Man Im Oem Precision Ajbs en

MT – Precision Junction Boxes 1 Ver.
01/13
Precision Junction Boxes

Installation and Service Manual
AJB540S
AJB641S, AJB841S
AJB541M
AJB540L
Installation and Service Manual
©
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
4 Height Adjustment with Four or More Load Cells ...................................

................................... 13
4.1 General ................................................................
................................................................................................
.................................................................................
................................................. 13
4.2 Manual Height Adjustment ................................................................
........................................................................................
........................................................ 13
4.3 Terminal Supported Height Adjustment ................................................................
........................................................................
........................................ 13
4.3.1 Terminal Supported Height Adjustment Procedure ........................................................... 15
5 Single Load Cell Check................................................................

............................................................................
............................................ 16
6 Shift Adjustment ................................................................

......................................................................................
...................................................... 17
6.1 General ................................................................
................................................................................................
.................................................................................
................................................. 17
6.2 Test Weight Positioning ................................................................
............................................................................................
............................................................ 17
6.3 Shift Adjustment with SW Switches ................................................................
.............................................................................
............................................. 17
6.4 Three Procedures for Shift Adjustment ................................................................
.........................................................................
......................................... 18
6.5 Set Adjustment Range to 350R, 1000R, 2000R ...........................................................
........................................................... 19
6.6 Initial Shift Adjustment................................................................
..............................................................................................
.............................................................. 19
6.6.1 Initial Shift Adjustment – Compensation of AUX cable ...................................................... 20
6.7 On-
On-Load Shift Adjustment ................................................................
.........................................................................................
......................................................... 21
6.7.1 On-Load - Single Corner Test - 2…n Load Cells ............................................................. 21
6.7.2 On-Load – Pair/Section Test – 4…n Load Cells .............................................................. 22
6.7.3 On-Load – Alternative Reference Determination............................................................... 23
6.8 Off-
Off-Load Shift Adjustment ................................................................
.........................................................................................
......................................................... 24
6.8.1 Off-Load - Single Corner Test – 2…n Load Cells ............................................................. 24
6.8.2 Off-Load – Pair/Section Test – 4…n Load Cells .............................................................. 25
6.8.3 Off-Load - Geometry Factor ......................................................................................... 26
6.9 Shift Adjustment out of Range................................................................
....................................................................................
.................................................... 27
7 Software Supported Shift Adjustment ....................................................

.................................................... 28
7.1 InSite Screen General ................................................................
...............................................................................................
............................................................... 28
©
7.2 InSite Screen Initial Shift Adjustment ................................................................

...........................................................................
........................................... 29
7.3 InSite Screen Off-
Off-Load Shift Adjustment ................................................................
.......................................................................
....................................... 30
8 Best Practice Scale Adjustment ..............................................................

.............................................................. 31
8.1 Tank Scale with 3 Load Cells ................................................................
....................................................................................
.................................................... 31
8.2 Tank Scale with 4 Load Cells and one Junction Box .....................................................
..................................................... 32
8.3 Tank Scale with 5 –12 Load Cells and multiple Junction Boxes ......................................
...................................... 34
8.4 Floor Scale with 4 Load Cells ................................................................
....................................................................................
.................................................... 36
8.5 Vehicle Scale with 4 Load Cells and one Junction Box ..................................................
.................................................. 37
8.6 Vehicle Scales with 6 – 12 Load Cells and Multiple Junction Boxes .................................
................................. 39
8.7 Mono Rail Scale with 2 Load Cells ................................................................
.............................................................................
............................................. 41
9 Scale Calibration (Span) ................................................................

..........................................................................
.......................................... 42
9.1 Calibration with Test Weights ................................................................
....................................................................................
.................................................... 42
9.2 Options for Calibration ................................................................
.............................................................................................
............................................................. 42
9.2.1 Calibration with Test Weights and Material Substitution ................................................... 42
9.2.2 Calibration with Material Transfer ................................................................................. 42
9.2.3 Electronic Calibration .................................................................................................. 42
9.2.4 CalFree™ - Calibration without Test Weights.................................................................. 43
10 Routine Care and Maintenance ...............................................................

............................................................... 44
10.1 General ................................................................
................................................................................................
.................................................................................
................................................. 44
10.2 Site Inspection ................................................................
................................................................................................
........................................................................
........................................ 44
10.3 Junction Box Inspection ................................................................
...........................................................................................
........................................................... 44
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
©
© METTLER TOLEDO 2011

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 AG
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
METTLER TOLEDO RESERVES THE RIGHT TO MAKE

REFINEMENTS OR CHANGES WITHOUT NOTICE.
©
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.
©
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.
FOLLOW these instructions

