Tension Weigh: Installation and Service Manual

0978
Tension Weigh
Module
Installation and Service
Manual
B15141500A
(8/00).00
Mettler-Toledo, Inc. 1997, 1999, 2000

No part of this manual may be reproduced or transmitted in any form or by any means, electronic or
mechanical, including photocopying and recording, for any purpose without the express written
permission of Mettler-Toledo, Inc.
U.S. Government Restricted Rights: This documentation is furnished with Restricted Rights.
METTLER TOLEDO
Publication Revision History

An overview of this manuals revision history is compiled below.
Publication Name: 0978 Tension Weigh Module Service Manual
Publication Part Number:
Part Number
Date
15141500A
Publication Date:
9/97
Revisions
A15141500A
12/99
Updated drawings and part numbers with new clevis pin design. Removed Smart
Mode junction box information, warranty information, and junction box wiring
diagrams.
B15141500A
8/00
Added grounding strap to drawings and parts lists.
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
declare under our sole responsibility that the product,
erklren, in alleiniger Verantwortung, da dieses Produkt,
dclarons sous notre seule responsabilit que le produit,
declaramos, bajo nuestra sola responsabilidad, que el producto,
verklaren onder onze verantwoordelijkheid, dat het product,
dichiariamo sotto nostra unica responsabilit, che il prodotto,
Type/ Tipo: Analog Load Cells/ Celdas de Carga Analgicas

Models:
736
(when used within the technical requirements listed in Test Certificate TC2826 and installed as a Load receptor as
listed in Type approval certificate T2206, Table 4.)
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.
Other Directives and Standards / Andere Richtlinien und Normen / Autres documents
corresponding to local requirements / entsprechend lokalen Anforderungen / correspondant aux exigences locales
R60
OIML International Recommendation , Metrological regulation for load cells
Darrell Flocken, Manager - Weights & Measures
Office of Weights and Measures

Worthington, Ohio USA
September, 1996
according to EN45014
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.
METTLER TOLEDO RESERVES THE RIGHT TO MAKE REFINEMENTS OR

CHANGES WITHOUT NOTICE.
Precautions
WARNING
READ this manual BEFORE
operating or servicing this
equipment.
FOLLOW these instructions

carefully.
SAVE this manual for future

reference.
DO NOT allow untrained

personnel to operate, clean,
inspect, maintain, service, or
tamper with this equipment.
PERMIT ONLY QUALIFIED PERSONNEL TO SERVICE

THIS EQUIPMENT. USE CARE WHEN MAKING CHECKS,
TESTS, AND ADJUSTMENTS THAT MUST BE MADE
WITH POWER ON. FAILING TO OBSERVE THESE
PRECAUTIONS CAN RESULT IN BODILY HARM.
WARNING
FOR CONTINUED PROTECTION AGAINST SHOCK
HAZARD, CONNECT TO PROPERLY GROUNDED OUTLET
ONLY. DO NOT REMOVE THE GROUND PRONG.
WARNING
DISCONNECT ALL POWER TO THIS UNIT BEFORE
REMOVING THE FUSE OR SERVICING.
CAUTION
ALWAYS DISCONNECT this
equipment from the power
source before cleaning or
performing maintenance.
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.
CAUTION
CALL METTLER TOLEDO for parts,
information, and service.
OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC

SENSITIVE DEVICES.
CONTENTS
1 Introduction ....................................................................................................... 1-1
Overview............................................................................................................................ 1-1
0978 Assembly Includes..................................................................................................... 1-1
Check Rods/Bumpers .......................................................................................................... 1-1
2 Sizing Load Cells............................................................................................... 2-1

Overview............................................................................................................................ 2-1
3 Installation Guidelines ....................................................................................... 3-1

Instructions ........................................................................................................................ 3-1
4 Installation Instructions...................................................................................... 4-1

Instructions ........................................................................................................................ 4-1
5 Wiring Weigh Modules to Junction Box ............................................................... 5-1

