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2012 METTLER TOLEDO Precision Junction Boxes – Installation and Service Manual
MT – Precision Junction Boxes 2 Ver. 01/13
Contents
1 Precautions ................................................................
................................................................................................
................................................................ 6
2 Specifications ................................................................
............................................................................................
............................................................ 7
2.1 Precision Junction Boxes................................................................
............................................................................................
............................................................ 7
2.2 Junction Box PCBA Functions ................................................................
.....................................................................................
..................................................... 7
2.3 Suitable Load Cells ................................................................
................................................................................................
....................................................................
.................................... 8
2.4 Suitable Terminals................................................................
................................................................................................
.....................................................................
..................................... 8
2.5 Junction Box Item Numbers ................................................................
........................................................................................
........................................................ 8
2.6 Power Supply Requirements................................
Requirements................................................................
........................................................................................
........................................................ 8
2.7 Accuracy ................................................................
................................................................................................
.................................................................................
................................................. 8
3 Installation ................................................................
................................................................................................
.................................................................
................................. 9
3.1 Inspection ................................................................
................................................................................................
................................................................................
................................................ 9
3.2 Installation ................................................................
................................................................................................
...............................................................................
............................................... 9
3.3 Home Run Cable Connection ................................................................
......................................................................................
...................................................... 9
3.4 Load Cell Connection................................................................
...............................................................................................
............................................................... 10
3.4.1 Connection of 6-wire load cell to 4-wire terminal junction boxes ....................................... 10
3.5 Connection of Multiple Jboxes via AUX ................................................................
.......................................................................
....................................... 11
11 Troubleshooting ................................................................
......................................................................................
...................................................... 45
11.1 General ................................................................
................................................................................................
.................................................................................
................................................. 45
11.2 Isolate the Problem ................................................................
................................................................................................
.................................................................
................................. 45
11.3 Check Wiring ................................................................
................................................................................................
.........................................................................
......................................... 46
11.4 Check Load Cells ................................................................
................................................................................................
....................................................................
.................................... 46
11.5 Load Cell Replacement Procedure ................................................................
..............................................................................
.............................................. 47
11.6 PCBA Replacement Procedure ................................................................
...................................................................................
................................................... 48
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2012 METTLER TOLEDO Precision Junction Boxes – Installation and Service Manual
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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 may be obtained by contacting your
local METTLER TOLEDO organization or writing, calling, or faxing:
METTLER TOLEDO
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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 materials for a period of one year from date of installation or
eighteen (18) 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 warranty
term, the Company will furnish necessary replacement parts and on-site technician’s service
free of charge, provided the Buyer agrees to pay reasonable technician’s travel time, vehicle
mileage, and associated travel 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 Analog Junction Box. 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 only applicable to the United States of America. Consult METTLER
TOLEDO for Export Warranty Terms and Conditions.
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.
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2012 METTLER TOLEDO Precision Junction Boxes – Installation and Service Manual
MT – Precision Junction Boxes 6 Ver. 01/13
1 Precautions
WARNING
PERMIT ONLY QUALIFIED PERSONNEL TO
SERVICE THIS EQUIPMENT. EXERCISE CARE WHEN
READ this manual BEFORE MAKING CHECKS, TESTS, AND ADJUSTMENTS
operating or servicing this THAT MUST BE MADE WITH POWER ON. FAILING
equipment. TO OBSERVE THESE PRECAUTIONS CAN RESULT
IN BODILY HARM.
CAUTION
BEFORE CONNECTING/DISCONNECTING ANY INTERNAL ELECTRONIC
ALWAYS DISCONNECT this
COMPONENTS OR INTERCONNECTING WIRING BETWEEN ELECTRONIC
equipment from the power source
EQUIPMENT, ALWAYS REMOVE POWER AND WAIT AT LEAST 30 SECONDS.
before cleaning or performing FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY
maintenance. 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.
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2 Specifications
2.1 Precision Junction Boxes
Precision junction boxes are used to connect multiple analog load cells (typical 2mV/V or 3mV/V output).
Furthermore, the junction boxes provide a convenient method to shift adjust each load cells for adjusting
corner error. Although METTLER TOLEDO takes all necessary care to electronically balance load cells in
production, the system may need to be further adjusted to obtain the desired system accuracy by means of
shift adjustment.