WARNING
carefully. FOR CONTINUED PROTECTION AGAINST SHOCK
HAZARD, CONNECT TO PROPERLY GROUNDED
OUTLET ONLY. DO NOT REMOVE THE GROUND
PRONG.
SAVE this manual for future

reference.
WARNING
DISCONNECT ALL POWER TO THIS UNIT BEFORE
INSTALLING, SERVICING, CLEANING, OR REMOVING
DO NOT allow untrained personnel THE FUSE. FAILURE TO DO SO COULD RESULT IN
to operate, clean, inspect, maintain, BODILY HARM AND/OR PROPERTY DAMAGE.
service, or tamper with this
equipment.
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.
©
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.
2.2 Junction Box PCBA Functions
Figure 1 – Junction Box Printed Circuit Board Assembly
Element Function
Load Cell Connection
LC1 – LCn
4/6 wire + shield
Termination
Home Run cable connection to terminal – shall be 6 wire + shield

Input
in all cases
Connection to another junction box for systems with more than 4
AUX load cells shall be 6 wire + shield in all cases
Read chapter 3.5 for more details
W1 – W4
To set box to ≥1000 Ohm load cell system cut all wires 1000R
Cut for 1000R
x16 Coarse shift adjustment ca. 1/1250 per step
Others
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
©
2.3 Suitable Load Cells

The junction boxes can be used with all analog load cells providing 1-3 mV/V output signals with 120 –
4000 Ohm resistance. Preferred load cell resistance values are 350, 1.000 and 2.000 Ohm nominal output
resistance. The typical adjustment range is 1.3% which is sufficient for single box systems. In case of
multiple box systems connected via AUX the adjustment range can be extended to 3.4% up to 1000 Ohm
load cells.
Note: Single point load cells are not meant for parallel connection. Doing so might lead to a shift error
beyond the adjustment range of these boxes.
2.4 Suitable Terminals

The junction boxes can be connected to all METTLER TOLEDO terminals with analog load cells input.
Please make sure the terminal can supply suitable power for the required number of load cells (see the
terminal’s technical manual for details)
2.5 Junction Box Item Numbers

Refer to the Precision Junction Box datasheet for a complete listing of item numbers.
2.6 Power Supply Requirements

The Analog Junction box is a passive device which receives power from a METTLER TOLEDO terminal.
Refer to the terminal’s service manual for the power requirements.
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.
©
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.
3.3 Home Run Cable Connection
Cord Grip Cap Body Insert
Rubber Grommet
Nut
Spherical Washer Junction Box Enclosure

Home Run Cable
Figure 2 - Standard Cord Connection Details
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
©
3.4 Load Cell Connection

Proceed similar to home run cable (above). To achieve best accuracy the junction box should be set
according to the load cell connection scheme in the tables below.
3.4.1 Connection of 6-wire load cell to 4-wire terminal junction boxes
Connect load cell cables as follows. For screw terminal double connection use common
sleeve
6-wire cell 4-wire

Load cell cable Load cell terminal junction box
Excitation + (Sleeve)
Excitation +
Sense + (Sleeve)
Excitation – (Sleeve)
Excitation -
Sense – (Sleeve)
Signal + Signal +
Signal - Signal -
Shield Shield
Table 1 – Connection of 6-wire load cells to 4-wire terminal boxes
©
3.5 Connection of Multiple Jboxes via AUX

The connection of several junction boxes via the AUX extension port is critical mainly in terms of the
connection cable influence. Resistance and temperature behavior of those cables cannot be compensated
by the terminal as with the homerun cable. Hence special care is required to achieve a well performing
scale in that case:
- Keep the connection cables as short as possible ideally below 1 m (5 ft). Otherwise see Figure 5 for
cable requirements. Make sure the cross section (AWG or mm^2) of the Connection Cable fit to the
cable length. Choosing the wrong cable will result in significant out of spec temperature behavior. Use
6 wire cable in any case.
- As a rule of thumb 1 Ohm wire resistance (equals 7m cable @ 0.14mm^2 – AWG 24) results in 1%
initial shift error with a 1000 Ohm and 3% with a 350 Ohm system. That is significant especially when
considering typical legal for trade scale tolerance of 0.03%. Effort to shift adjust will be increasing with
such large initial errors.
- Beyond 2 m cable length Initial Shift Adjustment is recommended before starting the shift adjustment.
See chapter 6.6. for more details.
- When CalFree calibration is planned keep the total connection cable length below 1m at 0.5mm^2
(AWG 20 or smaller) for 350 Ohm systems and below 4m for 1000 Ohm systems to keep the influence
below 0.1%.
Box2 Connection Cable Box1 Home Run Cable

INPUT
INPUT
AUX
Figure 3 – Daisy Chain Connection of Junction Boxes
Wire cross section AWG Resistance/m Resistance/ft

0.14 mm^2 24 0,14 Ohm/m 0.042 Ohm/ft
0.25 mm^2 23 0,08 Ohm/m 0.024 Ohm/ft
0.34 mm^2 22 0,06 Ohm/m 0.018 Ohm/ft
0.5 mm^2 20 0,04 Ohm/m 0.012 Ohm/ft
0.75 mm^2 18 0,03 Ohm/m 0.009 Ohm/ft
Figure 4 – Table – Cable Wire Resistance
©
Connection cable diameter mm2