Analog Junction Box ........................................................................................................... 5-1
DigiTOL Junction Box (DLC Mode) ....................................................................................... 5-3
IDNet Junction Box ............................................................................................................. 5-5
6 Calibration ........................................................................................................ 6-1

Overview............................................................................................................................ 6-1
Calibration with Test Weights.............................................................................................. 6-1
Calibration by Material Substitution Method......................................................................... 6-2
Calibration Using a Load Cell Simulator............................................................................... 6-2
7 Routine Care and Maintenance ........................................................................... 7-1

Overview............................................................................................................................ 7-1
8 Troubleshooting ................................................................................................. 8-1

Isolate the Problem ............................................................................................................ 8-1
Check Wiring...................................................................................................................... 8-1
Check Load Cells................................................................................................................ 8-2
Check Mechanical Components ........................................................................................... 8-2
9 Spare Parts List ................................................................................................. 9-1

Hardware US ...................................................................................................................... 9-1
50 - 300 lb ........................................................................................................................ 9-1
500 - 3,000 lb ................................................................................................................... 9-1
5,000 - 10,000 lb .............................................................................................................. 9-2
Hardware SI ....................................................................................................................... 9-3

25 - 100 kg ....................................................................................................................... 9-3
200 - 1,000 kg .................................................................................................................. 9-3
2,000 - 5,000 kg................................................................................................................ 9-4
10 Appendices...................................................................................................... 10-1
Appendix 1 ...................................................................................................................... 10-1
Appendix 2 ...................................................................................................................... 10-2
Certificate of Conformance .................................................................................................. 10-2
Appendix 3 .................................................................................................................... 10-11

Wiring Diagrams ............................................................................................................. 10-11
Appendix 4 .................................................................................................................... 10-12

Outline Dimensions.......................................................................................................... 10-12
Chapter 1: Introduction
Overview
Introduction
Overview
METTLER TOLEDO 0978 tension weigh modules for hopper and tank scales are
designed for installations requiring suspended mounting. The system safely tolerates
adverse loads commonly present in industrial weighing applications while providing
repeatable, accurate weighments.
The tension weigh module incorporates an NTEP or OIML Certified load cell, and
includes special mounting hardware to ensure that the load cell measures only the true
vertical load.
Individual weigh modules allow maximum application flexibility. Hoppers and tanks of
most sizes and shapes are easily suspended. Each tension weigh module has excellent
inherent side-load rejection characteristics to compensate for non-axial loading.
0978 Assembly
Includes
Clevis pins
Clevis
Jam nuts
Rod ends
Hair-pin cotters
Grounding strap
Load cell
Analog J-Box (standard)
0978 Tension Weigh Module Service Manual
Check Rods/Bumpers
The suspended hopper/tank system requires no check rods or bumpers to provide an
accurate weighing system. In some applications, however, rods or bumpers may be
required (see Figures 3-1 and 3-2) to prevent movement that could cause misalignment
of valves and gates, or slow settling times. Contact your local authorized METTLER
TOLEDO distributor for design assistance.
(8/00)
1-1
Chapter 2: Sizing Load Cells

Overview
Sizing Load Cells
Overview
Use the following method to determine the most appropriate 0978 tension weigh module
system for your application:
NOTE: A vessel situated outdoors
may be exposed to external forces
such as wind, updraft, etc. Consider
these forces when selecting a load
cell.
Load cell capacity must be larger

than the highest distributed load.
1.
Calculate the tank/hopper tare weight (weight of empty apparatus), plus attached
plumbing, agitators, vibrators, external forces, etc.
2.
Estimate the maximum weight of the tank/hopper contents (net product weight).
3.
Use the sum of the empty weight and the net weight to arrive at the gross
tank/hopper weight.
4.
Multiply the gross tank/hopper weight by 1.25, then divide that number by the total
number of cells to determine the minimum recommended load cell capacity. (The
1.25 factor is an allowance for low-tare estimates and unequal load distribution.)
Minimum Load Cell Capacity = 1.25 gross capacity/number of cells.
(8/00)
2-1
Chapter 3: Installation Guidelines

