Mettler Toledo Ultramount 0972 Manuale utente

Marca: Mettler Toledo

Modello: Ultramount 0972

Tipo: Manuale utente

15487600A

(5/99).01

0972

Ultramount

™

Weigh Modules

Service Manual

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.

Declaration of conformity

Konformitätserklärung

Déclaration de conformité

Declaración de Conformidad

Conformiteitsverklaring

Dichiarazione di conformitá

We/Wir/Nous/Wij/Noi: Mettler-Toledo, Inc.

1150 Dearborn Drive

Worthington, Ohio 43085

USA

declare under our sole responsibility that the product,

erklären, in alleiniger Verantwortung, daß dieses Produkt,

déclarons sous notre seule responsabilité que le produit,

declaramos, bajo nuestra sola responsabilidad, que el producto,

verklaren onder onze verantwoordelijkheid, dat het product,

dichiariamo sotto nostra unica responsabilitá, che il prodotto,

Type: Analog Load Cell

Models: 777

(when used within the technical requirements listed in Mettler Toledo documentation 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 Erklärung bezieht, mitder/den folgenden Norm(en) oder Richtlinie(n) übereinstimmt.

Auquel se réfère cette déclaration est conforme à la (aux) norme(s) ou au(x) document(s) normatif(s).

Al que se refiere esta declaración 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 è conforme alla/e sequente/i norma/e o documento/i normativo/i.

CE Conformity / CE-Konformität / Conformité CE

90/384/EU Nonautomatic Balances and Scales / Nichteselbsttätige Waagen / Balances à Functionnement non automatique

Article 1.2.a.

89/336/EU EMC Directive / EMU-Richtlinie / Directive concernant la CEM

EN55 022, B: 1987 Emissions / Funkstörungen

EN50 082-2: 1995 Immunity

73/23/EU Low Voltage / Niederspannung / basse tension

EN61010-1 el. Safety / el. Sicherheit / sécurité el.

76/117/EEC concerning equipment and protective systems intended for use in potentially explosive atmospheres

EN 50 014 : 1977 + A1…A5, General requirements

EN 50 020 : 1977 + A1…A5, 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 OIML International Recommendation , Metrological regulation for load cells

EEx ib IIC T4 el. Safety / el. Sicherheit / sécurité el. (PTB Nr. Ex-98.D.2155)

Darrell Flocken, Manager - Weights & Measures

Office of Weights and Measures

Worthington, Ohio USA

May, 1999

according to EN45014

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:

Model 0972 Ultramount Weigh Modules

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 0972 Ultramount Weigh Modules. 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.

METTLER TOLEDO

Publication Revision History

An overview of this manual’s revision history is compiled below.

Publication Name: 0972 Ultramount Weigh Modules Service Manual

Publication Part Number: 15487600A Publication Date: 6/98

Part Number Date Revisions

15487600A (5/99).01

Added Declaration of Conformity.

Precautions

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.

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

INSTALLING, SERVICING, CLEANING, OR REMOVING THE

FUSE. FAILURE TO DO SO COULD RESULT IN BODILY

HARM AND/OR PROPERTY DAMAGE.

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.

CAUTION

OBSERVE PRECAUTIONS FOR HANDLING

ELECTROSTATIC SENSITIVE DEVICES.

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.

ALWAYS DISCONNECT this

equipment from the power

source before cleaning or

performing maintenance.

CALL METTLER TOLEDO for parts,

information, and service.

CAUTION

DO NOT PASS WELDING CURRENT THROUGH THE LOAD CELLS! WHEN WELDING

ON A SCALE, ALWAYS GROUND THE WELDING DEVICE AS CLOSE TO THE WORK

AS POSSIBLE. NEVER WELD CLOSER THAN WITHIN 4 FEET (1.2 METERS) OF ANY

LOAD CELL WITHOUT REMOVING THE LOAD CELL.

WARNING

DO NOT USE THE DigiTOL JUNCTION BOX OR IDNet

JUNCTION BOX IN LOCATIONS CLASSIFIED AS

HAZARDOUS BY THE NATIONAL ELECTRICAL CODE (NEC)

ARTICLE 500.

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.

