2158 A 2160 D 2162 Idnet
2158 A 2160 D 2162 Idnet
2158 A 2160 D 2162 Idnet
2160 DigiTOL
2162 IDNet
B14691400A
(2/01).00
METTLER TOLEDO
Date
B14691400A
2/01
INTRODUCTION
This publication is provided solely as a guide for individuals who have received Technical Training in
servicing the METTLER TOLEDO product.
Information about METTLER TOLEDO Technical Training can be obtained by writing, calling, or faxing:
METTLER TOLEDO
1900 Polaris Parkway
Columbus, Ohio 43240 USA
Phone: (614) 438-4511
Fax: (614) 438-4958
www.mt.com
WARNING!
This equipment generates, uses, and can radiate radio frequency energy and if not installed and used
properly, i.e., in accordance with the instructions manual, may cause harmful interference to radio
communications. It has been tested and found to comply with the limits for a Class A computing device
pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection
against such interference when operated in a commercial environment. Operation of this equipment in a
residential area is likely to cause interference to radio communications in which case the user at his own
expense will be required to take whatever measures may be required to correct the interference.
Declaration of conformity
Konformittserklrung
Dclaration de conformit
Declaracin de Conformidad
Conformiteitsverklaring
Dichiarazione di conformit
We/Wir/Nous/Wij/Noi:
Mettler-Toledo, Inc.
1150 Dearborn Drive
Worthington, Ohio 43085 USA
to which this declaration relates is in conformity with the following standard(s) or other normative document(s).
auf das sich diese Erklrung bezieht, mitder/den folgenden Norm(en) oder Richtlinie(n) bereinstimmt.
Auquel se rfre cette dclaration est conforme la (aux) norme(s) ou au(x) document(s) normatif(s).
Al que se refiere esta declaracin es conforme a la(s) norma(s) u otro(s) documento(s) normativo(s).
Waarnaar deze verklaring verwijst, aan de volende norm(en) of richtlijn(en) beantwoordt.
A cui si riferisce questa dichiarazione conforme alla/e sequente/i norma/e o documento/i normativo/i.
CE Conformity / CE-Konformitt / Conformit CE
90/384/EU Nonautomatic Balances and Scales / Nichteselbstttige Waagen / Balances Functionnement non automatique
Article 1.2.a.
89/336/EU EMC Directive / EMU-Richtlinie / Directive concernant la CEM
EN55 022, B: 1987
Emissions / Funkstrungen
EN50 082-2: 1995
Immunity
73/23/EU Low Voltage / Niederspannung / basse tension
EN61010-1
el. Safety / el. Sicherheit / scurit el.
94/9/EC concerning equipment and protective systems intended for use in potentially explosive atmospheres
EN 50 014 : 1977 + A1A5, General requirements
EN 50 020 : 1977 + A1A5, Intrinsic safety i
Other Directives and Standards / Andere Richtlinien und Normen / Autres documents
corresponding to local requirements / entsprechend lokalen Anforderungen / correspondant aux exigences locales
R60
EEx ib IIC T4
EEx ib IIC T4
PROPRIETARY NOTICE
The information contained in this publication is derived in part from proprietary and patented data of METTLER TOLEDO. This
publication shall not be copied in whole or in part without prior written approval of METTLER TOLEDO, nor shall it be used for
any purpose other than that intended. This document is subject to change without notice.
STANDARD WARRANTY
METTLER TOLEDO warrants that the equipment covered by this warranty will be free from defects in workmanship and material
for two years from date of installation or twenty-six (26) months from date of shipment to the buyer, whichever comes first.
Should any such defects be found and reported during the first thirty (30) days after installation (if installation occurs during
the warranty period), METTLER TOLEDO (herein referred to as the Company) will, at its option, refund the purchase price or
correct such defects, furnishing replacement parts and service free of charge to the buyer. For the remainder of the first 12
months of the warranty term, the Company will furnish necessary replacement parts and on-site technicians service free of
charge, provided the Buyer agrees to pay reasonable technicians travel time, vehicle mileage, and associated travel expenses
to and from the nearest authorized Company service location. If the equipment is covered by a two-year warranty, for the last
12 months or remaining balance of the warranty period, whichever comes first, the Company will furnish the necessary
replacement parts to the Buyer free of charge, provided that the Buyer agrees to pay reasonable technicians on-site labor
services, travel time, mileage, and expenses to and from the nearest authorized Company service location. The following are
NOT covered under any of these warranties:
1. Initial installation and ongoing scale calibration.
2. Damage to scale components by gross abuse, fire, flooding, explosion, water, voltage surges, or civil disturbance.
3. Normal maintenance or consumable items.
This warranty covers only Model 2158, 2160, and 2162 VERTEX floor scales. Refer to METTLER TOLEDO Standard Product
Warranty for coverage of other scale system components, including scale instrument, printer, and/or other accessories.
THE COMPANY EXPRESSLY WARRANTS THE EQUIPMENT MANUFACTURED BY IT AS SET FORTH HEREIN. THE COMPANY
MAKES NO OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED (INCLUDING WITHOUT LIMITATION WARRANTIES AS TO
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE). IN ADDITION, THIS DOCUMENT SHALL CONSTITUTE THE SOLE
AND EXCLUSIVE REMEDIES OF THE BUYER FOR ANY BREACH BY THE COMPANY OF ITS WARRANTIES HEREIN.