Instructions
Installation Guidelines
Instructions
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.
NOTE: Provide a means for hanging
test weights from the vessel before
beginning installation.
WARNING
USE SAFETY CHAINS OR RODS TO PREVENT VESSEL FROM FALLING IN CASE OF
COMPONENT FAILURE.
1.
Place the load cells around the vessel so that each support point carries an equal
portion of the load.
2.
If the weighing system is subject to horizontal movement, provide suitable check

rods to limit horizontal movement to less than 1/8 inch (see Figures 3-1 and 3-2).
3.
Prevent nuts on support bolts or at both ends of the support rods from turning by
pinning, staking, or other means.
4.
The use of top and bottom backing plates allows for fit-up during installation. Tack
weld the backing plates in place after verifying that all cell assemblies hang
vertically (see Figure 3-3).
5.
To maintain the systems weighing accuracy, deflection of all scale support steel
must not exceed 1/16 inch under full working load.
6.
Use flexible lines on all dead-to-live connections. Rigid line connections should be
long enough to deflect without contributing weighing error.
7.
Properly vent the tank or hopper system to prevent pressure imbalances.
8.
If test weights are to be used, distribute them evenly, making sure they are
supported by or from the vessel, platform, or hopper to simulate the actual load
distribution.
(8/00)
3-1
METTLER TOLEDO 0978 Tension Weigh Module Installation and Service Manual
CAUTION
OVERLOADING LOAD CELLS AT ANY TIME AND FAILING TO INSTALL LOAD CELLS
AND ASSOCIATED PARTS IN STRICT CONFORMITY WITH THIS DOCUMENT MAY
RESULT IN LOAD CELL MALFUNCTION, WEIGHING INACCURACY, AND MAY
PERMANENTLY DAMAGE THE LOAD CELL.
3-2
(8/00)
Chapter 3: Installation Guidelines

Instructions
Check Rod
Vertical Column
Three-Module System
Check Rod
Vertical
Column
Four-Module System
Figure 3-1: Plan View
(8/00)
3-3
A
Side of Vessel
Gap
Section A-A, Gusset Removed
Figure 3-2: Overhead View
To Load Cell
Safety Rod
1/8
Backing Plate
Backing Plate
Double
Nuts
Washer
Figure 3-3: Mounting Detail
3-4
(8/00)
Chapter 4: Installation Instructions

Instructions
Installation Instructions
Instructions
1. Confirm that the tension weigh module system is complete. Refer to Figure 4-1 and
the spare parts list in Chapter 9.
Clevis
Clevis Pin
Hair-Pin Cotter
Grounding Strap
Jam Nut
Load Cell
Spherical Rod
End Bearing
Jam Nut
Figure 4-1: Single Weigh Module Assembly
(8/00)
4-1
2. Connect each weigh module clevis to an appropriately sized threaded rod to
suspend the vessel. See Table 4-1 for clevis thread sizes.
0978 Weigh Module Capacity
Clevis Thread Size
50 - 300 lb
3/8-16 UNC
500 - 3,000 lb
3/4-10 UNC
5,000 - 10,000 lb
1-8 UNC
25 - 100 kg
M8 x 1.25
200 - 1,000 kg
M12 x 1.75
2,000 - 5,000 kg
M24 x 2
Table 4-1: Clevis Thread Sizes
WARNING
USE SAFETY CHAINS OR RODS TO PREVENT VESSEL FROM FALLING IN
CASE OF COMPONENT FAILURE.
3. Make sure an appropriately sized jam nut is placed against the clevis to prevent the
threaded rod from turning.
4. Double-nut the safety rods on the top of the upper mount and the bottom of the
lower mount against a backing plate (see Figures 4-2 and 4-3).
4-2
(8/00)