Contents

1 Specifications.........................................................................................................1-1

Ultramount Weigh Modules.................................................................................................1-1

Model Number....................................................................................................................1-2

Load Cells and Suspension..................................................................................................1-2

Power Supply Requirements................................................................................................1-4

Accuracy............................................................................................................................1-4

2 Inspection and Site Selection...................................................................................2-1

Inspection..........................................................................................................................2-1

Site Selection.....................................................................................................................2-1

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

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

Modes of Operation ............................................................................................................3-4

Analog Mode.......................................................................................................................3-4

DigiTOL DLC Mode...............................................................................................................3-5

IDNet Mode.........................................................................................................................3-6

Home Run Cable Connection...............................................................................................3-8

4 Calibration..............................................................................................................4-1

Shift Adjust ........................................................................................................................4-1

Analog Junction Box Shift Adjustment......................................................................................4-1

DigiTOL Junction Box Shift Adjustment ....................................................................................4-2

IDNet Junction Box Shift Adjustment........................................................................................4-2

Scale Calibration (Span).....................................................................................................4-3

Options for Calibration..........................................................................................................4-3

5 Routine Care and Maintenance................................................................................5-1

General..............................................................................................................................5-1

Site Inspection ...................................................................................................................5-1

Weigh Module and Junction Box Inspection .........................................................................5-1

6 Troubleshooting ......................................................................................................6-1

General..............................................................................................................................6-1

Isolate the Problem ............................................................................................................6-2

Check Wiring......................................................................................................................6-2

Check Load Cells................................................................................................................6-3

Check Mechanical Components...........................................................................................6-4

Load Cell Replacement Procedure .......................................................................................6-4

7 Service Parts ..........................................................................................................7-1

Ball-and-Cup Assembly.......................................................................................................7-2

Load-Pin Assembly .............................................................................................................7-4

8 Reference Material..................................................................................................8-1

Reference Drawings............................................................................................................8-1

Recommended Spare Parts .................................................................................................8-1

Chapter 1: Specifications

Ultramount Weigh Modules

(5/99)

1-1

1 Specifications

Ultramount Weigh

Modules

Model 0972 Ultramount™ weigh modules are used to convert tanks, hoppers,

vessels, blenders, and mixers into weighing instruments. They provide horizontal

checking and an anti-tip feature, while still allowing for thermal expansion. Ultramount

weigh modules are available in capacities of 5 kg to 100 kg. Dimensions are shown

in Figure 1-1.

A B C D E* F Thread G

2.76 inches 0.62 inch 4.00 inches 0.50 inch 3.15 inches -- 2.19 inches

70 mm 16 mm 102 mm 13 mm 80 mm M12 x 1.75 56 mm

H J K L M N O Dia.

1.65 inches 0.71 inch 5.19 inches 2.99 inches 1.94 inches 1.64 inches 0.41 inch

42 mm 18 mm 132 mm 76 mm 49 mm 42 mm 10 mm

Figure 1-1: Model 0972 Ultramount Weigh Module Dimensions

*Dimension shown is in weighing configuration. Shipping height is 3.23 inches (82 mm) with top plate in raised position.

METTLER TOLEDO 0972 Ultramount Service Manual

(5/99)

1-2

Model Number

Table 1-1 shows how to use the model number to determine the proper load cell

configuration for Ultramount weigh modules.

Model Number Configuration

XXXX X X X X XX -X

Model Weigh

Module

Type

Cell Type # Load Cells # of

Modules

Cell Capacity Junction Box

0972 0 = None 0 = Pin (Static)

1 = Ball & Cup

(Dynamic)

0 = Dummy Load Cell

1 = 5kd NIST H44

2 = 3kd OIML

1, 3, or 4 X5 = 5 kg

01 = 10 kg

02 = 20 kg

05 = 50 kg

10 = 100 kg

1 = Analog J-Box

2 = No J-Box

Table 1-1: Load Cell Configuration

Load Cells and

Suspension

Model number: 777 Load Cells, 5 kg, 10 kg,

20 kg, 50 kg, 100 kg

Maximum excitation voltage: 18 VDC maximum

Recommended excitation voltage: 10 VDC

Full-scale output: 2 mV/V

Input terminal resistance: 350 to 480 ohms minimum

Output terminal resistance: 356 ± 0.12 ohms

Temperature range compensation: -10°C to +40°C

(+14°F to 104°F)

Safe side load: 100% of full load cell rating

Safe overload: 150% of full load cell rating

Ball-and-cup module suspension is provided by upper and lower cups with a ball

bearing between the cell and the receiver in the upper assembly (see Figure 1-2).

Load-pin module suspension uses a load pin between the cell and receiver in the

upper assembly (see Figure 1-3).