(6 wire cable – Exc and Sens connected)
Load Cell 20 AWG 23 AWG 24 AWG
Resistance 0.5 mm2 0.25 mm2 0.14 mm2
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.)
CalFree Calibration – 350 Ohm 1 m (5 ft.) Not Not

keep signal drop recommended recommended
below 0.1%.
Shift adjustment
obsolete
1000 Ohm <4 m (13 ft.) <2 m (6.5 ft.) <1 m (3.3 ft.)
Figure 5 – Max. Cable Length of Connection Cable in ft or m
©
4 Height Adjustment with Four or More Load Cells
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
4.2 Manual Height Adjustment

Floor Scales typically have adjustable feet. Find the rocking corner and adjust the height until rock is
eliminated. Lift up on each corner (using a bar if necessary) to roughly gauge the load distribution; adjust
foot height again if necessary.
Tank and hopper scales are usually constructed using weigh modules and height adjustment is typically
done by adding stainless steel shims. Proceed as described for floor scales above, adding shims as
required above or below the weigh module
4.3 Terminal Supported Height Adjustment
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):
[] + []

[] =

©
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
Figure 6 – Terminal Display related to Actual Load on Separated Load Cell

Examples for better understanding the upper diagram. Dead load is assumed to be 20.000 kg:
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
©
4.3.1 Terminal Supported Height Adjustment Procedure

This is a recommended step for heavy capacity scales with 4 and more load cells before electronic shift
adjustment. The result of proper height adjustment is a repeatable and well performing scale.
Procedure:
Empty scale
Initially calibrate the fully connected scale with a simulator or with CalFree, once complete, ensure that you
have also set, or adjusted the zero value for the terminal.
Know the approximate dead load DL (bridge weight, tare weight) of the scale
Setup terminal to allow unlimited negative display e.g. Scale > Zero > Under Zero Blanking = Disable
Separation can be done by disconnecting one signal wire for each load cell in the junction box (except the
target cell). Cells with dead load below average will provide negative weight level and those above average
positive. If the load on the load cell is close to average the signal will be close to 0%.
It is practical to bring all load cells into a display band of -50% G +50% of DL. The table below shows the
ideal dead load fraction and the related display value.
No of load Cells Ideal deal load fraction on Ideal terminal display for each
each load cell load cell in % of DL
4 0.25 0%
6 - Tank Scale 0.166 0%
6 - Truck Scale; middle 0.125 corner LC -25% corner LC
load cell typically carry
0.25 mid LC +50% middle LC
larger dead load
8 - Truck Scale; middle 0.08 corner LC -25% corner LC
load cell typically carry
0.16 mid LC +25% middle LC
larger dead load
Example:
4 load cells, dead load 20.000kg: Display with separated load cells: LC1: 10.000kg(50% DL), LC2:
-5.000kg(-25%DL), LC3: 10.000kg(50% DL), LC4: -15.000kg(-75% DL). (Remember the display is not
directly related to the real load. The diagram is needed to determine the real load on the load cells).
From the diagram get the dead load fractions: LC1: >0.35 ; LC2: 0.17 ; LC3: >0.35 ; LC4: 0.02. LC4 is the
one to adjust most.
Best practice would be to connect LC4 and apply shims till the signal is larger than -50% DL in this case
larger than -10.000kg. That would increase the dead load of LC4 to 0.125 and will automatically take dead
load off the other load cells at the same time.
Check the result by connecting each load cell again separately again. No load cell shall be below -50% DL
or above +50% of DL.
Setup terminal to requested display function: e.g. Scale > Zero > Under Zero Blanking = Enable
Note: Single load cell signals are typically less stable than fully connected systems.
©
5 Single Load Cell Check

It might be required to check the actual load on the single load cell. That requires to separate the load cells
and to measure their signal individually. An alternative method versus using voltmeter is using terminal
display for checking. As described above once the load cells are separated the terminal display needs
interpretation as it is not directly related to the actual load on the load cell, but it follows strict rules (provided
the scale has been calibrated before):
[] + []

[] =

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.
Example: Dead Load DL = 15.000kg, Number of load cells = 4
Load Cell Terminal display Calculation Actual load on load cell

1 30.000 kg (15.000 + 30.000) / 4 11.250 kg
2 20.000 kg (15.000 + 20.000) / 4 8.750 kg
3 25.000 kg (15.000 + 25.000) / 4 10.000 kg
4 18.000 kg (15.000 + 18.000) / 4 8.250 kg
Note: Single load cell signals are typically less stable than fully connected systems.
©
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.
6.2 Test Weight Positioning

Correct positioning of test weights is very important for a reliable shift adjustment procedure. First try to
repeat the positioning as good as possible between cycles. Good practice is to mark corner positions on
the scale deck. Secondly avoid undefined loading of any load cell in the system which might occur if
platform is loaded to the very edge. Best practice is to stay well in the distance between the load cells.
6.3 Shift Adjustment with SW Switches