Furthermore MT junction boxes support “weightless” calibration CalFree™ in the event other calibration
methods are inconvenient or impossible.
Element Function
Load Cell Connection
LC1 – LCn
4/6 wire + shield
Termination
SW1 – SWn
x1 Fine shift adjustment ca. 1/19.000 per step
To set box to ≥2000 Ohm load cell system cut open all through hole
Cut for 2000R resistors 2000R. Note: W1-Wn must be cut as well. Only available
for AJB541M, AJB540L
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2.7 Accuracy
Scale accuracy depends on:
• Correct height adjustment of the load cells. By that dead load is distributed in a proper manner and
changes in dead load distribution due to loading are avoided. Height adjustment is done by mechanical
means such a thin sheet metals or feet height adjustment. Height adjustment is recommended if four or
more load cells are used.
• Precise shift adjustment. A proper shift adjusted scale keeps tolerances in the event of eccentric
loading. Shift adjustment is done electronically with the load cell switches SW1-SWn in the junction
boxes. Shift adjustment is always recommended when load distribution changes while operation e.g.
for floor scales, vehicle scales etc. Shift adjustment is recommended if multiple junction boxes are
connected via AUX.
• Proper sealing of junction box to avoid ingress of humidity in the junction box
• Proper system earthing to avoid equalization currents through measurement cable.
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3 Installation
3.1 Inspection
When you receive the junction box, visually inspect the packing containers and modules for freight damage.
If you find damage such as loose components, on the circuit board, damaged enclosure or broken cable
glands; contact your freight carrier immediately, and inform METTLER TOLEDO. Generally speaking, oad
cell cables should not be repaired as it is integral to the cell’s temperature performance. If you discover a
broken cable replace the cell.
3.2 Installation
Note: Do not reduce the length of the load cell cables, excess cable should be coiled and placed so
that it does not interfere with the scale’s operation or pose a safety risk.
1. Mount the junction box in a location where the load cell cables can be properly terminated in the
junction box. Preferable mount the junction box on the dead side – wall, cabinet etc. – to avoid dead to
life crossing of the load cell cables.
2. Do not mount the junction box on hot surfaces. Mount in dry areas when possible and avoid
placing the box in direct sunlight to reduce rapid temperature influence.
3. After ensuring that the cables are free from dirt and oil, thread the cable through the junction boxes
cable glands (grommet) insuring that the gland’s inside bushing securely engages the cable; this will
ensure that water does not penetrate the connection (see figure 3 below).
4. Terminate wires according to the color code marked on each load cell and it’s corresponding position
in the junction box. Ensure that no stray wire threads cross the terminal clean remaining wire threads
from inside the box.
5. Connect the home-run cable from the scale terminal to the junction box.
6. Confirm that all live-to-dead connections (pipes, conduit, etc.) are flexible and securely anchored at
both the scale and the dead connection point.
Rubber Grommet
Nut
1. Thread the home run cable through the junction box cable gland insuring that the diameter of the
grommet securely engages the cable.
2. Connect the home run cable from the scale terminal to the junction box
3. Wire the home run cable to the PCB according
4. Remove any loose wire threads from the junction box
5. Place the desiccant bag inside the junction box.
6. Reinstall the junction box lid. Ensure that the rubber gasket is clean and correctly positioned so that it
contacts the enclosure edges to prevent water ingress.
7. Hand-tighten all screws and cord grip caps
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Connect load cell cables as follows. For screw terminal double connection use common
sleeve
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INPUT
AUX
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Test weight 350 Ohm <8 m (33 ft.) <4 m (16 ft.) <2 m (8 ft.)
calibration
Keep temperature
effects under 3.000e.
shift adjustment
recommended. 1000 Ohm <16 m (100 ft.) <8 m (50 ft.) <4 m (26 ft.)
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4.1 General
When scales with 4 or more load cells are first installed, inevitably they will “rock”, so the load cell
assemblies must be adjusted in height until all carry a portion of the dead load. Otherwise scales may be
non-repeatable, it may be impossible to get a proper calibration and, in the worst case, load cell(s) may be
damaged
For larger systems the dead load on each load cell need to be measured to height adjust the load cells.