Chapter 1: Specifications

Load Cells and Suspension

(5/99)

1-3

Figure 1-2: Ball-and-Cup Assembly

Figure 1-3: Load-Pin Assembly

Top Plate

Load Pin

Load Cell

Base Plate

Top Plate

Load Cell

Base Plate

Ball and Cup

METTLER TOLEDO 0972 Ultramount Service Manual

(5/99)

1-4

Power Supply

Requirements

A METTLER TOLEDO digital indicator is used to power the analog load cells in Model

0972 Ultramount weigh modules. The type of digital indicator that is used determines

which type of junction box (Analog, DigiTOL, or IDNet) is required for the weigh

modules.

Refer to the digital indicator’s service manual for the indicator’s power requirements.

Accuracy

Scale accuracy depends on:

• The design of the support steel for the module and of the receiving structure (tank,

hopper, conveyor, etc.) mounted to the modules

• The design and number of dead-to-live connections attached to the scale

• The total load cell capacity

• Environmental factors: wind, vibration, temperature variations, etc.

Refer to METTLER TOLEDO Weigh Module Systems Handbook *15598500A for

assistance.

* May have an alphabetical prefix.

Chapter 2: Inspection and Site Selection

Inspection

(5/99)

2-1

2 Inspection and Site Selection

Inspection

When you receive your weigh modules, visually inspect the packing containers and

modules for freight damage. Inspect:

1. Load cell and suspension assemblies

2. Load cell cables and summing junction box

3. Overall assembly

If you find damage, contact your freight carrier immediately. Fill out the enclosed

warranty card and return the weigh module to the address indicated.

Site Selection

Problems installing weigh modules are often caused by inappropriate site conditions.

Before installing the weigh modules, check the site for:

• Level support surfaces to within 1/8 inch (3.2 mm), highest to lowest location

• Adequate support, where each module meets the floor or structure, throughout the

scale’s weighing capacity

• Uniform deflection of the weigh module supports (top and bottom), maintaining

less than one-half degree out of level at gross capacity

• Proper drainage away from each of the weigh modules

• Heavy vibrations or wind currents at or near the scale

• Access around each weigh module for installation and service

• Locations on the scale to add test weights for calibration

• Access to the scale for moving test weights to the scale’s loading locations

• A position near the proposed scale location to mount the junction box

(Do not mount the junction box on the live portion of the scale.)

• Excessive or unusual loading caused by the site or type of equipment mounted to

the weigh modules

• Shared foundation: Does the vessel to be weighed have an exclusive, isolated

support foundation? Does it share supports with other vessels? Interaction may

occur if the vessel is on a shared foundation

If the site is appropriate based on the criteria above, proceed with the installation.

Otherwise, make necessary adjustments before installing the modules.

Chapter 3: Installation

Installation

(5/99)

3-1

3 Installation

Installation

Model 0972 Ultramount weigh modules can be oriented for tangential or radial

mounting (see Figure 3-1).

Figure 3-1: Plan View of Mounting Arrangements for Ultramount Weigh Modules

Install the weigh modules according to the following instructions. Make provisions for

required adjustments on the weigh structure to maintain correct module alignment:

1. Level each module’s base plate to within ±1/32 inch (0.8 mm). All base plates

must be on the same level plane within ±1/16 inch (1.6 mm).

2. Slowly lower the weigh structure onto the weigh modules.

3. Make sure that each load point on the weigh structure is well supported by the

module’s top plate, and that all top plates are level within ±1/32 inch (0.8 mm).

Otherwise, shim until each load point is supported and the top plate is level.

4. Bolt or weld the top plates of the weigh modules to the weigh structure supports,

using two M12 x 1.75 screws or 3/8-16 UNC bolts and nuts. Bolt or weld the

base plates of the weigh modules to the foundation or support steel, using four

M10 or 3/8-16 UNC anchor bolts.

5. If the top plates are to be welded to the weigh structure or the base plates are to be

welded to a structural steel support, the weld should be 3/16 inch (4.8 mm) fillet,

1 inch long (25.4 mm), and 3 inches (76.2 mm) pitch with 2 inches (50.8 mm)

between welds.

Note: Mounting plate bolts are not

supplied by METTLER TOLEDO.

Note: Always remove load cells when

welding top or base plates.