Shift adjustment changes the contribution of the single load cell to the sum signal by changing the
resistance in the individual load cell branch. Two rotary switches SW per load cell allow for coarse and fine
adjustment. Turning the switches from 0 to F increases – from F to 0 decreases load cell signal by typical
values. Use a 2-3mm flat-bladed screw driver to turn the switches:
The adjustment range is ca. 1.35% of the scale capacity. In case the required adjustment is out of range
see chapter 6.9.
Figure 7 – Load Cell Shift Adjust Switches (SW) – Position 00 shown
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
©
6.4 Three Procedures for Shift Adjustment

Basically there are three different procedures for electrical shift adjustment:
1. Optional initial adjustment when multiple boxes are used. The pre-adjustment compensates for the shift
error introduced by the connection cable. The pre-adjustment helps to faster adjust the scale finally with
tests weights.
2. “On-load” procedures where SW switches are operated while the test weight is on the tested load cell.
On-load is the simplest procedure. First load for reference and then load and adjust to reference cell by cell
till no adjustment is necessary anymore in a full cycle. After each cycle zero scale and perform a new
reference loading. This procedure is recommended when little experience exist about shift adjustment.
3. “Off-load” procedure where first a full test cycle is performed without changing SW switches. Then new
switch constellations are calculated off-load and SW switches are set accordingly at once. Off-load
procedures require knowledge about the scale system, but are fast and can be semi-automated i.e. the
testing can be done by machines. No reference loading is necessary for those procedures. The optimal
switch set can be determined by means of InSite software.
Type Description When to use Test Weight Test Weight Advantages

2-4 6 or more Disadvantages
Load Cells Load Cells
Initial Pre-adjustment to Multiple Jboxes - - + Speeds up the following
compensate AUX shift adjustment procedure.
(optiona
cable impact
l) + Calculates the AUX
connection cable impact
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.
©
6.5 Set Adjustment Range to 350R, 1000R, 2000R

The load cell output resistance is relevant for the box setup. To setup the adjustment ranges proceed as
following:
- No action in case of 350 Ohm to 999 Ohm load cells since the box is set to 350R initially.
- In case ≥ 1.000 Ohm Ohm load cells set box to 1000R by cutting all wires W1-Wn and bend
the ends apart. Make sure all wires are cut; otherwise a huge shift error will occur.
- In case of a ≥ 2.00Ohm load cell cut both all wires and all through resistors (only for AJB541M
and AJB540L)
1.000 Ohm Load Cells

Cut all wires
6.6 Initial Shift Adjustment

When multiple boxes are connected via AUX cable it is recommended to perform an Initial Shift Adjustment.
That will equalize the different sensitivities between the boxes cause by the AUX connection cable. Use the
below table or call InSite software in case you cannot find your box constellation and enter the required
data which you can take from the load cell Calibration Certificate supplied with the load cells.
Initial Shift Adjustment shall not be performed in conjunction with CalFree Calibration. See the connection
cable requirements in chapter 3.5
Initial Shift Adjustment is not a replacement for real corner testing since mechanical influences are not
taken into account.
©
6.6.1 Initial Shift Adjustment – Compensation of AUX cable
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
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
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
0.1 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
0.5 Ohm 61, 61 ,61, 61 C7, C7 ,C7, C7
0.6 Ohm 5B, 5B ,5B, 5B D8, D8 ,D8, D8
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
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
0.1 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
0.5 Ohm 4A, 4A ,4A, 4A C0, C0 ,C0, C0
0.6 Ohm 41, 41 ,41, 41 CE, CE ,CE, CE
Figure 8 – Table Initial Shift Adjustment
©
6.7 On-Load Shift Adjustment
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.
6.7.1 On-Load - Single Corner Test - 2Vn Load Cells

1. Set the box to 350R, 1.000R or 2.000R as shown in chapter 6.5
2. Perform an Initial Shift Adjustment (see chapter 5.6) when multiple junction boxes are used.
3. Perform test as following
2, 3 or 4 load cells 6 or more load cells
Any test weight >10% of scale capacity The test weight needs to be 3 equal parts for a
6 load cell; four equal parts for 8 load cells and
so on.
Reference loading – exactly in middle of scale Reference loading with three identically sized
weights
4000.0 12000.0
Corner test Corner test
4012.3 12050.0
4000.2
12000.4
a) Unload and zero scale a) Unload and zero scale

b) Apply test weight to the middle first. Record b) Apply split test weights to the middle section
terminal’s indication as a reference. such all load cells carry the same load. Take
terminal signal as a reference.
c) Load first corner .Adjust respective SW
switches to the above reference signal as c) Load first corner with all parts of the split test
close as possible. weight. Adjust respective load cell switches to
reference as close as possible
d) Load/adjust the next corner and so on until
last corner has been adjusted d) Load/adjust next corner till last has been
adjusted
e) Repeat a-d until no further adjustments are
necessary e) Repeat a-d till no corrections are necessary
f) Continue with span calibration f) Continue with span calibration
©
6.7.2 On-Load – Pair/Section Test – 4Vn Load Cells