COMPANY LIABILITY UNDER THIS WARRANTY OR ANOTHER WARRANTY, WHETHER EXPRESSED OR IMPLIED IN LAW OR
FACT, SHALL BE LIMITED TO THE REPAIR OR REPLACEMENT OF DEFECTIVE MATERIAL AND WORKMANSHIP, AND IN NO
EVENT SHALL IT BE LIABLE FOR CONSEQUENTIAL OR INDIRECT DAMAGES.
This warranty coverage is applicable only to the United States of America.
Export Products: The Company warrants equipment destined for export or sold for export to be free from defects in
workmanship and material for a period of one year from date of installation or 18 months from date of shipment to the Buyer,
whichever occurs first. Should any such defect be found within that period, parts will be furnished free of charge (ex works)
point of origin or final distribution center. If the Buyer requests the performance of warranty work provided for under the
foregoing warranty outside of the contiguous United States, the Buyer shall be required to pay for labor, travel time, living, and
travel expenses of any personnel required to perform such warranty work.
APPLICATION GUIDES
The only warranty of METTLER TOLEDO is for the product it supplies under the Product Warranty Statement listed above.
Weighing application guidelines pertain to METTLER TOLEDO products.
Precautions
WARNING
READ this manual BEFORE
operating or servicing this
equipment.
WARNING
FOR CONTINUED PROTECTION AGAINST SHOCK HAZARD,
CONNECT TO PROPERLY GROUNDED OUTLET ONLY. DO NOT
REMOVE THE GROUND PRONG.
WARNING
DO NOT allow untrained
personnel to operate, clean,
inspect, maintain, service, or
tamper with this equipment.
CAUTION
ALWAYS DISCONNECT this
equipment from the power
source before cleaning or
performing maintenance.
CAUTION
OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC SENSITIVE DEVICES.
CONTENTS
1
Calibration.................................................................................................... 8-1
Shift Adjust ........................................................................................................................ 8-1
Analog Junction Box Shift Adjustment.................................................................................. 8-1
DigiTOL Junction Box Shift Adjustment................................................................................. 8-3
IDNet Junction Box Shift Adjustment.................................................................................... 8-3
10
11
12
Chapter 1: Introduction
Model Numbers
Introduction
VERTEX industrial floor scales are heavy-duty scales that can be installed in a pit or
on top of the floor. Three models are available: 2158 for use with analog indicators,
2160 for use with DigiTOL indicators, and 2162 for use with IDNet systems.
Model Numbers
The following table shows how standard model numbers are determined for VERTEX
floor scales.
XXXX
-X
Model
Revision
Platform
Load Cell
Metrology
Junction Box
Size
Scale Capacity
Scale
Metrology
2158
2160
2162
0 = Mild steel,
tread plate
1 = Mild steel,
smooth plate
0 = 744 H44
0 = Analog
0 = 30"x30"
0 = 500 lb
-b
2 = 745 H44
1 = DigiTOL
1 = 3x3 feet
1 = 1,000 lb
-A
4 = 745 R60
3 = IDNet
2 = 4x4 feet
2 = 2,500 lb
-B
3 = 4x5 feet
3 = 5,000 lb
-C
4 = 5x5 feet
4 = 10,000 lb
-F
5 = 4x6 feet
5 = 20,000 lb
6 = 5x7 feet
6 = 250 lb
A = 1x1 m
A = 600 kg
B = 1.2x1.5 m
B = 1,500 kg
C = 1.2x1.2 m
C = 3,000 kg
D = 1.5x1.5 m
D = 6,000 kg
2 = Stainless
steel, tread plate
3 = Stainless
steel, smooth
plate
E = 10,000 kg
1
2,500d for 500-lb, 2,500-lb, and 5,000-lb capacities; 2,000d for 1,000-lb, 10,000-lb, and 20,000-lb capacities.
(2/01)
1-1
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
Load Cells
All VERTEX floor scales include stainless steel, cantilever-beam load cells with integral
four-conductor, shielded cables (see note). The load cell suspension uses a rocker pin
positioned between the cell and a fixed receiver in the frame (see Figure 1-1). Individual
load cell capacities for Models 2158, 2160, and 2162 are listed below:
Scale Platform
Capacity
Capacity of Each
Load Cell
Minimum Approved
Graduation Size
500 lb
1,000 lb
2,500 lb
5,000 lb
10,000 lb
20,000 lb
250 lb
500 lb
1,250 lb
2,500 lb
5,000 lb
10,000 lb
0.1 lb
0.2 lb
0.5 lb
1.0 lb
2.0 lb
5.0 lb
Platform
Overload
Stop Gap
Bumper Gap
Frame
Lower Receiver
Rocker Pin
O-Ring
Load Cell
1-2
(2/01)
Chapter 1: Introduction
Scale Accuracy
Scale Accuracy
Models 2158 and 2160 VERTEX floor scales meet or exceed the National Institute of
Standards and Technology (NIST) Handbook 44 requirements for Class III scales.
Standard VERTEX scales meet 5000-division accuracy. Certificates of Conformance No.
91-097 (2158) and No. 94-010 (2160) were issued under the National Type
Evaluation Program (NTEP) of the National Conference on Weights and Measures. The
Model 2162 VERTEX floor scale has not been submitted for approval.
+2.5
+2.0
+1.5
+1.0
Number
of
Divisions
+0.5
0
-0.5
500d
2000d
4000d
10,000d
-1.0
-1.5
-2.0
-2.5
Applied Weight
0 - 500 Divisions
501 - 2,000 Divisions
2,001 - 4,000 Divisions
4,001 - 10,000 Divisions
Allowable Error
1/2 Division
1 Division
1.5 Divisions
2.5 Divisions
+2.5
+2.0
+1.5
+1.0
Number
of
Divisions
+0.5
0
-0.5
500d
2000d
4000d
10,000d
-1.0
-1.5
-2.0
-2.5
Applied Weight
0 - 500 Divisions
501 - 2,000 Divisions
2,001 - 10,000 Divisions
Allowable Error
1/2 Division
1 Division
1.5 Divisions
1-3
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
End Loading
Models 2158, 2160, and 2162 may be end loaded up to 100% of the platforms rated
capacity or two times the individual load cell rating (whichever is less) across any end
of the scale.