Instructions
Washer
Double
Nuts
Backing Plate
Backing Plate
Safety Rod
Structural
Support
To Load Cell
To Load Cell
Safety Rod
Tank or
Hopper
Mounting
Bracket
1/8
Backing
Plate
Double
Nuts
Washer
Backing
Plate
(8/00)
4-3
5. Tack weld the backing plates into position after making sure that all weigh module
supports are hanging vertically (plumb).
6. The completed installation should resemble Figure 4-4. Make sure all support rods
are plumb. Ensure that all jam nuts are secure and that upper and lower rods are
double-nutted against supports.
NOTE: Check each weigh module to make sure that the grounding strap is not
touching the load cell.
7. Refer to Figures 4-5 through 4-7 for various installation configurations.
Typical Support Structure
Stiffener Plate
Double Nuts
Backing Plate
Stiffener Plates
Locking Jam Nut

(Table 4-1)
Tank or Hopper
Figure 4-4: Complete Installation
4-4
(8/00)

Instructions
Safety Wire Rope
Figure 4-5: Tank Supported with One Load Cell
Safety Chain
Figure 4-6: Tank Supported with Two Load Cells
(8/00)
4-5
Safety Rod
120
90
120
120
Three Support Plan View
90
(8/00)
90
Four Support Plan View
Figure 4-7: Tanks Supported with Three or Four Load Cells
4-6
90
Chapter 5: Wiring Weigh Modules to Junction Box

Analog Junction Box
Wiring Weigh Modules to Junction Box
Analog Junction Box

Turn all potentiometers fully
clockwise prior to calibration.
Use the wiring code tables provided to connect the load cells and instrument to the
analog junction box terminals.
Instrument
Function
Color
+Excitation
White
+Sense
Yellow
+Signal
Green
Shield
Orange
-Signal
Black
-Sense
Red
-Excitation
Blue
Load Cells
Function
Color
+Excitation
Green
-Excitation
Black
+Signal
White
-Signal
Red
Shield
Yellow
Table 5-1: Junction Box Wiring
(8/00)
5-1
To input terminal of second J-Box PCB for 5 8 cell

systems.
Individual load cell trimming

potentiometers. If trimming is
necessary, trim the high output
cells down to the lowest.
Load
Cell 1
Load
Cell 3
Aux
+EXE
+SIG
SHLD
-SIG
- EXE
Analog
PCB
LC1
LC2
LC3
LC4
+EXE
+SIG
SHLD
-SIG
-EXE
INPUT
-SEN
-EXE
+SEN
SHLD
+EXE
-SIG
+SIG
TO INDICATOR
Analog Junction Box
Figure 5-1: Junction Box Wiring
5-2
(8/00)
+EXE
+SIG
SHLD
-SIG
-EXE
Load
Cell 2
+EXE
+SIG
SHLD
-SIG
-EXE
Load
Cell 4

DigiTOL Junction Box (DLC Mode)
DigiTOL Junction Box

(DLC Mode)
WARNING
DO NOT USE THE DigiTOL JUNCTION BOX IN
LOCATIONS CLASSIFIED HAZARDOUS BY THE
NATIONAL ELECTRICAL CODE (NEC) ARTICLE 500.
The Model 0978 instrument uses a DigiTOL junction box to convert each load cell output
into a digital signal. Only DigiTOL indicators work with the DigiTOL junction box.
In the DLC mode, the indicator acts as the host for the DigiTOL junction box, allowing
you to adjust scale parameters via the indicator keypad. See Tables 5-2 and 5-3 for
cable connections and Figure 5-2 for PCB details.
Terminal Number
Position
Function
Wire Color
TB2
10
+20 VDC
Green
TB2
12
Ground
Blue
TB1
Shield
Orange
TB1
RXD A
Red
TB1
RXD B
White
TB1
TXD B
Yellow
TB1
TXD A
Black
Table 5-2: DigiTOL Junction Box Wiring DLC Mode
Function
Color
+Excitation
Green
+Signal
White
Shield
Yellow
-Excitation
Black
-Signal
Red
Table 5-3: Load Cell Color Codes (Code shown is for tension load)
(8/00)
5-3
See indicator
connection notes
Note 1: Jumper signal on any unused

load cell terminals.
1
1
Note 2: Jumpers W1 through W4 are set

to match the load cell output type (Factory
set "ON"):
TB2
TB1
ON - 2mV/V load cells