For this situation build load cell pairs LC1 + LC2, LC3 + LC4, etc.
1. Set the box to 350R, 1.000R or 2.000R as shown in chapter 6.5
3. Perform the test as follows
Pair-to-Pair
The test weight need to be three equal values for a six load cell, four equal parts for eight
load cells and so on.
Reference loading with numerous identical weights
12000.0
Pair-to-Pair test
12050.0
12000.3
a) Unload and zero scale

b) Apply split test weights over the load cells in the middle such all load cells carry the
same load. Note the terminal’s indication as a reference.
c) Load pair each pair with the entirety of the available test weight. Adjust respective load
cell switches pair wise to your noted reference as close as possible.
d) Load/adjust next pair till last pair has been adjusted
e) Repeat a-d till no corrections are needed
f) Verify result by placing a test load on all corners
g) Continue with span calibration
©
6.7.3 On-Load – Alternative Reference Determination

The nature of reference loading is to equally spread the test weight to all load all load cells. E.g. 10t test
weight with a 4 load cell system the ideal reference loading equally loads all load cells with 2.5t.
In cases split test weight are not available or it is not possible to load scale in the middle the reference can
be determined by several single loadings and averaging the results.
2, 3 or 4 load cells 6 or more load cells
Alternative Reference Determination Alternative Reference Determination
Reference loading – three corner tests Reference loading - three pair tests
12504
3998.0 12535
4002.5 12487
3999.0
a) Unload and zero scale a) Unload and zero scale

b) Apply test weight corner by corner and b) Apply test weight pair by pair and record signal
record signal
c) Average the single signals to determine the reference
c) Average the single signals to determine the signal, ex. 12508
reference signal, ex. 3999,83
d) Continue with On-Load shift adjustment
d) Continue with On-Load shift adjustment
©
6.8 Off-Load Shift Adjustment

Off-load shift adjustment uses calculations to achieve the required adjustment. A full test cycle is
performed first followed by off-load calculations. No special requirements for the test weight, i.e. any known
test weight least 10% of scale nominal weight can be used for this procedure. This procedure is
recommended for frequently repeated processes since it typically requires on test cycle and one
verification cycle only. In case the box is not accessible when scale is loaded this procedure might be
helpful. It also allows for automated un-manned testing.
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.
6.8.1 Off-Load - Single Corner Test – 2Vn Load Cells
2Vn load cells

Known test weight >10% of scale capacity
Preparations: Insite Software required
Corner test Corner test

b) Load first corner. Record terminal reading
c) Load next corner and record signal till last corner has been tested
d) Enter values in InSite
e) Set switches accordingly
f) Verify result by another test cycle. Repeat a-f if necessary
©
6.8.2 Off-Load – Pair/Section Test – 4Vn Load Cells
For that build load cell pairs LC1 + LC2, LC3 + LC4, etc.
1. Set the box to 350R, 1.000R or 2000R as shown in chapter 6.5

Pair corner test

Known test weight >10% of scale capacity
InSite Software required
Pair test

b) Load pair with test weight. Record terminal signal
c) Load second pair and record terminal signal etc.
d) Calculate new switch set by means of InSite.
e) Set switches accordingly
f) Verify result by another test cycle. Repeat a-f if necessary.
©
6.8.3 Off-Load - Geometry Factor
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.
Geometry factor Value Remark

(Apply to required signal shift)
No mechanical link between the load cells 1 Valid for all numbers of load cells
2 Load Cell System
Overhead rail scale 1,25 Load point 80% within load cell distance
3 Load Cell System
Tank scale 1,25
4 Load cell System
Floor scale, Tank scale, Pallet scale 1,3
Truck scale 1,3
6 Load Cell System
Truck Scale 1,25
8+ Load Cell System
Truck scale 1,15
Table 2 - Geometry Shift Adjustment Factor
©
6.9 Shift Adjustment out of Range
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.
Figure 9 – Shift Adjustment Extension from 350R to 1000R

b) In case the box is already in 1.000 R mode, cut open all through hole resistors (only available for
AJB541M and AJB540L. 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.
©
7 Software Supported Shift Adjustment

Mettler Toledo InSite software supports Initial and Off-Load shift adjustment.
7.1 InSite Screen General
JBox SetUp:
350R, 1000R, 2000R - See
chapter 6.5
Number of load cells:

All load cells in the system
Pair Adjustment:
Tick when pair/section
adjustment planed
Single load cell resistance:

Typical 350 or 1000 Ohm
Connection Cable resistance:

Resistance of one single wire
of Jbox connection cable.
Only relevant when multiple
Jboxes are used. Used for
Initial Shift Adjustment
©
7.2 InSite Screen Initial Shift Adjustment
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
New Start to Off-Load:

Copies new switch levels to
the Off-Load Adjustment
©
7.3 InSite Screen Off-Load Shift Adjustment
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
Move New Switche Values ..:

