%. Multiple column canister cells withstand more side load than the single column variety. The canister cell
ranges in size from 100 lbs up to 500,000 lbs. The normal safe overload is 150% of full scale (F.S.) but some models
are able to withstand a 300% F.S. overload. There is no means through visual inspection or labeling to identify which
cells are singular or multiple column. Refer to original manufacturer’s specifications or Rice Lake Weighing Systems’
Load Cell Product Selection Guide to determine your cell’s specifications.
Canister cells are made of high alloy tool steel with an epoxy finish, or stainless steel. Their rated excitation ranges
from 10 VDC to 20 VAC/DC. Common bridge resistances are 350Ω and 480Ω.
!Caution:
29

When replacing a compression type load cell, you should also replace the bearing plate. This
plate contacts the load button and applies the load to the cell. Over years of use the point
where the bearing plate contacts the load button becomes worn and forms a cup. The new
load cell load button will fit into that worn cup and cause side stress on the new load cell. In a
few months you will probably be replacing that new load cell. If you fabricate the bearing plate
yourself you will need to have it hardened. Some technicians turn the bearing plate over. If the
plate is not hardened on the new side it may wear prematurely.
7.2 Single Ended Shear Beam
The single ended shear beam cell is designed for low profile scale and process applications. The shear beam cell strain
30
LOAD CELL TYPES CONT.
in excess of the safe overload rating may permanently affect the accuracy and performance of the load. Shock loads
having peak values in excess of 120% of rated cell capacity may also affect the calibration and should be avoided.
Shear beams may be constructed of tool steel or stainless steel for use in harsh environments. Just because a cell is
made of stainless steel does not mean it can be used in washdown environments.
7.3 Double Ended Shear Beam
The double ended shear beam characteristics are similar to those of the single ended shear beam. The most common
gauge cavity contains a thin metal diaphragm onto which the strain gauges are mounted. Typical shear beam capaci-
ties range from 1,000 lbs through 20,000 lbs, although some manufacturers offer shear beams up to 40,000 lbs. One
end of the shear beam contains the mounting holes while the opposite end is where the cell is loaded. The cell should
be mounted on a flat, smooth surface with high strength hardened bolts. The larger shear beam cells have more than
two mounting holes to accommodate extra bolts to keep the hardware from stretching under stress load. See Figure
10-- Single Ended Shear Beam.
Shear beams operate best in a temperature range of +15°F to 115°F. Their maximum safe operating range with minimum
performance change is from 0°F to 150°F. Shear beam zero outputs should be frequently checked when operating at
high temperatures. These cells may be overloaded statically up to 150% of rated load without damage. Overloads
Mounting
Bolts
Shear Strain Gages
Load
Stable
Foundation
SINGLE ENDED SHEAR BEAM
Figure 10

31
bridge resistance for this load cell is 700Ω. It is most commonly used in truck scales and tank and hopper applica-
tions. Instead of being secured at one end and the load applied to the other end as in the single ended shear beam, the
double ended shear beam is secured at both ends and the load is applied to the center of the load cell. As in all shear
beam designs the strain gauges are mounted on a thin web in the center of the cell’s machined cavity. See Figure 11
– Double Ended Shear Beam.
7.4 Cantilever Beam
Cantilever beams are similar to shear beams. However, the cantilever beam does not have a thin web located in the
strain gauge cavity. The cantilever beam is machined all the way through. The strain gauges are mounted along the
inner edges of the cavity. Most cantilever beams have a bridge resistance of 350Ω and either 3 mV/V or 2 mV/V full
scale outputs. They range from capacities of 25 lb up to 10,000 lbs. However, there may be a few larger cantilever
beams being used. They can be used in tension or compression applications.
7.5 S Beam
S Beam load cells derive their name from their shape which, of course, is the shape of the letter S. The S beam is nor-
mally used in tension applications. However, there are S beams available which are bidirectional. They are primarily
used for mechanical-to-electronic scale conversions, platform scale and general purpose weighing applications. They
vary in size from as low as 25 lbs to as high as 20,000 lbs. When mounting an S beam, remember to include the side
from which the cable extends in the dead portion of the system. Movement of the cable in the live part of the system
can be a source of weighing errors.
Load
Application
Neoprene
Sealing Boot
Shielded Cable
Mounting
Hole
Shear
Strain Gauge
Metal
Clamp
Mounting
Hole
DOUBLE ENDED SHEAR BEAM
Figure 11

