To ensure accurate and reliable performance of the weighing system, it's essential to follow proper installation and maintenance practices. Here are some key guidelines:
1. Use structural components that allow for automatic positioning or resetting, such as spherical bearings, joint bearings, or positioning fasteners. These help prevent lateral forces from affecting the sensor. It’s important to note that not all lateral forces come from mechanical installation—thermal expansion, wind, or vibration from agitators on container scales can also cause issues. In cases where the scale is mounted directly onto the structure (like a container pipe), make sure those connections are as flexible as possible in the direction of the sensor’s load axis to avoid "eating" the true load, which could lead to measurement errors.
2. Although load cells have some overload capacity, it's crucial to avoid overloading them during installation. Even a brief overload can cause permanent damage. If necessary, replace the sensor with a height block during installation and then reinsert the sensor afterward. Always include mechanical overload protection, such as a stop mechanism. When using screws to fix the sensor, apply the correct torque and ensure sufficient screw depth. High-strength screws are typically recommended for secure mounting.
3. Leveling is critical. First, level the mounting base of each individual sensor. For systems with multiple sensors, especially those with more than three, ensure the entire mounting surface is perfectly horizontal. This helps distribute the load evenly across all sensors. When using the system, always apply the load in the intended direction, avoiding lateral forces, bending moments, or torque that could affect accuracy.
4. Handle sensors with care, particularly small-capacity ones made from alloy aluminum. Any impact or drop can significantly affect their performance. For larger load cells, use appropriate lifting equipment like chain hoists or electric hoists. Ensure the mounting surface is clean, flat, and free of oil or debris. The base itself should be strong and rigid, ideally stronger than the sensor to prevent deformation.
5. Install protective baffles or cover the sensor with a thin metal plate to prevent dust or foreign particles from interfering with moving parts. To check if the system is functioning properly, add or remove approximately 0.1% of the rated load and observe if the indicator responds. A response indicates that the movable parts are not obstructed.
6. Protect the sensor from electrical damage by connecting hinged copper wires (about 50 mm² in cross-section) to bypass any welding currents or lightning strikes. Avoid exposing the sensor to intense heat, especially on one side.
Following these steps will enhance accuracy, simplify operation, and reduce the risk of damage.
In terms of electrical connections, avoid running signal cables parallel to power or control lines. If they must run together, keep a minimum distance of 50 cm and use metal conduit for the signal cables. Twist power and control cables at 50 rpm. If extending the signal cable, use a sealed junction box. If soldering is necessary, ensure proper sealing and moisture protection. After connection, test the insulation resistance to meet the standard of 2000–5000 MΩ. Recalibrate the sensor if needed. For long signal cables requiring high precision, consider using a relay amplifier with a compensation circuit.
All shielded cables should be used for connections to the display. Grounding points should be properly placed, either through the mechanical frame or an external ground. Do not leave shields floating. If three sensors are connected, a 6-wire configuration may be used in the junction box instead of the standard 4-wire setup. Avoid placing the sensor signal readout circuit in the same cabinet as devices that generate interference, such as thyristors or contactors. If heat is a concern, install a baffle and a fan inside the cabinet. The sensor’s measuring circuit should ideally have its own power supply transformer to avoid interference from shared power sources.
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