Copy New Start to Start for
next test cycle
©
8 Best Practice Scale Adjustment

8.1 Tank Scale with 3 Load Cells
1. CalFree™ Calibration Decision Jbox

If scale shall be calibrated by CalFree set all switches to 80 and continue
with calibration
2. Shift Adjustment – Not Relevant for Liquid Weighing

If load cells resistance is ≥1.000 Ohm cut all W1-Wn wires
Set all switches to 80
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 use On-Load shift adjustment.
2a. On-Load Shift Adjustment
Calculate average reading from former test results for 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 respective switches up or down till terminal 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 results.
If not in tolerance calculate average of latest test result as reference and repeat shift adjustment till in
tolerance
2b. Alternative Off-Load Shift Adjustment
Start InSite software
Select Off-Load Shift Adjustment
Enter Geometry Factor 1,25
Enter switch settings
Enter shift test results
Calculate new switch settings and set box switches accordingly
Check shift error and repeat adjustment if necessary
3. Scale Calibration
Perform scale calibration, refer to terminal manual
©
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.
2. CalFree™ Calibration Decision

If scale shall be calibrated by CalFree™ set all switches to 80 and continue with calibration
3. Shift Adjustment – Not relevant for Liquid Weighing

If load cells resistance is ≥1.000 Ohm cut all W1-Wn wires
Zero scale
Calculate average reading of former test results for 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.
Check shift error by applying test weight again on each corner and record readings.
If not in tolerance calculate average reading of latest test result as reference and repeat shift adjustment till
in tolerance
©

©
8.3 Tank Scale with 5 –12 Load Cells and multiple Junction Boxes
1. Junction Box Connection Cable

If the scale shall be calibrated by CalFree™ make sure the total length
of all connection cables is no longer than 2m and the wires
are at least 0,5 mm^2 (AWG20).
For all other calibration methods make sure that the connection
cables fit the requirements. Jbox Jbox
Know the connection cable wire resistance.
For larger tanks systems perform a terminal supported height adjustment:
Know the approximate dead weight of the scale
3. CalFree™ Calibration Decision

If scale shall be calibrated by CalFree™ set all switches to 80 and continue with calibration
4. Initial Shift Adjustment

It is strongly recommended to perform Initial Shift Adjustment to compensate the connection cable effect.
If load cells resistance is ≥ 1.000 Ohm cut all W1-Wn wires
Measure the junction box connection wire resistance or determine from table
Pre-adjust junction boxes after the values from Figure 8
5. Shift Adjustment
Zero Scale
If shift error is out of tolerance preferably perform Off-Load Shift Adjustment.
5a. Off-Load Shift Adjustment
Enter switch set for each load cell and shift test results
Calculate new switch set and set box switches accordingly
©

5b. Alternative - On-Load Shift Adjustment

Calculate average of former test results 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 all other
corners. In case of exceeding the shift range set box to next range and restart shift adjustment procedure.
If not in tolerance calculate average of latest test result as reference and repeat shift adjustment till in
tolerance
©
8.4 Floor Scale with 4 Load Cells
Perform a manual height adjustment while scale is empty.
Jbox
2. Shift Adjustment
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.
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.
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
©
8.5 Vehicle Scale with 4 Load Cells and one Junction Box
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™
2. Shift Adjustment
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.
Use center load reading as reference. Never use the lowest or highest reading for reference as the
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.
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
Tick Pair Adjustment when desired
Enter switch settings for each cell
Enter test results for each load cell or pair
©
©
8.6 Vehicle Scales with 6 – 12 Load Cells and Multiple Junction Boxes
1. Junction Box Connection Cable

Make sure the connection cables fit the requirements.
Failure to do so will result in bad temperature behavior and
large initial shift error beyond the range of the boxes. Jbox
Know the connection cable wire resistance.
Perform a terminal supported height adjustment:
Know the approximate dead weight of the bridge
Scale > Zero > Under Zero Blanking = Disable Jbox
3. Initial Shift Adjustment

It is strongly recommended to perform Initial Shift Adjustment to compensate the connection cable effect.
Measure the junction box connection wire resistance or determine from table
Pre-adjust junction boxes after the values from Figure 8
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
Tick Pair Adjustment when required
Enter switch settings for each load cell
Enter test results of each corner test or pair test
©
4b. Alternative On-Load Shift Adjustment

Determine the reference reading by using similar test weights and apply one on each pair. Make sure all
load cells get the same share of the full test weight. It is not appropriate to use less test weights than
number of pairs as it does not allow the equally load the cells.
Load first corner or pair with full test weights 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. In
case of exceeding the range set box to next range and restart the shift adjustment procedure.
Check shift error by applying test weight again on each corner / pair and record readings.
If not in tolerance load scale for reference again as described above and use reading as reference for the
next cycle. Repeat shift adjustment till in tolerance
©
8.7 Mono Rail Scale with 2 Load Cells
1. Shift Adjustment
If load cells resistance is ≥1.000 Ohm cut all W1-Wn wires Jbox
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
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.
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
©
9 Scale Calibration (Span)