7.6 Platform
The platform load cell is sometimes called a dual-guided cantilever beam cell but is more commonly referred to as a
single point cell. They are used in light capacity bench scales. They are most commonly made out of aluminum. Some
platform scales have built-in overload stops. Safe overloading of 200% full scale is permissible at the center loading
point on some platform load cells. They are commonly made in 2 kg through 1000 kg and 2 lbs through 1000 lb sizes.
The bridge resistance is commonly 350Ω. See Figure 12—Platform Load Cell.
Strain
Gauges
Compression
Tension
Compression
Tension
Load
PLATFORM LOAD CELL
Figure 12
32

8.0 LOAD CELL MOUNTING ASSEMBLIES
8.1 Tank and Hopper Kits
8.1.1 Isolated Tension Cell Mounting Assembly (ITCM)
The ITCM is designed for tank and hopper weighing applications and mechanical scale conversions. It utilizes an S
beam load cell mounted between clevis and rod end ball joint assemblies. This construction reduces the overall length
to less than half of the traditional tension cell mounts. The clevis mounts with nylon insulating washers and TeﬂonTM
-
lined rod end ball joints, thus isolating the load cell from stray currents. Additional electrical protection is provided
by a bonding strap connecting the two clevis assemblies, routing stray currents around the load cell. Capacities range
from 100 lbs through 20,000 lbs per assembly. See Figure 13—ITCM.
RL20000 NTEP Certiﬁed S beam Load Cell
JB4SS NEMA 4X Stainless Steel signal trim J-box
25 ft. of hostile environment load cell cable
8.1.2 RL50210TA Mini Tank Weighing Assembly
The RL50210TA provides a cost-effective alternative for low range weighing requirements. Beside tank and hopper
applications, this assembly can be used for small platform scales where shock loading may be a problem and for con-
veyor/in-motion weighing. The 50 lb, 100 lb, 150 lb and 250 lb assemblies come with a RL50210 cantilever beam load
cell. ARL35023 single ended beam load cell is used for the 500 lb to 2500 lb models. Neoprene isolation/compression
mounts allow for minor misalignment, thermal expansion and shock absorption. See Figure 14—RL50210TA Tank
Weighing Assembly.
ITCM
Figure 13
33

8.1.3 RL1800 Series Mounting Assembly
The RL1800 assembly is designed for medium range capacities (250 lbs - 10,000 lbs). Available in stainless steel or
mild steel, the 1K, 2K, 2.5K, 4K, 5K and 10K load cells are NTEP certiﬁed (1000-10,000 lbs). The assembly utilizes
the RL35023 shear beam load cell. The RL1800 is a center-pivoted, tension loaded design mount. The load is sus-
pended on a high strength bolt. It is self-checking with multi-directional movement. The mount also can be ordered
with RL35023S stainless steel NTEP load cells in 1000-10,000 lb capacity. See Figure 15—RL1800 Series Mounting
Assembly.
The RL1800 is also compatible with the following load cells:
RL35023 Sensortronics 65023-5107
RL35082 Sensortronics 65023-0113
RL35083 Sensortronics 65023S-5113
Sensortronics 65083
RTI 5123
RTI 9123
Celtron SQB
LOAD CELL MOUNTING ASSEMBLIES CONT.
JB4SS NEMA 4X stainless steel signal trim J-Box
3 or 4 RL50210 or RL35023 load cells
Neoprene isolation/compression mounts
25 ft. of hostile environment load cell cable
RL50210TA TANK WEIGHING ASSEMBLY
Figure 14
34