Platform Assembly
VERTEX floor scales have a single-channel reinforced platform with a plate that can be
removed to gain access to the junction box. Standard mild steel scales have a safety
tread plate surface. Stainless steel scales have a platform structure very similar to the
mild steel unit. Standard stainless steel scales have a smooth deck surface with a glass
bead blast finish. Threaded holes are provided in the platform. When installing or
removing a platform, screw eyebolts into these holes and lift the platform by the
eyebolts.
Support Frames
Standard
Above-Floor Frame
Standard VERTEX scales have a formed-angle frame with all sides turned under the
scale for a fully captured assembly (see Figure 1-4). When used for top-of-floor
installations, the scales can be equipped with optional ramps to provide access to all
four sides of the scale. Optional scale guards can be mounted on sides of the scale that
do not have ramps, to provide protection in high-traffic areas. Standard VERTEX frames
can be used for in-floor applications; however, a Quick-Pit frame is recommended.
VERTEX Scale Platform
1-4
(2/01)
Chapter 1: Introduction
Support Frames
VERTEX Scale
Floor
Floor
(2/01)
1-5
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
Access Ramps
Access ramps are available for all 2158, 2160, and 2162 VERTEX floor scales. VERTEX
ramps can accommodate single or multi-directional traffic. Ramps are available in 36"
or 60" lengths, depending on the width of the scale. The maximum ramp angles are
listed below:
1-6
(2/01)
Scale Capacity
Scale Height
Ramp Length
Ramp Angle
500 to 5,000 lb
500 to 5,000 lb
10,000 lb
20,000 lb
3"
3"
3 3/8"
4"
36"
60"
36"
36"
4.4
2.6
4.9
5.9
Inspection
When the VERTEX floor scale is delivered, visually inspect it for any damage that might
have occurred during shipment and handling. Inspect the following:
1. Frame assembly for any warping or bent angles
2. Load cell and suspension assemblies
3. Load cell cables
4. Load cell summing junction box
5. Overall platform assembly
If you find any damage, contact your freight carrier immediately.
Site Selection
Many problems associated with floor scale installations are caused by improper site
conditions. Before installing the scale, check the proposed location for the following
conditions:
1. The area where the scale will be located should be level to within 1/4" from the
highest to the lowest corner.
2. The floor/support at each corner of the scale must be strong enough to maintain
support throughout the entire weighing capacity of the scale.
3. There should be proper drainage away from the scale.
4. There should be no heavy vibrations or wind currents at or near the scale.
5. The scale should not be subjected to excessive or unusual loading due to the
location or type of equipment used.
If the site is acceptable, proceed with the installation. If not, choose a new location or
select another scale.
(2/01)
2-1
Locate Scale
After inspecting the site, place the VERTEX floor scale in the desired location.
Remove Platform
To remove the scale platform from the frame, install eyebolts (two 3/4-10 UNC eyebolts
are required) in the threaded holes provided in the platform. Make sure that the eyebolts
are snug and completely threaded into the holes before lifting the platform. Attach a
chain or strap to the eyebolts, and lift the platform with a forklift or crane.
WARNING
USE EXTREME CAUTION WHEN LIFTING AND MOVING
THE SCALE TO THE DESIRED LOCATION. DO NOT
ATTEMPT TO LIFT AND MOVE THE SCALE BY YOURSELF
OR INJURY COULD OCCUR.
Anchor Frame
1. Locate the anchor holes in all four corners of the frame. There are a total of eight
anchor holes, two holes per corner (see Figure 3-1). Scale frames with sides 7 feet
long or longer require an additional anchor at the midpoint of each of those sides.
2. Drill anchor holes into the floor, using the frame as a guide. The 1/2" anchors are
to be provided by others or can be purchased from METTLER TOLEDO. Drill anchor
holes to the diameter and depth specified by the supplier.
3. All corners of the frame must touch the floor and must be level within 1/16". If the
scale is out of level or if gaps exist between the frame and floor, shim between the
frame and the floor. Corner shims (1/16" thick) can be purchased from METTLER
TOLEDO (Part No. 58-030025) or fabricated using Figure 3-2 as a guide.
4. Secure the frame to the floor by installing the anchors and flat head socket cap
screws (1/2-13 UNC x 1.5" long). The screws are provided with the scale. Be sure
to use flat head screws to maintain clearance between the head of the screw and
the bottom of the deck throughout the weighing range.
(2/01)
3-1
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
6.5"
1.5"
1.5"
6.5"
Fixed Receiver
Frame
Countersunk Anchor Holes
for 1/2" Flat Head Screws
(typical each corner)
1.25"
6.25"
Two 1.06" Diameter Holes
6.88"
1.19"
1.25"
1.19"
6.25"
6.88"
3-2
(2/01)
45
1.88"
Route/Attach
Instrument Cable
1. Remove the junction box access plate from the platform.
2. A loose coil of instrument cable is located inside the platform channel on either side
of the junction box assembly.
3. Thread the instrument cable through the hole provided in the scale frame and
platform, continuing through the inside of the platform channel and stopping at the
junction box (see Figure 3-3).