OFF - 3mV/V load cells
W4
Note 1
LC 4
W3
+EXC
+EXC
+SIG
+SIG
CGND
-EXC
-EXC
W1
W2
+EXC
+EXC
+SIG
+SIG
CGND
CGND
-SIG
-SIG
-EXC
-EXC
Figure 5-2: PCB Detail
5-4
(8/00)
LC 3
CGND
-SIG
-SIG
LC 2
Note 2
LC 1

IDNet Junction Box
IDNet Junction Box
LC1&2 Ground
Standoff
W4
W8
W7
Indicator Plug
W9
LC3&4 Ground
Standoff
W6
ST 2
ST 3
W1
-SIG +SIG
LC 2
P7 P8
7
3
9
P1 P2
W3
#1
#2
#3
#4
8
7
6
5
4
3
2
1
4
-SEN +SEN
LC 1
Cell
P5
P3
LC 3
-EXC +EXC
LC 4
W2
+ Excitation
Green
4
3
2
1
Terminal
- Excitation
+Signal
Black
White
4
9
3
8
2
7
1
6
-Signal
Red
9
8
7
6
SA 1
W5
Figure 5-3: Default Factory Setting
Jumper
Status
Description
W1
Closed
Matching the gain at 2 mV/V load cells
W2
Closed
No external sensing (-SEN)
W3
Closed
No external sensing (+SEN)
W4
Closed
Internal reference voltage = 3.5 V
W5
Open
Excitation voltage for load cells = 4.0 V
W6
Closed
Internal supply voltage = 7.1 V
W7
23
Protocol IDNet
W8
12
Interface 20 mA
W9
Open
Supply voltage IDNet
SA1
Closed
Trim Potentiometers Circuit Disabled
Table 5-4: IDNet Junction Box Wiring and Default Factory Setting
(8/00)
5-5
Chapter 6: Calibration
Overview
Calibration
Overview
NOTE: Refer to the proper users guide
for calibration procedures for your
digital indicator.
If the hopper or tank is located high
above the floor, it may be feasible to
suspend test weights from below. If
the tank or hopper is situated close to
the floor and you must place the test
weights on the structure, you may
need to provide brackets or shelves
for safety.
WARNING
After installing the weigh modules and the instrument, you must calibrate the system. If
the scale is used for legal trade (buying and selling) purposes, calibrate it with certified
test weights traceable to a recognized standard.
Plan provisions for calibration in advance: Always contact the local Weights and
Measures authorities prior to any scale installation to verify exact requirements for
calibration and certification.
To achieve maximum accuracy and Weights and Measures authorities approval,
perform the final check using approved test weights. In certain instances, a combination
of test weights and material in the tank or hopper can be built up to the necessary
weight.
Calibration with Test

Weights
1.
Remove all weight from the vessel.
2.
Zero the indicator (follow manufacturers instructions).
3.
Evenly distribute the test weights on the vessel. For best results, test weights should
equal or approach scale capacity.
4.
Adjust the indicator until it reads the weight applied to the vessel.
5.
Remove the test weights and check the return to zero. Adjust if necessary.
6.
Re-apply the weights to verify the calibration.
(8/00)
6-1
Calibration by Material
Substitution Method
1.
Remove all weight from the vessel.
2.
Zero the digital weight indicator.
3.
Place test weights on the vessel equal to a minimum of 5 percent of scale capacity.
4.
Adjust the indicator until it reads the weight applied to the vessel.
5.
Remove the test weights and replace with material until the indicator displays the
value of the certified test weights.
6.
Place the test weights on the vessel with the material.
7.
Record the indicators reading of the material and test weights.
8.
Remove test weights and replace with additional material until the indicator reads
the total recorded weight.
9.
Repeat this process until the applied weight (certified test weights and added
material) is 80-100 percent of total capacity.
1.
Disconnect the cable from the junction box at the indicator.
2.
Connect a load cell simulator.
3.
Adjust the simulator to zero output.
4.
Zero the indicator.
5.
Adjust the simulator to full-scale output.
6.
Adjust the indicator to read the summed capacity of all load cells in the system.
7.
Cycle the simulators output in steps to check linearity and return to zero.
8.
Remove the simulator and reconnect the load cells.
9.
Re-calibrate zero to take into account the actual dead weight of the vessel.
Calibration Using a
Load Cell Simulator
NOTE: It is best to verify system
calibration using test weights or a
combination of test weights and
material substitution.
6-2
(8/00)
Chapter 7: Routine Care and Maintenance