RL1900 SERIES MOUNTING ASSEMBLY
Figure 16
8.1.4 RL1900 Series Mounting Assembly
The RL1900 design is similar to the RL1800 except the RL1900 is a stainless steel mount, utilizing a stainless steel,
RLSSB welded seal load cell. It is available in capacities of 1K, 2K, 5K and 10K. The RL1900 is also compatible with
RTI SSB and HBM SB3 load cells.
RL1800 SERIES MOUNTING ASSEMBLY
Figure 15
35

8.1.5 RL1600 Series Tank Weighing Assembly
The RL1600 is used for medium to heavy tank and hopper weighing applications. It is available in capacities ranging
from 1K through 75K. Its self-checking, easy-to-use design allows the assembly to be bolted directly to the tank leg
without requiring additional mounting plates or load buttons. The standard mount is of zinc plated steel construction
with a RL75016 double ended shear beam load cell. There is an optional stainless steel model available which utilize
the RL75016SS stainless steel load cell or the RL75016WHE hermetically sealed stainless steel load cell. The RL1600
is compatable with Sensortronics 65016, 65016W and 65016WH and Celtron DSR. See Figure 17—RL1600 Series
Tank Weighing Assembly.
RL1600 SERIES TANK WEIGHING ASSEMBLY
Figure 17
8.1.6 EZ MOUNT 1 - Tank Weighing Assembly
The EZ MOUNT1 Assembly is a medium to high capacity mount ranging from 5K through 250K. It uses a RL70000
double ended shear beam load cell. The load cells are NTEP ceritiﬁed in capacities of 5K-200K. Its sliding pin design
compensates for temperature variations. This mount can be bolted directly to the tank and ﬂoor. It is a self-checking
mount. See Figure 18—EZ Mount 1 Tank Weighing Assembly. Stainless steel mounts using the RL71000HE hermeti-
cally sealed load cells are also available.
36

8.1.7 Paramounts®
Paramounts®
kits are used for mounting SB4 or SB10 load cells to vessels, tanks, hoppers, platforms and roller tables
in light to medium applications. They are useful where thermal expansion and contraction of the weighing vessel are
likely, and where dimensional changes caused by loading can occur. Each Paramounts®
kit includes:
One JB4SS Junction Box
One ﬁxed pin mount with SB4/SB10 load cell
One side stop mount with SB4/SB10 load cell
One (or more) free sliding mount(s) with SB4/SB10 load cell(s)
25 ft. of load cell cable
37
EZ MOUNT 1 TANK WEIGHING ASSEMBLY
Figure 18

Figure 20-A
Typical module application Typical module application for
for cylindrical vessels. square/rectangular vessels.
Fixed pin mounts allow the top plate to rotate only. Side stop mounts allow the top plate to slide along the cell only.
Free sliding mounts allow the top plate to slide freely in all directions. See Figure 19.
Fixed Pin Free Sliding Side Stop
Figure 19
The free sliding and side stop mounts have loading pins with TeﬂonTM
coated top surfaces that slide on stainless steel
plates attached to the underside of the top plates. The following ﬁgures show some typical applications. See Figures
20-A, B, C, D, and E.
38
Side Stop Fixed Pin
Mount Mount
Fixed Pin Side Stop
Mount Mount
Free Sliding Free Sliding
Mount Mount
Free Sliding
Mount

Figure 20-B
∞ less than 45° ∞ less than 45°
Six load cells on rectangular vessel
Figure 20-E
Four load cells Four load cells on
on round vessel rectangular vessel
Figure 20-C Figure 20-D
39
Free SlidingFree SlidingFree Sliding
Fixed PinFree SlidingSide Stop