Scale Platform
Frame
Instrument Cable
Top of Floor
Scale Platform
Frame
Ramp
Top of Floor
Frame
Top of Floor
Conduit
(2/01)
3-3
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
4. Remove the junction box lid.
5. Loosen the instrument cable connector, and thread the cable through the connector
(pull enough cable to reach the INPUT terminal on the junction box PCB).
6. Route the cable as shown in Figure 3-4.
7. Connect the instrument cable to the INPUT terminal on the PCB as shown in Figure
3-6 For Analog, Figure 3-7 For DigiTOL, or Figure 3-8 For IDNet.
8. Place the desiccant bag inside the junction box.
9. Reinstall the junction box lid. Make sure that the rubber gasket is clean and
correctly positioned. Tighten all screws and make sure all cord grip caps are secure
(see Figure 3-5).
Cable
Cable
Load
Cell
Load
Cell
Incorrect Routing
Correct Routing
Body Insert
Rubber Grommet
Spherical Washer
3-4
(2/01)
Nut
Junction Box
Enclosure
Modes of Operation
Analog Mode
A Model 2158 floor scale is used with an analog junction box for summing the load cell
outputs. Only analog-compatible indicators work with the analog junction box. See
Figure 3-6 and Table 3-1 for the correct cable connection.
LC2
LC4
Load Cell Orientation
(Top View of Platform)
LC1
LC3
To LC4
LC2
LC4
A
U
X
ANALOG JBOX
A/N 13640300A
+EXE
+SEN
+SIG
SHLD
-SIG
-SEN
-EXE
To Indicator
LC3
+EXE
+SIG
SHLD
-SIG
-EXE
LC1
I
N
P
U
T
+EXE
+SIG
SHLD
-SIG
-EXE
+EXE
+SEN
+SIG
SHLD
-SIG
-SEN
-EXE
+EXE
+SIG
SHLD
-SIG
-EXE
+EXE
+SIG
SHLD
-SIG
-EXE
To LC2
To LC1
To LC3
Function
Color
+Excitation
+Sense
+Signal
Shield
-Signal
-Sense
-Excitation
Green
Not Used
White
Yellow
Red
Not Used
Black
Function
Color
+Excitation
White
+Sense
Yellow
+Signal
Green
Shield
Orange
-Signal
Black
-Sense
Red
-Excitation
Blue
*(Based on METTLER TOLEDO
Cable Number 510624370)
(2/01)
3-5
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
WARNING
DO NOT USE THE DigiTOL JUNCTION BOX IN LOCATIONS
CLASSIFIED AS HAZARDOUS BY THE NATIONAL
ELECTRICAL CODE (NEC) ARTICLE 500.
LC2
LC4
Load Cell Orientation
(Top View of Platform)
TO CELL 2
TO CELL 4
LC1
LC3
W3
W4
TO DigiTOL
INDICATOR
LC4
GROUND
12
TB 2
LC3
LC1
8510*
8520
8522
8530**
JAGUAR
LYNX
+20 VDC
10
-EXC
-SIG
SHIELD
+SIG
+EXC
LC2
-EXC
-SIG
SHIELD
+SIG
+EXC
W1
SHIELD
RXD A
RXD B
TXD B
TXD A
W2
TB 1
TO CELL 1
Terminal Number
Position
Function
Wire Color
TB2
TB2
TB1
TB1
TB1
TB1
TB1
10
12
1
2
3
4
5
+20 VDC
Ground
Shield
RXD A
RXD B
TXD B
TXD A
Green
Blue
Orange
Red
White
Yellow
Black
3-6
(2/01)
IDNet Mode
A Model 2162 floor scale is used with an IDNet junction box to output an IDNet data
format compatible with the METTLER TOLEDO ID1 and ID5 weight display, or the Jaguar
industrial terminal. See Figure 3-8 and Table 3-3 for cable connections. For information
about the indicator and how to operate it, refer to the appropriate indicator manual.
WARNING
DO NOT USE THE IDNet JUNCTION BOX IN LOCATIONS
CLASSIFIED AS HAZARDOUS BY THE NATIONAL
ELECTRICAL CODE (NEC) ARTICLE 500.
LC 1 & 2 Ground
Standoff
W4
W8
W7
LC2
Indicator Plug
LC4
Load Cell Orientation
(Top View of Platform)
LC1
LC3
W9
W6
LC 3 & 4 Ground
Standoff
ST3
+EXC
ST2
LC3
P7 P8
-SIG +SIG
-EXC
LC4
LC2
8
7
6
5
4
3
2
1
3
8
LC1
4
9
-SEN +SEN
W1
P1 P2
W3
W2
SA1
Cell
#1
#2
#3
#4
+ Exc.
Green
4
3
2
1
Terminal
- Exc.
+ Sig.
Black
White
4
9
3
8
2
7
1
6
- Sig.
Red
9
8
7
6
W5
(2/01)
3-7
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
Jumper
Status
W1
W2
W3
W4
W5
W6
W7
W8
W9
SA1
Closed (ON)
Closed (ON)
Closed (ON)
Closed (ON)
Open (OFF)
Closed (ON)
2-3
1-2
Open (OFF)
Closed (ON)
Description
Matching the gain at 2 mV/V load cells
No external sensing (-SEN)
No external sensing (+SEN)
Internal reference voltage = 3.5 Volts
Excitation voltage for load cells = 4.0 Volts
Internal supply voltage = 7.1 Volts
Protocol IDNet
Interface 20 mA
Supply voltage IDNet
Trim Potentiometers Circuit Disabled
Table 3-3: IDNet Default Factory Setting
Reinstall Platform
1. Clear all debris from the scale area. Make sure that all four load pin receivers in the
frame are clean and free of all foreign material.