That can be done with a volt meter measuring the voltage signal of each load cell separately. The signal
strength is low though, which might cause practical problems. Eg. 10V terminal excitation, 10% load on
load cell, typical signal is 0.002 V.
As an alternative the terminal can be used for that measurement. The terminal can easily cope with such
low signals and display in practical resolution. Once a cell is isolated, the terminal can show a variety of
positive and negative values not easily related to the scale settings, unless you are prepared to perform
calculations. Relation between terminal display and actual load on the separated load cell is given by the
following equations (provided the scale has been calibrated before):
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The below diagram shows this equation in relation to fractions of dead load. That allows to quickly
determining how much of the total dead load is on the checked load cell. For clarity reasons any % number
mentioned below related to the terminal display, any number related to the actual load on the load cell is
given in fractions of 1. Eg 20% means the display shows 20% of the total dead load (here also negative
values are possible), 0.2 means 0.2 of total dead load is on the measure load cell.
10 LC 8 LC
6 LC
4 LC
4 LC: Terminal display 0 kg = 0% of DL – actual load on cell is 0.25 of dead load thus 5.000 kg
6 LC: Terminal display -7.000 kg = -35% of DL – actual load on cell is 0.1 of dead load thus 2.000 kg
8 LC: Terminal display 12.000 kg = 60% of DL – actual load on cell is 0.2 of dead load thus 4.000 kg
8 LC: 0.20 dead load on load cell – terminal display 60% of 20t = 12t
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Note: Single load cell signals are typically less stable than fully connected systems.
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Separation can be done by disconnecting one signal wire for each load cell in the junction box (except the
target cell). To determine the actual load on the cell add the scale dead load to the terminal display and
divide by the number of load cells in the system.
Note: Single load cell signals are typically less stable than fully connected systems.
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6 Shift Adjustment
6.1 General
Shift adjustments should be made only after checking all mechanical parts and after proving that the scale
activity is repeatable. To check repeatability, repeatedly place a test weight in the same position on the
scale to make sure that the scale gives the same weight reading each time. If the scale doesn’t give the
same reading every time check for mechanical binding, the scale should also be plumb level and square.
Once you have confirmed there is no binding re-perform the height adjustment mentioned above.
Only after the mentioned checking perform an shift adjustment to make the weight reading at or near each
load cell the same for the same test weight following the steps below.
Many technicians perform both the height adjustment and shift adjustments with the terminal expanded
mode. This is generally listed in each of the terminal’s service manuals either as “10x“ or as “expanded”. A
normal weighing terminal displays the smallest increment which is called e and this value is affected by the
zero indication. Pressing the 10x key allows this value to be expanded into d (1/10 e), or the lowest
observable displayed increment. In the service and maintenance section it is also possible to expand the
display to read the smallest available “d” calculated by the terminals Analog to Digital converter.
The amount of test weight used for the shift test should equal or greater 10 percent of the rated scale
capacity.
In total 256 steps per load cell are possible. Initially the switches shall be set to 80 allowing for both 128
positive and 128 negative adjustment steps for each load cell. In the initial setting resistor tolerance are
kept low for gaining from load cell matching.
Note: Switching one step past position FF to 00 goes back to the lowest load cell signal and you will
observe quite a large change, if you exceed 00 or FF in you adjustment you should review Range
Extension possibilities in chapter 6.9
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On-load While test weight is on In field No precise Precisely split test + No calculation
corner turn SW to knowledge about weight into 3 part
reference. PC not available the test weight is for 6 load cells, 4 + Any test weight >10% up
necessary. parts for 8 load to 4 load cells
Typically several test cells etc.
cycles needed. Shall be above + Not critical, always works
10% of nominal Alternative if no - Takes more time
No calculations scale load. split test weights
needed. are available see - Split test weight required
chapter 6.7.3 beyond 4 load cells
or Perform full test cycle. Frequently Any known test Any known test + Fast
repeated test weight above 10% weight above 10%
Off-load Calculate shift nominal scale nominal test weight + Any known test
adjustment Box not accessible weight weight >10%
while loading
Set SW respectively + No reference loading
Semi automation
possible - Calculations needed
- Parameter set required,
thus preparation needed
Note: The test weight requirements apply to shift adjustment only. Calibration needs known test weight in any
case.