Figure 22
8.3 TransLink
The Translink load cell mount is used for heavy capacity tank and truck weighing applications. The mount is made of
fabricated and hardened tool steel in capacities of 25,000 lb to 100,000 lb. The pendulous action of the links allows
self-centering of the weighing platform, and the platform has free movement in all directions in the horizontal plane.
Install platform bumpers to prevent overtravel.
The mount is compatible with four different tool steel, double ended shear beam load cells. The RL75040 and the Sen-
sortronics 65040A load cells are environmentally protected styles, whereas the RL75223, RTI 5223, and Sensortronics
65040S load cells are welded seal styles.
Paramounts®
are available in capacities of 1 kilonewton (225 lbs) through 100 kilonewton (22,500 lbs). The SB4/SB10
cells are hermetically sealed and made of stainless steel. A jacking screw allows the EMPTY vessel to be lifted clear
of the load cell for maintenance. The cell outputs are matched to ±.07%. It should not be necessary to trim the load
cell outputs because of their closely calibrated outputs. The trimming capability of the EL604ET J-box is disabled by
the presence of shunt wires. A Paramounts®
Installation Manual is available.
8.2 MVS
The MVS Assembly unilink suspension design checks lateral assembly movement while allowing controlled ﬂoating
of the scale deck. The need for check rods, links, and expansion assemblies is eliminated. The MVS is designed to be
used with the RL75058 and Sensortronics load cell model 65058A, or optional stainless steel model RL75060 (ordered
separately), which is a double ended shear beam design. Besides truck scale applications, the MVS can be used for
track and horizontal tank applications. Its capacities range from 10K through 125K.
40
Figure 21

9.0 LOAD CELL SELECTIONS
OBJECTIVE: Select proper load cell size and determine output sensitivity.
9.1 Mechanical to Electronic Conversion
It is sometimes necessary to convert a mechanical scale indicator (balance beam or mechanical dial) to an electronic
indicator. The electronic indicator provides a direct weight readout and output signals which can be sent to a number of
types of peripheral equipment, such as printers, computers, data loggers, programmable controllers and remote displays.
The cost of the electronic indicator and load cell may be more economical than maintaining that mechanical dial.
9.1.1 Determine Scale Multiple
You must ﬁrst determine the scale multiple or pull at the point of the load cell installation. The load cell is normally
installed in the steelyard rod, which connects the transverse lever to the balance beam or cabinet dial tare lever. Figures
23 and 24 show locations of the steelyard rod.
Figure 24
Figure 23
Cabinet Dial
Steelyard Rod
Transverse Lever
Steelyard Rod
Load Cell
Beam
41
SLOPE TO DRAIN

You may have an information sheet for your scale that gives you the scale multiple. However, with most old scales
this sheet is no longer available. You still can determine the multiple by using the following procedure.
Balance the scale at zero
Hang a 1 lb weight on the steelyard rod
Rebalance the scale and read the new value
The new value is the scale multiple. The multiple is typically 20:1 or 25:1 on dormant scales and 400:1 on motor
truck scales.
9.1.2 Load Cell Size
Now that you know the scale multiple, you must determine the proper load cell size. If you choose a load cell that
is too light, you may overload it. If you choose a cell that is too heavy, its output may be insufﬁcient to maintain a
proper and stable indicator reading. The load cell size equals the sum of the live load (scale capacity) plus the dead
load (weight of weighbridge and levers) divided by the scale multiple
Live Load (LL) + Dead Load (DL)
Load Cell Size = Scale Multiple
If the required load cell size falls between commonly manufactured load cell sizes, then choose the next higher load
cell size.
Let’s use the following example and determine the proper load cell size.
Live Load = 5000 lbs
Dead Load = 1000 lbs
Scale Multiple = 20
Using our formula:
LL + DL
Load Cell Size = multiple
= 5000 lbs + 1000 lbs
20
= 6000 lbs
20
= 300 lbs
Three hundred pounds (300 lbs) is not a common load cell size. The next higher common load cell is 500 lbs. You
don’t want to select a cell lower than 300 lbs as it would be overloaded.
If the scale is to be used in a Legal-for-Trade application where NTEP is a requirement, then consult RLWS’ publica-
tion “What is Handbook 44 & What is NTEP” for guidance in selecting a suitable load cell.
9.1.3 Microvolt Per Graduation
So now we know how large our load cell has to be. But will the selected load cell develop enough signal to provide a
stable indicator display? The analog input sensitivity or microvolt per graduation (μV/grad) rating of indicators vary,
depending on manufacturer and indicator gain settings. Typical μV/grad ranges are from 1 μV/grad to 30 μV/grad.
The μV/grad rating tells us how much signal it takes to change the display by one graduation . See the manufacturer’s
manual for your particular indicator. Using our previous example, let’s ﬁgure our μV/grad sensitivity.
Live Load = 5000 lbs
Dead Load = 1000 lbs
Scale Multiple = 20
Load Cell Size = 500 lbs
With 5000 lbs of live load on the scale having a multiple of 20, the live load felt by the load cell is 250 lbs.
42
LOAD CELL SELECTIONS CONT.