2. Replace the platform into the frame. Make sure there is slack in the cable between
the frame and platform and that no cable pinching occurs.
3. Move the platform back and forth in both directions to make sure that the rocker
pins are seated in the receivers and there is no binding.
4. Calibrate the scale according to the METTLER TOLEDO indicator manual.
3-8
(2/01)
Screw
Ramp
Lock Washer
Figure 4-2: Ramp Attachment Detail
5. Make sure that the ramp is stable. Shim under the corners of the ramp if required.
Proceed with installation of the platform. The instrument cable can be routed
through the ramp via the slot below the attachment lug and the cable access hole.
(2/01)
4-1
If the scale capacity is 500 to 5,000 lb, the 3" leg of the guard should be
vertical (equal to platform deck height).
If the scale capacity is 10,000 lb, the 3-3/8" leg should be vertical.
It is important that the scale guard does not touch the scale platform.
2. Two 9/16" diameter holes are provided for anchoring the scale guards to the floor.
Using the holes as a drill template, install 1/2" anchors into the floor (anchors and
anchor bolts by others).
3. Insert the 1/2" anchor bolts and tighten them to secure the scale guard to the floor
(see Figure 5-1).
3"
3-3/8"
4"
(10K)
(500-5K)
(20K)
3/8"
Min.
Scale Guard
Platform
Frame
3"
3-3/8"
4"
(500-5K)
(10K)
(20K)
Anchor
Top of Floor
(2/01)
5-1
2. Inspect the separate forklift frame. Along with the frame there should be four
clamping bars, eight flat head screws (1/2-13 x 1.5" long), and four 5/8" spacers
(10,000-lb capacity scale only). Each clamping bar should have two tapped
holes. These parts are used for mounting the scale frame to the forklift frame.
3. Also included is a bubble level assembly, which mounts on the side of the forklift
frame as shown in Figure 6-1. The bubble level is used to check the suitability of
the chosen location. Mount the bubble level first before beginning assembly of the
scale to the forklift frame.
4. Remove the platform from the standard VERTEX frame.
5. Place the standard VERTEX frame into the forklift channel frame. Line up the eight
mounting holes in both frames, two per corner. Insert the eight mounting screws
into the holes and through both frames.
6. Install a clamping bar beneath each frame corner by threading the two projecting
screws into the tapped holes provided. Tighten all screws until they are finger-tight
(see Figure 6-1).
7. Make sure that there is an equal gap between the two frames on all sides. The
oversized mounting holes in the forklift frame allow for any required adjustment.
Once the gap is equal, finish tightening all mounting screws.
8. While the platform is removed from the frame, wire the instrument cable to the
junction box PCB. Route the cable out the appropriate corner of the platform. Place
the rocker pins into the load cells.
9. Reinstall the platform into the frame, carefully routing the instrument cable out the
appropriate corner of both frames.
10. Continue with the installation and calibration as described in the METTLER TOLEDO
digital indicator manual.
(2/01)
6-1
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
Platform
Bumper
Bubble Level
Load Cell
Scale Frame
Forklift Frame
Clamping Bar
Flat Head Mounting Screws
6-2
(2/01)
7
Contact METTLER TOLEDO for latest pit
construction drawings.
10. Once the concrete has properly cured, mount the standard VERTEX frame inside the
Quick-Pit frame. Lower the standard frame into the Quick-Pit frame, center it, and
then locate the eight anchor holes in the corners. METTLER TOLEDO supplies eight
1/2-13 UNC x 1.5" long (2" long for 10K capacity) flat head socket cap screws for
securing the frame. The 1/2" anchors are to be supplied by others or can be
purchased from METTLER TOLEDO. Using the frame as a guide, drill anchor holes
to the diameter and depth specified by the supplier. Install the anchors into the
concrete, and then secure the frame using the eight flat head screws provided (see
Figure 7-2).
11. Install the scale platform and have the scale calibrated by an authorized METTLER
TOLEDO service technician.
(2/01)
7-1
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
Quick-Pit Frame
Corner Plate
Shipping/Pit Frame
Support Bracket
Conduit Entry
Quick-Pit Frame
Quick-Pit Frame
7-2
(2/01)
Top of Floor
Chapter 8: Calibration
Shift Adjust
Calibration
Shift Adjust
WARNING
PERMIT ONLY QUALIFIED PERSONNEL TO SERVICE THIS
EQUIPMENT. EXERCISE CARE WHEN MAKING CHECKS, TESTS,
AND ADJUSTMENTS THAT MUST BE MADE WITH POWER ON.
FAILING TO OBSERVE THESE PRECAUTIONS CAN RESULT IN
BODILY HARM.
When you shift adjust a scale, you are adjusting the output voltage (signal) of each
load cell so that all load cells in the system produce a consistent signal. A correctly
adjusted scale will give the same weight reading no matter where on the platform you
place a test weight. Each VERTEX floor scale is shift adjusted at the factory. For a new
installation, the only adjustment that should be needed is minor load cell trimming.
After the scale has been installed and shimmed, check all mechanical parts to make
sure that they work properly. Then check the scales repeatability by placing a test
weight on the same location on the platform several times to make sure that you get the
same weight reading each time. After checking for repeatability, adjust the load cell
trimming potentiometers as needed.