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Based on the load cell resistance and box constellation load cell switches shall be set acc. to the following
table. Note: Not for CalFree calibration
Inital Setup of Systems with Two Precision Junction Boxes
Load Cell Connection Cable
Resistance Total number of load cells Wire Resistance Switch Set 1st Box Switch Set 2nd Box
0.1 Ohm 6E, 6E ,6E, 6E A4, A4 ,A4, A4
6
0.2 Ohm 5D, 5D ,5D, 5D CC, CC ,CC, CC
(4 first box, 2 second box)
0.3 Ohm not recommended not recommended
0.1 Ohm 68, 68 ,68, 68 98, 98 ,98, 98
6
0.2 Ohm 51, 51 ,51, 51 B3, B3 ,B3, B3
(3 first box, 3 second box)
350 Ohm 0.3 Ohm not recommended not recommended
(Boxes set to 0.1 Ohm 63, 63 ,63, 63 8E, 8E ,8E, 8E
350R) 6
0.2 Ohm 48, 48 ,48, 48 9E, 9E ,9E, 9E
(2 first box, 4 second box)
0.3 Ohm not recommended not recommended
0.1 Ohm 60, 60 ,60, 60 A1, A1 ,A1, A1
8 0.2 Ohm 43, 43 ,43, 43 C5, C5 ,C5, C5
(4 first box, 4 second box) 0.3 Ohm 27, 27 ,27, 27 EB, EB ,EB, EB
0.4 Ohm not recommended not recommended
0.1 Ohm 79, 79 ,79, 79 8D, 8D ,8D, 8D
0.2 Ohm 73, 73 ,73, 73 9A, 9A ,9A, 9A
0.3 Ohm 6D, 6D ,6D, 6D A9, A9 ,A9, A9
6
0.4 Ohm 67, 67 ,67, 67 B8, B8 ,B8, B8
(4 first box, 2 second box)
0.5 Ohm 61, 61 ,61, 61 C7, C7 ,C7, C7
0.6 Ohm 5B, 5B ,5B, 5B D8, D8 ,D8, D8
0.7 Ohm not recommended not recommended
0.1 Ohm 77, 77 ,77, 77 88, 88 ,88, 88
0.2 Ohm 6F, 6F ,6F, 6F 91, 91 ,91, 91
0.3 Ohm 66, 66 ,66, 66 9B, 9B ,9B, 9B
6
0.4 Ohm 5E, 5E ,5E, 5E A5, A5 ,A5, A5
(3 first box, 3 second box)
0.5 Ohm 57, 57 ,57, 57 AF, AF ,AF, AF
1000 Ohm 0.6 Ohm 4F, 4F ,4F, 4F B9, B9 ,B9, B9
(Boxes set to 0.7 Ohm not recommended not recommended
1000R) 0.1 Ohm 75, 75 ,75, 75 85, 85 ,85, 85
0.2 Ohm 6B, 6B ,6B, 6B 8A, 8A ,8A, 8A
6 0.3 Ohm 62, 62 ,62, 62 90, 90 ,90, 90
(2 first box, 4 second box) 0.4 Ohm 58, 58 ,58, 58 95, 95 ,95, 95
0.5 Ohm 4F, 4F ,4F, 4F 9B, 9B ,9B, 9B
0.6 Ohm not recommended not recommended
0.1 Ohm 74, 74 ,74, 74 8B, 8B ,8B, 8B
0.2 Ohm 69, 69 ,69, 69 98, 98 ,98, 98
0.3 Ohm 5E, 5E ,5E, 5E A5, A5 ,A5, A5
8
0.4 Ohm 54, 54 ,54, 54 B2, B2 ,B2, B2
(4 first box, 4 second box)
0.5 Ohm 4A, 4A ,4A, 4A C0, C0 ,C0, C0
0.6 Ohm 41, 41 ,41, 41 CE, CE ,CE, CE
0.7 Ohm not recommended not recommended
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Corners are adjusted based on the actual weight display while test weight is on scale and thus needs
manual operation. It does not need any calculations and typically 2-4 test cycles and one verification cycle
are needed to achieve an acceptable result. For scales with more than 4 load cells equally split test
weights are needed. Refer to chapter 6.7.3 in case split test weights are not available. This is easiest and
most uncritical procedure - unfortunately more time consuming.