43
LL
Live Load on Cell = multiple
= 5,000 lbs
20
= 250 lbs
The live load, 250 lbs, comprises 50% of our total load cell capacity of 500 lbs.
If our 500 lb load cell is rated at 3 mV/V, it will output 3 mV for each volt of excitation voltage applied at full load.
If we apply 15 volts of excitation, the load cell will output 45 mV, with 500 lbs applied (3 mV/V x 15V = 45 mV).
Since only 50% of our load cell is being utilized by the live load, then the live load millivolt output will be 22.5 mV or
22500 μV. (45 mV x .5 = 22.5 mV). To determine the μV/grad of our load cell, divide the live load microvolt output
by the number of graduations for which our indicator is programmed. We will program our indicator for 5000 gradu-
ations to weigh 5000 lbs in l lb graduation sizes.
Live load output (μV)
μV/grad = Programmed Graduations
= 22,500 μV
5,000
= 4.5 μV/grad
This signal is sufficient for most indicators. Check your indicator manual to be sure your load cell output is adequate
for your indicator.
The following formula can also be used to figure μV/grad.
Load cell rating (mV/V) x Excitation Voltage (V) x grad size (lb/grad)
μV/grad = Scale ratio x load cell size
= 3 mV/V (15V) (1 lb/grad)
20 (500)
= 4,500 μV(1 lb/grad)
10,000 lbs
= 4.5 μV/grad
9.2 Tank and Hopper
We have previously selected a load cell for a mechanical - electronic conversion. Now we will select load cells for an
electronic weighing system utilizing a tank. We will use three load cells for our configuration. The following informa-
tion about our system is known:
Live Load = 10,000 lbs Load Cell Output = 3 mV/V
Dead Load = 2,000 lbs Excitation = 10V
Scale Capacity = 10,000 lbs x 2 lbs
To figure out our total system weight at capacity we add the live load and dead load.
Total System Weight = LL + DL
= 10,000 lbs + 2,000 lbs
= 12,000 lbs

The weight will be shared equally by all the cells, so each cell will handle 4,000 lbs (12,000 lbs ÷ 3). The cells we
have available are 5,000 lb load cells, so the total load cell capacity is 15,000 lbs. Given 10 volts of excitation and a
full capacity load cell output of 3 mV/V, our load cells will output 30 mV at full load (15,000 lbs). Our live load is
10,000 lbs. At 10,000 lbs our load cell will output 20 mV. This is calculated by ﬁnding the ratio of live load to load
cell capacity and multiplying this ratio by our full scale millivolt output.
Live load
Live Load Output = Load cell capacity
= 10,000 lb
15,000 lb
= 2/3 x 30 mV
= 20 mV
To determine our μV/grad sensitivity we will divide the live load signal by our scale resolution. Since our scale capac-
ity is 10,000 lbs x 2 lb graduations, our resolution is 5000 graduations.
μV/grad = 20 mV
5000 grads
= 20,000 μV
5000 grads
= 4 μV/grad
Using our formula method, our calculations are as follows:
Load cell rating (mV/V) x Excitation voltage (V) x grad size (lb/grad)
μV/grad = No. of load cells x load cell size
= 3mV/V x 10V x 2 lb/grad
3 x 5000
= 60,000 μV -lb/grad
15,000lbs
= 4 μV/grad
Using either method, our load cell output sensitivity is 4 μV/grad.
load cell rating (mV/V) x Excitation voltage (V) x grad size (lb/grad)
No. of load cells x load cell size
3 mV/V x 10V x 2 lb/grad
3 x 5000
60,000 μV lb/grad
15,000 lbs
4 μV/grad
44
x 30 mV
x Full Scale mV/output