Overview
Routine Care and Maintenance
Overview
Once you install the scale, you should periodically inspect and calibrate the assembly.
If the scale is used for legal-for-trade purposes, consult the local Weights and Measures
authority for minimum inspection requirements. Contact your authorized METTLER
TOLEDO representative for information on periodic inspection and calibration services.
(8/00)
7-1
Chapter 8: Troubleshooting
Isolate the Problem
Troubleshooting
Isolate the Problem
WARNING
To determine whether the problem is in the scale assembly or the indicator:

1.
Remove power from the system.
2.
Disconnect the 0978 scale assembly and connect an analog load cell simulator to
the indicator (analog simulator available from METTLER TOLEDO).
3.
Reapply power and test.
4.
If the problem persists, consult the indicator manual for further troubleshooting
assistance.
If the problem is NOT present with the load cell simulator attached to the indicator:
1.
Remove power.
2.
Disconnect the simulator, and reconnect the 0978 scale assembly.
3.
If the problem re-occurs, further scale assembly troubleshooting is required.
1.
Remove power from the system.
2.
Remove the cover from the junction box and check the interior for moisture,
corrosion, or any foreign material.
3.
Ensure that all wiring connections are tight and that no insulation material is
touching the terminal contacts. Check all cable connections for correct wiring. The
wiring color codes for Analog and DLC modes are provided in Chapter 5.
4.
Check all cable connectors on the junction box. Tighten any loose connectors.
Check Wiring
(8/00)
8-1
Check Load Cells

1. Remove power from the system. Fully disconnect each load cell and check for
proper input/output resistances (see Table 8-1).
Measuring Points
Resistance
Any lead to shield or ground
Infinity
+Exc (Green) to -Exc (Black)
350 Ohm minimum
+Signal (White) to -Signal (Red)
347 to 353 Ohms
Table 8-1: Load Cell Resistance

2. If resistance is within specification, perform a shorted-signal symmetry test.
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.
With the power on, measure the output from the suspect load cell. The no-load
zero output should be 1.0% 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 0.3 mV.
6. If a load cell fails any of the above tests, replace it.
Check Mechanical
Components
Due to the simplicity of the 0978 weigh modules, there are few mechanical components
to troubleshoot:
8-2
(8/00)
Make sure the safety rods are plumb (hanging vertically).
Tighten all jam nuts.
Check for wear or damage at rod end bearings, clevis pins, or clevis brackets.
Check for any environmental influences such as wind, temperature, or vibrations.
Check for mechanical binds in the piping connections, etc.
Chapter 9: Spare Parts List

Hardware US
Spare Parts List
Hardware US
50 - 300 lb
2
Item
Qty.
Part Number
Description
TN800744
Clevis Pin
3/8 x 1.25
TN600892
Clevis
TN600903
Grounding Strap
MZ0901020036
Nut 3/8-24
MZ0901040014
Rod End
3/8-24 RH
MZ0904000006
Hair-Pin Cotter
MZ0901010155
Screw 10-32
Item
Qty.
Part Number
Description
TN800745
Clevis Pin
1/2 x 1.75
TN600893
Clevis
TN600903
Grounding Strap
MZ0901020039
Nut 1/2-20
MZ0901040013
Rod End
1/2-20 RH
MZ0904000006
Hair-Pin Cotter
MZ0901010155
Screw 10-32
1
6
4
3
S-Cell
7
5
500 - 3,000 lb
(8/00)
9-1
5,000 - 10,000 lb
Item
Qty.
Part Number
Description
TN800746
Clevis Pin
3/4 x 2.50
TN600894
Clevis
TN600903
Grounding Strap
MZ0901020038
Nut 3/4-16
MZ0901040013
Rod End
3/4-16 RH
MZ0904000077
Hair-Pin Cotter
MZ0901010155
Screw 10-32
Load Cells
Capacity (lb)
Class III 3kd
50 lb
TA600238
100 lb
TA600240
200 lb
TA600242
300 lb
TA600244
500 lb
TA600246
1,000 lb
TA600250
2,000 lb
TA600252
3,000 lb
TA600254
5,000 lb
TA600256
10,000 lb
TA600258
Table 9-1: Spare Parts List (U.S. Units)
9-2
(8/00)
Chapter 9: Spare Parts List