METTLER TOLEDO 0972 Ultramount Service Manual

(5/99)

3-2

CAUTION

DO NOT PASS WELDING CURRENT THROUGH THE LOAD CELLS! WHEN

WELDING ON A SCALE, ALWAYS GROUND THE WELDING DEVICE AS

CLOSE TO THE WORK AS POSSIBLE. NEVER WELD CLOSER THAN WITHIN 4

FEET (1.2 METERS) OF ANY LOAD CELL WITHOUT REMOVING THE LOAD

CELL.

6. After securing all the top plates and base plates, slowly back out the nut and

centering washer on the hold-down bolt, carefully lowering the top plate and weigh

structure onto the load cells.

7. After all the top plates are down, apply load to the load cells and make sure there

is adequate clearance between the hold-down bolts and retaining holes. See

Figure 3-2 and Figure 3-3.

Figure 3-2: Hold-Down Bolt Assembly

Hold-Down Bolt

Top Plate

Base Plate

Chapter 3: Installation

Installation

(5/99)

3-3

Figure 3-3: Hold-Down Bolt Assembly - Cross Section

Mount the junction box in a location where the load cell cables can be properly

terminated in the junction box. Do not mount the junction box on the scale.

9. Connect the load cell cables to the junction box and terminate wires according to

the wiring and color code decal on the underside of the junction box lid.

10. Connect the home run cable from the scale indicator to the junction box.

11. Confirm that all live-to-dead connections are flexible and securely anchored at both

the scale and the dead connection point.

Top Plate

Clearance

Baseplate

Clearance

Note: Consider calibrating the scale

before connecting any piping to the

scale. The scale can then be used as

a meter to determine if a proper live-

to-dead connection was made.

METTLER TOLEDO 0972 Ultramount Service Manual

(5/99)

3-4

Modes of Operation

Analog Mode

Ultramount weigh modules can be used with an analog junction box for summing the

load cell outputs. Only analog-compatible indicators work with an analog junction box.

See Figure 3-4 and Table 3-1 for cable connections.

Figure 3-4: Analog Junction Box Detail

Load Cell Wiring Instrument Cable Wiring

Function Wire Color Function Color

+ Excitation Blue + Excitation White

+ Sense Green* + Sense Yellow

+ Signal White + Signal Green

Shield Yellow Shield Orange

- Signal Red - Signal Black

- Sense Gray* - Sense Red

- Excitation Black - Excitation Blue

Based on METTLER TOLEDO

cable no. 510624370

Table 3-1: Analog Junction Box Wiring Codes

Note: Turn all potentiometers fully

clockwise prior to calibration.

*For load cell connections, the

+Excitation and +Sense wires

should be connected to the same

terminal; the -Excitation and -Sense

wires should be connected to the

same terminal.

+EXC/

+SE

+SI

SHL

-SIG

-SE

-EX

+EXC/

+SE

+SI

SHL

-SIG

-SE

-EX

EXC/

SIG

+EXC/

-SI

-SE

-EX

Chapter 3: Installation

Modes of Operation

(5/99)

3-5

DigiTOL DLC Mode

Ultramount weigh modules can be used with a DigiTOL junction box for summing load

cell outputs. Only DigiTOL indicators work with a DigiTOL junction box. In the DLC

mode, the indicator serves as the host for the DigiTOL junction box, allowing you to

use the indicator’s keypad to adjust scale parameters. See Figure 3-5 and Table 3-2

for cable connections. Load cell wiring for DigiTOL DLC mode is the same as for

analog mode.

WARNING!

DO NOT USE THE DigiTOL JUNCTION BOX IN

LOCATIONS CLASSIFIED AS HAZARDOUS BY THE

NATIONAL ELECTRICAL CODE (NEC) ARTICLE

500.

Figure 3-5: DigiTOL Junction Box Detail

Terminal No. Position Function Wire Colors

TB2 10 +20 VDC Green

TB2 12 Ground Blue

TB1 1 Shield Orange

TB1 2 RXD A Red

TB1 3 RXD B White

TB1 4 TXD B Yellow

TB1 5 TXD A Black

Table 3-2: DigiTOL Junction Box Wiring DLC Mode

Note: The DigiTOL junction box is not

compatible with the Model 8510

panel mount indicator, Models 8572

and 8582 counting scales, or Model

8530VS.

Note: For 2 mV/V load cells, jumpers

W1, W2, W3, and W4 must be ON

(shorting the pins).

Note: For load cell connections, the

+Excitation and +Sense wires

should be connected to the same

terminal; the -Excitation and -Sense

wires should be connected to the

same terminal.

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Modello: Ultramount 0972

Tipo: Manuale utente

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