10.0 LOAD CELL TRIMMING
OBJECTIVE: Perform excitation and signal load cell trimming.
When using load cells in parallel it is essential to match their outputs. It is much cheaper to manufacture load cells
with outputs that are not exactly matched and trim them in the ﬁeld than to manufacture load cells with outputs that are
exactly matched. A device called a junction box is used to tie the multi-cell system leads together to provide a single
entry point for load cell excitation and a single exit point for the load cell system signal. Variable resistors are also
provided to trim or adjust the load cell signal. Each load cell has a different sensitivity than others parallel to it. When
weight is placed on the scale, the load cells do not react with the same output. By trimming these cells their outputs
are matched to give accurate measurements. We will discuss two trimming methods: excitation trim and signal trim.
10.1 Excitation Trim
This is the oldest method of load cell trimming. With excitation trimming, series resistance is added to the excitation
circuit of the load cell. This method reduces the amount of excitation voltage that is dropped across the load cell.
By adjusting these variable series resistances (potentiometers) the load cell outputs can be matched. A junction box
diagram is shown in Figure 25.
Since the potentiometer is in series with the excitation inputs, the sum of the voltages dropped across the potentiometer
and load cell is equal to the applied excitation voltage. Most excitation trim J-boxes are three-stage devices. In paral-
lel with the potentiometer, there is a low value resistor which limits current ﬂow through the potentiometer to limit its
range. This also reduces the thermal affect and noise of the potentiometer. Also, a jumper wire is installed around the
potentiometer to keep it out of the circuit when trimming of that particular cell is not desired. It is better to trim a cell
as little as necessary, as the less resistance introduced into the circuit the better.
There is a method of pretrimming load cells utilizing excitation trim. This method allows pretrimming load cells to
within ±2 graduations without even touching a test weight. You will need an adjustment screwdriver, calculator and/or
pencil and paper, a wire snippers, digital volt meter and the calibration data sheet for each load cell. For greater ac-
curacy it is recommended that your volt meter have at least a 4 1/2 digit display.
EXCITATION TRIM JUNCTION BOX
Figure 25
45
+Exc
Variable Resistors
Load Cells
To Indicator
-Exc
+Sig
-Sig

We will pretrim a six cell truck scale.
Refer to each load cell calibration data sheet and write down each of the load cells mV/V rated output
at full load.
CELL # SERIAL # FULL LOAD mV/V
1 65059 3.005
2 66078 2.995
3 64098 3.002
4 65077 2.990
5 66002 3.014
6 65034 2.987
The next step is to determine our reference cell. The reference cell is always the cell with the
lowest mV/V output. In our case, the reference cell is Cell 6 at 2.987 mV/V. The lowest cell
is considered the reference cell because with excitation trimming we can only add resistance
in the excitation circuit and lower the voltage seen by the load cell. We cannot raise the lower
cells to meet the cells with higher outputs. So we can say the reference cell is the ﬁxed point of
our system.
Connect the indicator and junction box that you will be using in your system to the load cells
you want to trim. Allow 20 minutes for the system to come to operating temperature.
Turn all potentiometers fully clockwise to reduce the resistance value of the pot to its lowest
value. It is not necessary to turn the lowest cell (reference cell) potentiometer since it will remain
jumped out of the circuit. There will be a slight audible click when the pots are at their fully
clockwise positions.
Cut the jumper wires from around all the potentiometers except the reference cell potentiometer.
This allows the potentiometer to add resistance as you adjust it.
Divide the rated mV/V output of the reference load cell by the mV/V outputs of the remaining
cells.
Cell #
1 2.987/3.005 = .9940
2 2.987/2.995 = .9973
3 2.987/3.002 = .9950
4 2.987/2.990 = .9990
5 2.987/3.014 = .9910
Since we are dividing the mV/V reading of the lowest cell by others that are higher, our readings
should be less than 1.0000. If you get a number greater than 1.000, reﬁgure your math.
LOAD CELL TRIMMING CONT.
46