Shift Adjustment is not recommended for CalFree Calibration.
4000.0 12000.0
4012.3 12050.0
4000.2
12000.4
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12000.0
Pair-to-Pair test
12050.0
12000.3
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Reference loading – three corner tests Reference loading - three pair tests
12504
3998.0 12535
4002.5 12487
3999.0
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This procedure is fast but requires preparation. The key for fast results is keeping loading conditions
constant. Extreme differences in load cell sensitivity might force iteration.
Perform an Initial Shift Adjustment (see chapter 6.6) when multiple junction boxes are used.
Shift Adjustment is not recommended for CalFree Calibration.
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For that build load cell pairs LC1 + LC2, LC3 + LC4, etc.
Pair test
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The shift adjustment result is depending on the actual load spread while testing. The calculation formulas
assume full load on one load cell while testing, which is not the case in practice due to scale geometry and
mechanical link between corners. Typically the shift result is too small and requires iterative steps to
achieve an acceptable result. In order to speed up the procedure it is recommended to apply the suitable
Geometry Factor to the required shift results. Values in the below table are typical only.
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An Out of Range event typically only occurs with multiple box systems where the connection cable
resistance is significant. For single box systems that event is an indication for mechanical incorrect
installation.
a) In case of 350 Ohm load cells, set box to 1.000R by cutting open all wires W1-Wn. By that the
adjustment range is approx. 2.6 times wider and adjustment steps are coarser. Set all SW back to
80 and restart adjustment procedure from the beginning.
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JBox SetUp:
350R, 1000R, 2000R - See
chapter 6.5
Pair Adjustment:
Tick when pair/section
adjustment planed
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This calculation is only relevant for multiple junction box systems. First look for the system constellation in
chapter 6.6.1. If not listed there use InSite software.
Sensitivity Value:
Typical 2 or 3 mV/V
Belongs to Box:
1 or 2
Output R:
Typical 350 or 1000 Ohm for
matched load cells.
Start Switch:
Initial setup of boxes – always
80
Calculate:
Press for Initial Shift
Adjustment
New Start.
Set box switches to those
levels
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Geometry:
Select our scale
1 - n:
Enter corner test results.
For pair adjustment only enter
odd numbers 1,3,5 etc
Start Switch:
Start position of switches
while corner test was
performed
Calculate:
Press to calculate new switch
positions.
New Start:
Set box switches to those
levels
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3. Scale Calibration
Perform scale calibration, refer to terminal manual
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8.2 Tank Scale with 4 Load Cells and one Junction Box
1. Height Adjustment
1a. Manual Height
For small tanks perform a manual height adjustment while tank is empty.
Jbox
1b. Terminal Supported Height Adjustment
For larger tanks systems perform a terminal supported height adjustment:
Know the approximate dead weight of the scale
Roughly calibrate the scale either with test weight or with CalFree™
Set terminal such it can display negative weights e.g.
Scale > Zero > Under Zero Blanking = Disable
Unhook all load cells from the signal by opening all Sig+ wires
Record each load cell readings by connecting Sig+ separately
Ideally all signals are close to zero.
If readings are lower than -50% of dead weight shim the respective load cells or weigh modules
Repeat the height adjustment process till condition mentioned is fulfilled.
4. Scale Calibration
Perform scale calibration, refer to terminal manual
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8.3 Tank Scale with 5 –12 Load Cells and multiple Junction Boxes
2. Height Adjustment
For larger tanks systems perform a terminal supported height adjustment:
Know the approximate dead weight of the scale
Roughly calibrate the scale either with test weight or with CalFree™
Set terminal such it can display negative weights e.g.
Scale > Zero > Under Zero Blanking = Disable
Unhook all load cells from the signal by opening all Sig+ wires
Record each load cell readings by connecting Sig+ separately
Ideally all signals are close to zero.
If readings are lower than -50% of dead weight shim the respective load cells or weigh modules
Repeat the height adjustment process till condition mentioned is fulfilled.
5. Shift Adjustment
Zero Scale
Check the corner error by applying at least 10% test weight on each corner and record readings. If in
tolerance continue with scale calibration.
If shift error is out of tolerance preferably perform Off-Load Shift Adjustment.