9.1 Calibration with Test Weights
The most accurate, reliable way to calibrate a scale is to use test weights. Calibrate the scale using test
weights equal to the scale capacity. With the proper test weight, continue calibrating the weighing system
according to the instructions provided in your digital terminal manual.
9.2 Options for Calibration

9.2.1 Calibration with Test Weights and Material Substitution
The substitution method is recommended for larger installations where it is physically impossible to hang
test weights equal to the tank’s maximum capacity. When performed correctly, this method provides weight
readings for plotting a reliable performance graph.
• For example, you might hang 1,000 kg of test weights, take a weight reading, and then remove
the test weights.
• Add enough water to the tank to equal the weight reading obtained with the test weights.
• Leave the water in the tank. Hang the same test weights again, take a second weight reading, and
then remove the test weights.
• Add enough additional water to the tank to equal the second test weight reading.
• Repeat this procedure until the tank is full.
9.2.2 Calibration with Material Transfer
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.
9.2.3 Electronic Calibration

When using the electronic calibration method, replace the load cell cables with leads from a load cell
simulator. The simulator sends out a signal equal to the signal the load cells should produce. Electronic
calibration is noted for its speed and simplicity; however, it calibrates only the electronics. It does not verify
the scale performance because it assumes that the tank and all mechanical connections are in perfect
working order.
• With the simulator adjusted to zero output, set the terminal to zero.
• Adjust the simulator to full output, a signal that all the load cells should produce at their rated capacity.
• Adjust the terminal to show the total capacity of all load cells in the system.
• Attach the load cell input to the terminal.
• “Zero off” the empty weight of the tank.
©
9.2.4 CalFree™ - Calibration without Test Weights

CalFree™ allows for calibration w/o weight, by using load cell sensitivity data and METTLER TOLEDO
terminals. CalFree calibration accuracy is limited and not capable for legal for trade applications. As no test
weights are available shift adjustment with test weights cannot be performed. For CalFREE™ set box the
following:
a) When using one box only
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.
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.
©
10 Routine Care and Maintenance

10.1 General
Once you have installed your weighing equipment, you should have an authorized METTLER TOLEDO
representative periodically inspect and calibrate it. If the scale is used for legal-for-trade purposes, consult
the local weights and measures authorities for minimum inspection requirements. Contact your local
authorized METTLER TOLEDO service representative for information on periodic inspection and
calibration services. The calibration interval should be based on the importance of the scale in the system
and the criticality of the weight value to customer’s overall operation. More calibration and adjustment
intervals insure that the weighing results remain accurate and the certainties of weighing results are better
known.
10.2 Site Inspection

Make sure that the scale site remains in good condition. Check for alterations in the dead-to-live
connections, alterations in support for the load cells, overloading and excessive vibration, and debris or
material build-up on, under or around the scale that could inhibit freedom of movement. Damages load
cells or load cells cables should be replaced. Mounting bolts should be inspected to insure that there are
no lose mechanical connections.
10.3 Junction Box Inspection

During periodic inspections of the system, check:
• Junction box lid: Is it properly sealed? Are all cord grips tight?
• Moisture or foreign material present around or inside the junction box assembly
• Periodically remove and replace the desiccant bags inside the junction box.
• Instrument cable: Is it damaged? Does it bind the scale?
• Is there any physical damage to the scale, load cells or junction box (es)
• Repeatability and shift of the scale.
©
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.
11.2 Isolate the Problem

• To determine whether the problem is in the scale or the digital terminal:
• Remove power from the system.
• Disconnect the digital terminal from the scale, and connect the terminal to a load cell simulator (analog
load cell simulators are available from METTLER TOLEDO).
• Reapply power. If the problem persists, consult the digital terminal manual for further troubleshooting
assistance.
• If the problem is NOT present with the load cell simulator attached to the terminal, remove power.
Disconnect the simulator and reconnect the scale. If the problem persists, continue troubleshooting the
scale.
©
11.3 Check Wiring

• Remove power from the system.
• Remove the lid from the junction box and check the interior for moisture and foreign material.
• Make sure that all wiring connections are tight and that no insulation material is touching the terminal
contacts.
• Check all cable connections for correct wiring. Check all cable connectors and cord grip caps on the
junction box. Tighten any loose connectors.
11.4 Check Load Cells

Remove load cell leads from terminal strip and check each load cell for proper bridge resistances.
If bridge resistances are within specification, perform a shorted-signal symmetry check.