Using the digital volt meter, measure the excitation voltage present at the reference cell excita-
tion leads. We will say that the measured value is 14.95 volts.
Take each reading obtained when dividing the reference cell by each of the other cells and mul-
tiply them by the reference excitation voltage.
Cell #
1 .9940 x 14.95 = 14.86
2 .9973 x 14.95 = 14.91
3 .9950 x 14.95 = 14.88
4 .9990 x 14.95 = 14.94
5 .9910 x 14.95 = 14.82
These calculated voltages must be present across each respective load cell excitation terminal before each load cell
can output the same amount of signal. Place the voltmeter leads on Cell 1 and adjust its potentiometer for 14.86 VDC.
Then place the volt meter leads on Cell 2s excitation terminals and adjust the potentiometer for a 14.91 VDC reading.
Repeat this procedure for each of the load cells. Before disconnecting your system be sure to mark the junction box
as to what cells go where so you can put them back in the same junction box terminals when permanently installing
the system at the job site. You must use the entire cable supplied by the load cell manufacturer. Shortening this cable
can slightly alter the load cell output. This junction box pretrimming system will not eliminate the need to use test
weights but it will minimize the number of passes needed to calibrate the system and save time and effort for move-
ment of test weights.
10.2 Signal Trim
Signal trimming first appeared as an alternative to excitation trimming for use with indicators with gated or chopped
power supplies. Since the signal lines are static (not chopped), the trimming resistor is placed in the signal or output
load cell circuit. The signal strength is very low as compared to the excitation voltage strength (15 mV vs. 15 volts).
If the trim resistor is placed in series with the output the system will be very non linear and unstable. Instead, the trim
resistor is placed in parallel with the output. This parallel resistance is relatively high (40KΩ to 200KΩ). It takes a
large resistance change to make a small output signal change. Thus low cost resistors and potentiometers can be used
with little concern for temperature coefficient and drift as long as the noise characteristics of the resistor are low. A
signal trim diagram is shown in Figure 26.
Cermet pots and metal filmed non-inductive wire wound resistors are excellent for signal trim components. To leave this
system as it is will cause an interaction problem between cells in a multiple load cell system. The adjusting of one load
cell will affect the other load cell outputs. To prevent this interaction, a series resistor is placed in each of the signal
SIGNAL TRIMMING OF LOAD CELLS
Figure 26
47
EXCITATION
SIGNAL
TRIM POT