(2/01)
8-1
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
C
Figure 8-1: Test Weight Locations
3. Place the test weight at the location immediately clockwise from the location at
which you got the lowest weight reading. Then adjust the trimming potentiometer for
the load cell that corresponds to the corner of the scale where the test weight is
positioned (see Figure 8-2). Make the adjustment by turning the potentiometer until
the weight reading matches the lowest reading.
LC4
LC2
Load Cell Orientation
(Top View of Platform)
LC1
LC3
To LC4
LC2
LC4
A
U
X
I
N
P
U
T
ANALOG JBOX
A/N 13640300A
To Indicator
LC3
+EXE
+SIG
SHLD
-SIG
-EXE
LC1
+EXE
+SEN
+SIG
SHLD
-SIG
-SEN
-EXE
+EXE
+SIG
SHLD
-SIG
-EXE
+EXE
+SEN
+SIG
SHLD
-SIG
-SEN
-EXE
+EXE
+SIG
SHLD
-SIG
-EXE
+EXE
+SIG
SHLD
-SIG
-EXE
To LC2
To LC1
To LC3
Individual Load Cell
Trimming Potentiometer
4. Proceeding clockwise, repeat the adjustment described in Step 3 for the next two
test weight locations.
8-2
(2/01)
Chapter 8: Calibration
DigiTOL Junction Box Shift Adjustment
NOTE: Because the trimming potentiometers interact with each other, any
adjustment will affect the weight readings at all four corners of the scale.
5. Repeat Steps 2 to 4 until the weight readings at all corners of the platform are the
same or are within the specified National Institute of Standards and Technology
(NIST) Handbook 44 Scale Accuracy Requirements.
6. Replace the junction box lid and platform access plate.
(2/01)
8-3
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
ST3
ST2
+EXC
LC3
P7 P8
-SIG +SIG
-EXC
LC4
6
Potentiometer Pair LC2
2
7
LC2
LC1
9
-SEN +SEN
8
7
6
5
4
3
2
1
P1 P2
LC4
LC3
LC2
LC1
SA1
Hook Switches
Scale Calibration
METTLER TOLEDO recommends calibrating the scale using test weights equal to the
scales capacity. Follow the calibration instructions in the manual provided with the
scale terminal.
8-4
(2/01)
General
Once the scale has been installed, it should be inspected and calibrated periodically by
an authorized METTLER TOLEDO representative. If the scale is used for legal-for-trade
purposes, consult the local weights and measures authorities for minimum inspection
requirements. Contact your local authorized METTLER TOLEDO service representative for
information about periodic inspection and calibration services.
Site Inspection
Make sure that the scale site remains in good condition. Check for alterations in the
surrounding floor, excessive vibrations, and possible overloading conditions.
Platform Inspection
During periodic inspections of the scale, check the following:
1. Are there any unusual wear points, paths, or marks on the weighing platform?
2. Is the scale frame bent or damaged?
3. Is the junction box lid properly sealed and all cable connectors tight against the
enclosure?
4. Is there any moisture or foreign material around or inside the junction box
assembly?
5. Is the instrument cable damaged or binding the scale?
6. Is there any debris or material build-up under or around the platform that could
prevent the platform from moving freely?
7. For pit installations, is the floor drain clear and providing adequate drainage?
8. Visually inspect the load cells, rocker pins, and fixed bumpers for signs of unusual
wear.
9. Check repeatability and shift of the scale.
(2/01)
9-1
10
Troubleshooting
General
If the scale does not operate properly, find out as much about the problem as possible.
Try to determine whether the problem is constant or intermittent. Mechanical and
electrical influences can cause malfunctions, so be patient and use sound logic when
troubleshooting.
When troubleshooting a VERTEX floor scale, examine the scales physical location.
Check for the presence of water, corrosive materials, unlevel floors, high vibrations, air
currents, or physical damage to the scale platform or frame. Also check the instrument
cable for damage, and all connections for loose or improper wiring.
WARNING
PERMIT ONLY QUALIFIED PERSONNEL TO SERVICE THIS
EQUIPMENT. EXERCISE CARE WHEN MAKING CHECKS,
TESTS, AND ADJUSTMENTS THAT MUST BE MADE WITH
POWER ON. FAILING TO OBSERVE THESE PRECAUTIONS
CAN RESULT IN BODILY HARM.
CAUTION
BEFORE CONNECTING/DISCONNECTING ANY INTERNAL ELECTRONIC
COMPONENTS OR INTERCONNECTING WIRING BETWEEN ELECTRONIC
EQUIPMENT, ALWAYS REMOVE POWER AND WAIT AT LEAST THIRTY (30)
SECONDS. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN
BODILY HARM OR DAMAGE TO OR DESTRUCTION OF THE EQUIPMENT.
(2/01)
10-1
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
2. Connect the digital indicator to a load cell simulator (analog simulator available
from METTLER TOLEDO).
3. Reapply power and test the indicator. If the problem persists, consult the digital
indicator manual for further troubleshooting assistance.
4. If the problem is NOT present with the load cell simulator attached to the indicator,
remove power, disconnect the simulator, and reconnect the scale. If the problem
persists, continue troubleshooting the scale.
Check Wiring
1. Remove power from the system.
2. Remove the access cover plate from the scale platform.
3. Remove the lid from the junction box and check the interior for moisture and foreign
material.
4. Make sure that all wiring connections are tight and that no insulation material is
touching the terminal contacts.
5. Check all cable connections to make sure they are wired correctly. The wiring color
codes are given in Table 10-1:
Load Cell Wiring
Function
Color
Function
Color
+Excitation
Green
+Excitation
White
+Sense
Not Used
+Sense
Yellow
+Signal
White
+Signal
Green
Shield
Yellow
Shield
Orange
-Signal
Red
-Signal
Black
-Sense
Not Used
-Sense
Red
-Excitation
Black
-Excitation
Blue
Instrument cable color code based on METTLER TOLEDO cable no. 510624370
* See Figure 3-7 for DigiTOL instrument cable wiring.