Hardware SI
Hardware SI
25 - 100 kg
2
1
6
Item
Qty.
Part Number
Description
TN600556
Clevis Pin 8 mm
TN600553
Clevis 8 mm M8 x 1.25
TN600903
Grounding Strap
MZ0901020094
Nut, Hex Jam

M8 x 1.25 NI
MZ0901040017
Rod-End 8 mm
M8 x 1.25 M RH
MZ0904000006
Hair-Pin Cotter #3
MZ0901010489
Screw M4 x 0.7
Item
Qty.
Part Number
Description
TN600557
Clevis Pin 12 mm
TN600554
Clevis 12 mm M12 x
1.75
TN600903
Grounding Strap
MZ0901020095
Nut, Hex Jam

M12 x 1.75 NI
MZ0901040018
Rod-End 12 mm
M12 x 1.75 M RH
MZ0904000072
Hair-Pin Cotter #16
MZ0901010489
Screw M4 x 0.7
4
3
S-Cell
7
5
200 - 1,000 kg
(8/00)
9-3
2,000 - 5,000 kg
Item
Qty
Part Number
Description
TN600558
Clevis Pin 25 mm
TN600555
Clevis 25 mm M24 x 2
TN600903
Grounding Strap
MZ0901020096
Nut, Hex Jam

M24 x 2 NI
MZ0901040019
Rod-End 25 mm
M24 x 2 M RH
MZ0904000073
Hair-Pin Cotter #6
MZ0901010489
Screw M4 x 0.7
Load Cells
Capacity (kg)
Class III 3kd
25 kg
TA600536
50 kg
TA600537
100 kg
TA600538
200 kg
TA600539
500 kg
TA600540
1,000 kg
TA600541
2,000 kg
TA600542
5,000 kg
TA600543
Table 9-2: Spare Parts (SI Units)
9-4
(8/00)
Chapter 10: Appendices

Appendix 1
10
Appendices
Appendix 1
(8/00) 10-1
Appendix 2
Certificate of Conformance
10-2 (8/00)

Appendix 2
(8/00) 10-3
10-4 (8/00)

Appendix 2
(8/00) 10-5
10-6 (8/00)

Appendix 2
(8/00) 10-7
10-8 (8/00)

Appendix 2
(8/00) 10-9
10-10 (8/00)

Appendix 3
Appendix 3
Wiring Diagrams
Reference Drawings
TB100505 Analog Systems
TB100575 DigiTOL Systems
TB100600 IDNet
NOTE: Contact MTMS document supervisor for latest drawing revision.
(8/00) 10-11
Appendix 4
Outline Dimensions
Load Cell Capacity
50 lb - 300 lb
7 5/8"
2"
1 3/8"
3/8-16 UNC
500 lb - 3,000 lb
10 9/16"
2 1/4"
1 7/8"
3/4-10 UNC
5,000 lb
12 5/8"
2 3/4"
2 3/4"
1-8 UNC
10,000 lb
12 5/8"
3"
2 3/4"
1-8 UNC
25 kg - 100 kg
180 mm
50.8 mm
32 mm
M8 x 1.25
200 kg - 1,000 kg
250 mm
57.2 mm
49 mm
M12 x 1.75
2,000 kg
450 mm
69.9 mm
83 mm
M24 x 2
5,000 kg
450 mm
76.2 mm
83 mm
M24 x 2
A (Nominal)
Load
Cell
Figure 10-1
10-12 (8/00)
METTLER TOLEDO
Publication Suggestion Report