leads between load cell and indicator. These resistors must be stable and very well matched. Typical isolation resistance
values are 2.5KΩ ± 0.1%. The temperature coefficient should be no more than 10 parts per million (PPM) or .001%,
with 5 PPM being more acceptable. If these resistors are not matched the system will be very non-linear.
Besides being able to trim the system easily, there is almost no interaction between zero and span. This factor outweighs
the cost of the resistors. Since there is very little zero span interaction and excellent temperature stability, single pass
calibration is attainable along with fine trimming resolutions. Although signal trimming was developed to be used with
chopped power supplies, it is becoming more popular for all multiple load cell applications.
10.3 Junction Box Care
Some of the causes of junction box troubles are:
Aging
Shock and impact loading
Water
Animals
Aging can cause load cell parameters to drift, thus retrimming may be necessary. Shock and/or impact loading can
cause a zero shift and unstable readings, if not total load cell mechanical failure. Water, both in the form of liquid and
humidity, can be the cause of erratic junction box performance. Scales can become erratic during wet periods and then
correct themselves during dry weather. Humidity promotes fungus growth on circuit cards. This fungus is electrically
conductive and can be very corrosive. Coatings are available to protect the circuit board from contaminants.
NEMA 4 junction boxes are not designed for immersion. Unless the boxes are properly sealed and fittings tightened,
these boxes will not provide the protection for which they are designed. If a silicone based sealant is used, be careful
as it gives off acetic acid as it cures. This acid will corrode plating and discolor solder. A vent is necessary if silicone
is used. Place desiccant in metal boxes that are used in humid areas or areas subject to wide temperature variations.
Rice can also be used but fill the bag only half full as rice expands when it absorbs moisture. Change the desiccant
about every six months. If chemicals, salt or water are likely to be used around the junction box, consider using a non-
metallic junction box. They sweat less, won’t corrode, and are less likely to support fungal growth.
Cables sometimes are an overlooked source of problems.Animals, especially rodents, can chew away cable insulation.
Moisture then gets into the cable and wicks its way to the load cell, causing an apparent calibration shift from winter to
summer and erratic performance. For outdoor use, the cable should be contained in a sheath. If rigid conduit is used,
slope the conduit to drain the water away from the load cell. Do not allow it to droop, which can cause water to settle
in the conduit. Metallic conduit also acts to reduce the effect of electric transients.
Before replacing an existing J-box, consider these points.
Is the scale properly mounted?
Have you checked for mechanical friction and binding?
Are any of the load cells suspected of drift or damage?
Have any cables been underwater, crushed or abraded?
A new junction box will not cure the above problems. Electronic scales must be properly installed to decrease binding
and friction. Quality installation provides quality performance. Load cell cables are the arteries of the system. If the
cables are damaged or internally damp, the scale will not perform properly. Do not change the J-box unless you have
checked for other problem causes.
48

49
Appendix A - Units of Measure
Voltage, current and resistance are electrical properties. These properties each have their own units of measure as
shown in the chart below.
UNIT MEASUREMENT OF ABBREVIATION
Volt Voltage V
Ohm Resistance Ω
Ampere Current A
Instead of writing out 25 volts, we can write 25V; l ampere can be written as lA; and 100 ohms can be written as 100Ω.
Often times these units are too large or small for easy use. For these cases, we can use prefixes to further qualify each
unit of measure. Refer to the chart below for the most common prefixes.
PREFIX SYMBOL VALUE FACTOR
Mega M 1,000,000 106
Kilo K 1,000 103
Centi c .01 10-2
Milli m .001 10-3
Micro μ .000001 10-6
Whole number symbols are represented by upper case letters while fractional number symbols are represented by lower
case letters. The symbol for micro is the Greek letter “μ” NOT a lower case “u.” Resistance readings can range from
millionths of ohms to several million ohms. Let’s look at an example of 60,000 ohms and find another way to write it.
The prefix for 1000 is kilo and its symbol is K. The symbol for ohms is Ω. So we can write 60,000 ohms as 60KΩ.
Essentially, we made our value 1000 times larger. (Ohms to kilohms).
When working with electronic weighing systems, it is very common to find very low current and voltage levels. A
common value is 3 mV. We can also write 3 mV as:
.003 volts
3 mV
3 x 10-3
volts
NOTE: 10-3
is the same as .001, 1/1000, 1/103
or 1/ (10 x 10 x 10)
It is sometimes desirable to convert millivolts (mV) to microvolts (μV). Millivolts are 1000 timers larger than micro-
volts. So to change millivolts to microvolts we need to multiply the number of millivolts by 1000. For example:
3 millivolts = 3 x 1000 microvolts
3 mV = 3000 μV
These two numbers both represent the same quantity values.
56
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Loadcell troubleshooting

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