5a. Off-Load Shift Adjustment
Start InSite software
Select Off-Load Shift Adjustment
Enter Geometry Factor 1,15
Enter switch set for each load cell and shift test results
Calculate new switch set and set box switches accordingly
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6. Scale Calibration
Perform scale calibration, refer to terminal manual
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1. Height Adjustment
Perform a manual height adjustment while scale is empty.
Jbox
2. Shift Adjustment
If load cells resistance is ≥ 1.000 Ohm cut all W1-Wn wires
Set all switches to 80
Zero scale
Load scale with test weight in the center thus all load cells are loaded the same, record reading
Check the corner error by applying test weight on each corner and record readings. If in tolerance continue
with scale calibration.
If shift error is out of tolerance preferably use On-Load shift adjustment.
2a. On-Load Shift Adjustment
Use center load reading as reference. Never use the lowest or highest reading for reference as the
procedure might not meet target in this case.
Load first corner and turn switches up or down till reading equals reference. Do the same for the other
corners.
Unload and zero scale
Check shift error by applying test weight again on each corner and record readings.
If not in tolerance load scale in center and use reading as reference for the next cycle. Repeat shift
adjustment till in tolerance
2b. Alternative Off-Load Sift Adjustment
Start InSite software
Select Off-Load Shift Adjustment
Enter Geometry Factor 1,3
Enter switch settings
Enter shift test results
Calculate new switch settings and set box switches accordingly
Unload and zero scale
Check shift error and repeat adjustment if necessary
3. Scale Calibration
Perform scale calibration, refer to terminal manual
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8.5 Vehicle Scale with 4 Load Cells and one Junction Box
1. Height Adjustment
Perform a terminal supported height adjustment:
Know the approximate dead weight of the bridge Jbox
Roughly calibrate the scale either with test weight or
with CalFree™
Set terminal such it can display negative weights e.g.
Scale > Zero > Under Zero Blanking = Disable
Unhook all load cells from the signal by opening all Sig+ wires
Record each load cell readings by connecting Sig+ separately
Ideally all signals are close to zero.
If readings are lower than -50% of dead weight shim the respective load cells or weigh modules
Repeat the height adjustment process till condition mentioned is fulfilled.
2. Shift Adjustment
If load cells resistance is ≥ 1.000 Ohm cut all W1-Wn wires
Set all switches to 80
Zero scale
Load scale with test weight in the center thus all load cells are loaded the same, record reading
Check the corner error by applying test weight on each corner and record readings. If in tolerance continue
with scale calibration.
If shift error is out of tolerance preferably use On-Load shift adjustment.
2a. On-Load Shift Adjustment
Use center load reading as reference. Never use the lowest or highest reading for reference as the
procedure might not meet target in this case.
Load first corner or pair and turn switches up or down till reading equals reference. In case of pair
adjustment treat both load cell switches the same. Do the same for the other corners / pair.
Unload and zero scale
Check shift error by applying test weight again on each corner / pair and record readings.
If not in tolerance load scale in center and use reading as reference for the next cycle. Repeat shift
adjustment till in tolerance
2b. Alternative Off-Load Shift Adjustment
Start InSite software
Select Off-Load Shift Adjustment
Enter Geometry Factor 1,3
Tick Pair Adjustment when desired
Enter switch settings for each cell
Enter test results for each load cell or pair
Calculate new switch settings and set box switches accordingly
Unload and zero scale
Check shift error and repeat adjustment if necessary
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3. Scale Calibration
Perform scale calibration, refer to terminal manual
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8.6 Vehicle Scales with 6 – 12 Load Cells and Multiple Junction Boxes
2. Height Adjustment
Perform a terminal supported height adjustment:
Know the approximate dead weight of the bridge
Roughly calibrate the scale either with test weight or with CalFree™
Set terminal such it can display negative weights e.g.
Scale > Zero > Under Zero Blanking = Disable Jbox
Unhook all load cells from the signal by opening all Sig+ wires
Record each load cell readings by connecting Sig+ separately
Ideally all signals are close to zero.
If readings are lower than -50% of dead weight shim the respective load cells or weigh modules
Repeat the height adjustment process till condition mentioned is fulfilled.
4. Shift Adjustment
Zero scale
Check the corner error by applying test weight on each corner or pair and record readings. If in tolerance
continue with scale calibration.