Table 10-1: Load Cell Wiring Color Codes
6. Check all cable connectors and cord grip caps on the junction box.
7. Tighten any loose connectors.
10-2 (2/01)
Resistance
Infinity
348-352 ohms
Short the signal leads together and place one multimeter lead on the shorted
signals and one lead on the +Excitation wire. Note the resistance value.
Remove the lead from the +Excitation wire and place it on the Excitation wire.
The two resistance values should be approximately equal.
3. If the load cells pass the shorted-signal test, reconnect them and reapply power to
the scale. Confirm that the proper excitation voltage is reaching the load cells by
placing multimeter leads on the excitation positions of each load cell terminal.
4. If proper excitation voltage is reaching the load cells, check the output signal from
each cell by disconnecting the signal leads and measuring voltage output. If one
cell has a particularly high or low dead-load output, it is suspect. The maximum
output possible from any cell is 30 mV at 15 VDC excitation and loaded to gross
capacity.
5. If any load cell has an unusual signal, remove all load from that cell.
Note: Remove signal leads from
terminals to measure output.
With the power on, measure the output from the suspect load cell. The no-load
zero output should be 1.5% of the full scale output. For example, if the
excitation voltage is 15 VDC, then the full scale output would be 30 mV and
the no-load zero output should be within 0.45 mV.
(2/01)
10-3
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
Check Mechanical
Components
Because the VERTEX design is so simple, there are only a few mechanical components
to troubleshoot. Make sure that the platform can move freely and that the load cells are
not resting against the fixed bumpers. If the load cells touch the fixed bumpers when
there is no motion in the scale platform, check the following:
1. The platform should be level and should not rock. Otherwise, shimming may be
required.
2. Check the rocker pins for unusual wear. Replace any rocker pins that are unevenly
worn or have flattened bearing surfaces.
3. Examine the rocker pin receivers in the frame. If the bearing surface is sunken,
depressed, or unevenly worn, replace the frame.
4. If the fixed bumpers on the frame are excessively worn or damaged, the entire frame
should be replaced.
5. Inspect the platform and frame for physical damage. Replace any platform or frame
that is bent or has broken welds.
6. Verify that the load cell overload stop gap is set properly:
Note: 5,000-lb and 10,000-lb load
cells do not have an overload stop.
250 lb
0.009" to 0.012"
500 lb
0.009" to 0.015"
1250 lb
0.012" to 0.018"
2500 lb
0.017" to 0.023"
Load Cell
Replacement
1. Remove power to the digital indicator and disconnect the instrument cable.
2. Remove the access plate from the platform to gain access to the junction box.
Remove the junction box cover and locate the defective load cell terminal.
3. Disconnect the defective load cell cable from its terminal on the summing PCB.
4. Loosen the cable connector on the junction box and remove the cable from the
enclosure.
Note: The instrument cable may need
to be removed from the junction box to
allow the platform to be removed.
5. Carefully remove the platform from the frame assembly, lifting it by eyebolts
screwed into the holes in the platform. Position the platform on a stable surface that
allows access to the defective load cell and cable as well as offering protection to
the other load cells during disassembly.
6. Attach a string to the end of the defective load cells cable. The string should be
long enough and strong enough to pull the new load cells cable through the
platform structure.
10-4 (2/01)
7. Remove the two load cell mounting screws and keep them for reinstalling the new
load cell. Use a 3/8" hex Allen socket wrench to remove the 1/2-13 UNC socket
head cap screws that mount 250-lb to 5,000-lb load cells. Use a 1-1/8" hex Allen
socket wrench to remove the 3/4-10 UNC socket head cap screws that mount
10,000-lb load cells. Then lift the load cell from the mounting surface.
8. Carefully pull the defective load cells cable through the platform while feeding the
string in at the junction box opening. Once the string is at the load cell location,
detach it from the load cell cable.
9. Remove the rocker pin with O-rings from the defective load cell. Reinstall it in the
new load cell.
10. Attach the new load cells cable to the pulling string and carefully thread it through
the platform into the junction box opening. Coil any excess cable and store it within
the platform side channel.
Note: Make sure load cell and platform
mounting surfaces are free of grease
and other foreign materials.
Note: 5,000-lb and 10,000-lb load
cells do not have an overload stop.
11. Secure the new load cell to the platform. Apply an anti-seize compound such as
Never-Seez to the threads of the mounting screws and tighten with a calibrated
torque wrench to 100 ft-lb (250-lb to 5,000-lb load cells) or 250 ft-lb (10,000-lb
load cells).
12. Verify that the load cell overload stop gap is set properly:
Load Cell Capacity
250 lb
0.009" to 0.012"
500 lb
0.009" to 0.015"
1250 lb
0.012" to 0.018"
2500 lb
0.017" to 0.023"
Platform
Overload
Stop Gap
Frame
Lower Receiver
Rocker Pin
O-Ring
Load Cell
13. Thread the load cell cable through the connector on the junction box. When enough
cable is inside the box, tighten the connector.
14. Wire the new load cell cable to the proper terminal on the PCB according to the
wiring codes shown in Chapter 3.
15. Reinstall the platform in the frame. Make sure that the rocker pins are properly
seated and aligned with the receivers in the frame.
16. Reconnect the instrument cable and power-up the indicator. Perform a shift adjust
and recalibrate the scale.