If you have suggestions concerning this publication, please complete this form and fax it to (614) 841-7295
Publication Name: METTLER TOLEDO 0978 Tension Weigh Module Service Manual
Publication Part Number: B15141500A
PROBLEM(S) TYPE:
Publication Date: 8/00

DESCRIBE PROBLEM(S):
Technical Accuracy
Text
Completeness
What information is
missing?
Procedure/step
Example
Explanation
INTERNAL USE ONLY
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: (
Fax this completed form to METTLER TOLEDO at (614) 841-7295

Mettler-Toledo, Inc.
Printed in USA
14981600A
METTLER TOLEDO
1900 Polaris Parkway
Columbus, Ohio 43240 USA
P/N: B15141500A
METTLER TOLEDO is a trademark of Mettler-Toledo, Inc.
1997, 1999, 2000 Mettler-Toledo, Inc.
Printed in U.S.A.
B15141500A

Tension Weigh: Installation and Service Manual

Transféré par

Informations du document

Description originale:

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Tension Weigh: Installation and Service Manual

Transféré par

Droits d'auteur :

Formats disponibles

0978

Mettler-Toledo, Inc. 1997, 1999, 2000

Publication Revision History

Added grounding strap to drawings and parts lists.

Type/ Tipo: Analog Load Cells/ Celdas de Carga Analgicas

OIML International Recommendation , Metrological regulation for load cells

Darrell Flocken, Manager - Weights & Measures

Office of Weights and Measures

METTLER TOLEDO RESERVES THE RIGHT TO MAKE REFINEMENTS OR

FOLLOW these instructions

SAVE this manual for future

DO NOT allow untrained

PERMIT ONLY QUALIFIED PERSONNEL TO SERVICE

BEFORE CONNECTING/DISCONNECTING ANY INTERNAL ELECTRONIC

OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC

2 Sizing Load Cells............................................................................................... 2-1

3 Installation Guidelines ....................................................................................... 3-1

4 Installation Instructions...................................................................................... 4-1

5 Wiring Weigh Modules to Junction Box ............................................................... 5-1

6 Calibration ........................................................................................................ 6-1

7 Routine Care and Maintenance ........................................................................... 7-1

8 Troubleshooting ................................................................................................. 8-1

9 Spare Parts List ................................................................................................. 9-1

Hardware SI ....................................................................................................................... 9-3

Appendix 3 .................................................................................................................... 10-11

Appendix 4 .................................................................................................................... 10-12

Analog J-Box (standard)

0978 Tension Weigh Module Service Manual

Chapter 2: Sizing Load Cells

Sizing Load Cells

Load cell capacity must be larger

Chapter 3: Installation Guidelines

If the weighing system is subject to horizontal movement, provide suitable check

Properly vent the tank or hopper system to prevent pressure imbalances.

Chapter 3: Installation Guidelines

Section A-A, Gusset Removed

Figure 3-2: Overhead View

Figure 3-3: Mounting Detail

Chapter 4: Installation Instructions

Figure 4-1: Single Weigh Module Assembly

Clevis Thread Size

Table 4-1: Clevis Thread Sizes

Chapter 4: Installation Instructions

Figure 4-2: Mounting Detail

Figure 4-3: Mounting Detail

Typical Support Structure

Locking Jam Nut

Figure 4-4: Complete Installation

Chapter 4: Installation Instructions

Safety Wire Rope

Figure 4-5: Tank Supported with One Load Cell

Figure 4-6: Tank Supported with Two Load Cells

Three Support Plan View

Four Support Plan View

Figure 4-7: Tanks Supported with Three or Four Load Cells

Chapter 5: Wiring Weigh Modules to Junction Box

Wiring Weigh Modules to Junction Box

Analog Junction Box

To input terminal of second J-Box PCB for 5 8 cell

Individual load cell trimming

Analog Junction Box

Figure 5-1: Junction Box Wiring