Short the signal leads together and place one multi-meter lead on the shorted signal and one lead
on the +Excitation wire.
• Record the resistance value.
• Remove the lead from the +Excitation wire and place it on the –Excitation wire.
• Both resistance values should be approximately equal.
• If the cells pass the above test:
• Reapply power to the scale platform.
• Confirm that proper excitation voltage is reaching the load cells by placing multi-meter leads on the
excitation positions of each load cell terminal. Excitation voltage can vary from 6 VDC to 15 VDC,
depending on the application and digital terminal so check the terminal’s manual for the exact value
• If proper excitation voltage is reaching the load cells, check the output signal from each cell.
• If one cell has a particularly high or low dead-load output, it is suspect. The maximum output from any
cell is 30 mV at 15 VDC excitation when loaded to gross capacity.
• If any cell has an unusual signal, remove all load from that cell by raising the platform.
• With the power still on, measure the output from the suspect load cell. The “no-load” zero output should
be ±1.5% of the full scale output. For example, if the excitation voltage is 15 VDC, then the full scale
output is 30 mV and the load zero output should be within ±0.45 mV.
• If the load cell is out of specification, replace it.
• If a load cell fails any of the above tests, replace it.
©
11.5 Load Cell Replacement Procedure

• Remove power from the digital terminal and disconnect the instrument cable.
• Remove the junction box cover and locate the defective load cell terminal.
• Disconnect the defective load cell cable from its terminal on the printed PCB.
• Loosen the watertight cable connector on the junction box and remove the cable from the
enclosure.
• If the load cell cable runs through a conduit, attach a string to the end of the defective load cell
cable. The string should be both strong enough and long enough to pull the new load cell cable
through the conduit.
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.
©
11.6 PCBA Replacement Procedure

Spare PCBA fit the former housing as shown in the table. For systems with multiple boxes always
exchange all PCBAs to the new principle. Mixing trim pot principle with Precision Junction Box would relate
in very poor scale performance.
Precision Junction Box Spare PCBA – Item No.

AJB540S 30206062
AJB641S 30206064
AJB541M 30206063
AJB540L 30206063
Former Junction Boxes Suitable PCBA
AJB015 30206062 (exchange all PCBAs in the scale)
TB100458 – Large 5 Hole 30206063 (exchange all PCBAs in the scale)
TB100481 – Standard 6- Hole 30206063 (exchange all PCBAs in the scale)
• 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
©

Man Im Oem Precision Ajbs en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Man Im Oem Precision Ajbs en

Uploaded by

Copyright:

Available Formats

MT – Precision Junction Boxes 1 Ver.

Precision Junction Boxes

Installation and Service Manual

4 Height Adjustment with Four or More Load Cells ...................................

5 Single Load Cell Check................................................................

6 Shift Adjustment ................................................................

7 Software Supported Shift Adjustment ....................................................

7.2 InSite Screen Initial Shift Adjustment ................................................................

8 Best Practice Scale Adjustment ..............................................................

9 Scale Calibration (Span) ................................................................

10 Routine Care and Maintenance ...............................................................

© METTLER TOLEDO 2011

METTLER TOLEDO RESERVES THE RIGHT TO MAKE

FOLLOW these instructions

SAVE this manual for future

2.2 Junction Box PCBA Functions

Figure 1 – Junction Box Printed Circuit Board Assembly

Home Run cable connection to terminal – shall be 6 wire + shield

2.3 Suitable Load Cells

2.4 Suitable Terminals

2.5 Junction Box Item Numbers

2.6 Power Supply Requirements

3.3 Home Run Cable Connection

Cord Grip Cap Body Insert

Spherical Washer Junction Box Enclosure

Figure 2 - Standard Cord Connection Details

3.4 Load Cell Connection

3.4.1 Connection of 6-wire load cell to 4-wire terminal junction boxes

6-wire cell 4-wire

Table 1 – Connection of 6-wire load cells to 4-wire terminal boxes

3.5 Connection of Multiple Jboxes via AUX

Box2 Connection Cable Box1 Home Run Cable

Figure 3 – Daisy Chain Connection of Junction Boxes

Wire cross section AWG Resistance/m Resistance/ft

Figure 4 – Table – Cable Wire Resistance

Connection cable diameter mm2

CalFree Calibration – 350 Ohm 1 m (5 ft.) Not Not

Figure 5 – Max. Cable Length of Connection Cable in ft or m

4 Height Adjustment with Four or More Load Cells

4.2 Manual Height Adjustment

4.3 Terminal Supported Height Adjustment

 [] +    []

Figure 6 – Terminal Display related to Actual Load on Separated Load Cell

4.3.1 Terminal Supported Height Adjustment Procedure

5 Single Load Cell Check

 [] +    []

Example: Dead Load DL = 15.000kg, Number of load cells = 4

Load Cell Terminal display Calculation Actual load on load cell

6.2 Test Weight Positioning

6.3 Shift Adjustment with SW Switches

Figure 7 – Load Cell Shift Adjust Switches (SW) – Position 00 shown

6.4 Three Procedures for Shift Adjustment

Type Description When to use Test Weight Test Weight Advantages

6.5 Set Adjustment Range to 350R, 1000R, 2000R

1.000 Ohm Load Cells

6.6 Initial Shift Adjustment

6.6.1 Initial Shift Adjustment – Compensation of AUX cable

Figure 8 – Table Initial Shift Adjustment

6.7 On-Load Shift Adjustment

6.7.1 On-Load - Single Corner Test - 2Vn Load Cells

Corner test Corner test

a) Unload and zero scale a) Unload and zero scale

6.7.2 On-Load – Pair/Section Test – 4Vn Load Cells

[] + []

[] + []