(2/01)
10-5
11
Service Parts
2
To Indicator
4
5
Part Number
TB600488
TB600488-1
TB600529-2
TB600529-3
TB600363-1
TB600363
TB600342-1
TB600342
TB600343-1
TB600343
TB600364-1
TB600454-2
TB600454
TB600455-2
TB600455
TB600456-2
TB600456
TB600457
TN800647
TN800650
TN800654
TN200050
MN21018
TN201975
MZ0909000005
MZ0909000012
510624370
Description
250-lb load cell (5000d) with 7.5-foot cable
250-lb load cell (5000d) with 15-foot cable (5 x 7 platform only)
500-lb load cell (5000d) with 7.5-foot cable
500-lb load cell (5000d) with 15-foot cable (5 x 7 platform only)
1250-lb load cell (5000d) with 7.5-foot cable
1250-lb load cell (5000d) with 15-foot cable (5 x 7 platform only)
2500-lb load cell (5000d) with 7.5-foot cable
2500-lb load cell (5000d) with 15-foot cable (5 x 7 platform only)
5000-lb load cell (5000d) with 7.5-foot cable
5000-lb load cell (5000d) with 15-foot cable (5 x 7 platform only)
10000-lb load cell (5000d) with 15-foot cable
550-kg C3 R60 OIML with 7.5-foot cable
550-kg C3 R60 OIML with 15-foot cable (5 x 7 platform only)
1100-kg C3 R60 OIML with 7.5-foot cable
1100-kg C3 R60 OIML with 15-foot cable (5 x 7 platform only)
2200-kg C3 R60 OIML with 7.5-foot cable
2200-kg C3 R60 OIML with 15-foot cable (5 x 7 platform only)
4400-kg C3 R60 OIML with 15-foot cable (5 x 7 platform only)
1/2-13 bolt x 1.75" long (250-lb - 2.5K load cell)
1/2-13 bolt x 2" long (5K load cell)
3/4-10 bolt x 2.5" long (10K load cell)
Rocker pin (250-lb - 2.5K load cell)
Rocker pin (5K load cell)
Rocker pin (10K load cell)
O-ring (250-lb - 5K load cell)
O-ring (10K load cell)
24-gauge, 6-conductor, shielded home run cable
Qty.
4
8
Varies
(2/01)
11-1
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
Scale Platform
3
4
7
2
9
6
11
5
Scale Frame
8
Scale Frame
10
13
Fork Lift Frame
15
12
Scale Frame
16
14
Floor Opening
11-2 (2/01)
Ref. No.
1
Part Number
TB100395
TB100515-5
TB100569-4
2
3
4
NS
MZ0901010379
MZ0901010035
MZ0901010298
ME504235
Junction Box
Description
Analog junction box assembly (model 2158)
Consists of:
*13640300A Analog PCB
TA800218 Desiccant Bag
DigiTOL junction box assembly (model 2160)
Consists of:
*13839900A DigiTOL PCB
TA800218 Desiccant Bag
IDNet junction box assembly (model 2162)
Consists of:
ME209351 IDNet PCB
ME200308 Lock Nut
ME209911 Washer
TA800218 Desiccant Bag
1/4-20 Phillips head screw x 1/4" long
3/8-16 flat head screw x 3/4" long
1/2-13 flat head screw x 1.5" long
Cable, IDNet x 5 m long
Qty.
1
4
2
8
-
5
6
7
8
9
10
11
12
13
14
15
16
TA201611
MZ0901030076
MZ0901010124
TN201817
MZ0901010298
MZ0901010451
TN202231
TN201705
TN202623
MZ0901010033
MZ0901030011
MZ0901010249
TN201705
2
2
2
1
8
4
4
4
8
8
8
4
(2/01)
11-3
METTLER TOLEDO 2158/2160/2162 VERTEX Floor Scale Installation and Service Manual
2
5
4
3
Indicator Column
Ref. No.
1
2
3
4
5
11-4 (2/01)
Part Number
TB203682
MZ0901010076
MZ0901020016
MZ0901030060
MZ0901030076
Description
Indicator Column
3/8-16 bolt x 1.25" long, SS
3/8-16 hex nut, SS
3/8" washer, SS
3/8" lock washer, SS
Qty.
1
3
3
3
3
12
Reference Material
Reference Drawings
Scale Capacity
General
Dimensions
Quick-Pit Assembly
1,000-5,000 lb
TC201789
TB201773
TC201787
10,000 lb
TC201789
TC201774
TC201787
20,000 lb
TC202033
TC201774
--
Recommended Spare
Parts
For part numbers refer to service parts.
Quantity
Description
(2/01)
12-1
METTLER TOLEDO
Publication Name: 2158 VERTEX Floor Scales Installation and Service Manual
Publication Part Number: B14691400A
PROBLEM(S) TYPE:
DESCRIBE PROBLEM(S):
Technical Accuracy
Text
Completeness
Procedure/Step
Example
Explanation
Illustration
Illustration
Definition
Guideline
Feature
Other (please explain below)
information in
manual
information not in
manual
Clarity
What is not clear?
Sequence
What is not in the right order?
Other Comments
Use another sheet for
additional comments
Your Name:
Location:
Phone Number: (
Printed in U.S.A.
14981600A
METTLER TOLEDO
1900 Polaris Parkway
Columbus, Ohio 43240 USA
P/N: B14691400A
(2/01).00
METTLER TOLEDO, VERTEX, and DigiTOL are trademarks of Mettler-Toledo, Inc.
1996, 2001 Mettler-Toledo, Inc.
Printed in U.S.A.
B14691400A