If shift error is out of tolerance preferably perform Off-Load Shift Adjustment.
4a. Off-Load Shift Adjustment
Start INSITE
Select Off-Load Shift Adjustment
Enter Geometry Factor 1,15
Tick Pair Adjustment when required
Enter switch settings for each load cell
Enter test results of each corner test or pair test
Calculate new switch settings and set box switches accordingly
Unload and zero scale
Check shift error and repeat adjustment if necessary
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5. Scale Calibration
Perform scale calibration, refer to terminal manual
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1. Shift Adjustment
If load cells resistance is ≥1.000 Ohm cut all W1-Wn wires Jbox
Set all switches to 80
Zero scale
Load test weight on the center and calibrate scale.
Check the corner error by applying test weight near each corner, but stay in the inner load cell distance.
Record readings.
If in tolerance continue with scale calibration.
If out of tolerance take center reading for reference. Never use one corner reading for reference as the
procedure might not meet target in this case.
Load first corner and turn respective switches up or down till terminal equals reference. Do the same for
the other corner. Again keep load in load cell distance.
Unload and zero scale
Check shift error by applying test weight again on each corner and record results.
If not in tolerance repeat center loading for reference and shift adjustment till in tolerance
2. Scale Calibration
Perform scale calibration, refer to terminal manual
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When calibrating with material transfer, weigh a material (usually water) on an existing scale and transfer it
to the tank scale being calibrated. Do this in a single transfer or in stages until you reach the tank’s
maximum capacity. This method provides only a rough calibration. It is only as accurate as the existing
scale and the transfer process. Even under the best circumstances, you cannot tell if allowable errors are
cumulative or compensating.
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b) When using two or more boxes connected via AUX (daisy chaining)
Keep the total length of all junction box connection cables below 2 m at 0.5mm^2 (AWG20) not to
exceed 0.1% sensitivity drop. This limitation is not valid for the home run cable from the first junction box
to the terminal.
Set box to 350R in-depended of load cell resistance. (In case box has been set to 1000R or 2000R
CalFree is still possible with slightly reduced accuracy)
Set all SW switches to 80 (coarse 8, fine 0). Thus no shift adjustment shall be performed.
Follow the instruction for CalFree from the terminal handbook.
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11 Troubleshooting
11.1 General
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.
If a scale is not working 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.
When troubleshooting, check the instrument cable for damage and check all connections for any
loose/incorrect wiring. Examine the physical location of the scale, checking for the following:
1. Proper clearance between live and dead portions of scale base or weigh module
2. Water
3. Corrosive materials
4. Unleveled floors
5. High vibrations
6. Air currents
7. Physical damage to the scale platform or frame
CAUTION
BEFORE CONNECTING/DISCONNECTING ANY INTERNAL
ELECTRONIC COMPONENTS OR INTERCONNECTING WIRING
BETWEEN ELECTRONIC EQUIPMENT, ALWAYS REMOVE
POWER AND WAIT AT LEAST 30 SECONDS. FAILURE TO
OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY
HARM OR DAMAGE TO OR DESTRUCTION OF THE
EQUIPMENT.
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CAUTION
BE SURE TO BLOCK THE SCALE WHEN IT IS IN THE RAISED
POSITION. OBSERVE ALL APPROPRIATE SAFETY
PROCEDURES WHEN INSTALLING AND SERVICING THE WEIGH
MODULES.
• Carefully pull the defective load cell cable through the conduit while feeding the string through the
junction box opening. Once the string is at the load cell location, detach it from the load cell cable.
Attach the new load cell cable to the pulling string and carefully thread it through the conduit into
the junction box opening.
• Reattach the instrument cable and power-up the terminal. Perform a shift adjust if required, and
recalibrate the scale.
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• Remove power from the digital terminal and disconnect the instrument cable.
• Remove the junction box covers (for all boxes in the scale).
• Disconnect all cables from the PCBAs
• Inspect old PCBAs for cause of failure. In case of moister and corrosion damages search for
leakage.
• Set boxes range according to the former PCBAs e.g. cut all wires if applicable
• Set new SW according to the old schematic
• Mount PCBAs and close boxes
• Check scale performance
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2012 METTLER TOLEDO Precision Junction Boxes – Installation and Service Manual