0990

Monorail Overhead
Track Scale
Installation and Service
Manual






















A14859600A
(9/04).00









































Mettler-Toledo, Inc. 1996, 2004
No part of this manual may be reproduced or transmitted in any form or by any means, electronic or
mechanical, including photocopying and recording, for any purpose without the express written permission
of Mettler-Toledo, Inc.
U.S. Government Restricted Rights: This documentation is furnished with Restricted Rights.

METTLER TOLEDO
Publication Revision History
An overview of this manuals revision history is compiled below.

Publication Name: 0990 Monorail Overhead Track Scale Installation and Service Manual

Publication Part Number: 14859600A Publication Date: 6/96

Part Number Date Revisions
A14859600A 9/04 Revised and reformatted manual.



INTRODUCTION
This publication is provided solely as a guide for individuals who have received Technical Training in
servicing the METTLER TOLEDO product.
Information about METTLER TOLEDO Technical Training can be obtained by writing, calling, or faxing:
METTLER TOLEDO
1900 Polaris Parkway
Columbus, Ohio 43240 USA
Phone: (614) 438-4511
Fax: (614) 438-4958
www.mt.com




FCC Notice
This device complies with Part 15 of the FCC Rules and the Radio Interference Requirements of the
Canadian Department of Communications. Operation is subject to the following conditions: (1) this device
may not cause harmful interference, and (2) this device must accept any interference received, including
interference that may cause undesired operation.
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant
to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment. This equipment generates,
uses, and can radiate radio frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio communications. Operation of this equipment
in a residential area is likely to cause harmful interference in which case the user will be required to correct
the interference at his own expense.







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
material for 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 first 12
months of the warranty term, the Company will furnish necessary replacement parts and on-site technicians service free of
charge, provided the Buyer agrees to pay reasonable technicians travel time, vehicle mileage, and associated travel
expenses to and from the nearest authorized Company service location. If the equipment is covered by a two-year warranty,
for the last 12 months or remaining balance of the warranty period, whichever comes first, the Company will furnish the
necessary replacement parts to the Buyer free of charge, provided that the Buyer agrees to pay reasonable technicians on-site
labor services, travel time, mileage, and expenses to and from the nearest authorized Company service location. The
following are NOT covered under any of these warranties:
1. Initial installation and ongoing scale calibration.
2. Damage to scale components by gross abuse, fire, flooding, explosion, water, voltage surges, or civil disturbance.
3. Normal maintenance or consumable items.
This warranty covers only the Model 0990 monorail overhead track scale. Refer to METTLER TOLEDO Standard Product
Warranty for coverage of other scale system components, including scale instrument, printer, and/or other accessories.
THE COMPANY EXPRESSLY WARRANTS THE EQUIPMENT MANUFACTURED BY IT AS SET FORTH HEREIN. THE COMPANY
MAKES NO OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED (INCLUDING WITHOUT LIMITATION WARRANTIES AS TO
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE). IN ADDITION, THIS DOCUMENT SHALL CONSTITUTE THE
SOLE AND EXCLUSIVE REMEDIES OF THE BUYER FOR ANY BREACH BY THE COMPANY OF ITS WARRANTIES HEREIN.
COMPANY LIABILITY UNDER THIS WARRANTY OR ANOTHER WARRANTY, WHETHER EXPRESSED OR IMPLIED IN LAW OR
FACT, SHALL BE LIMITED TO THE REPAIR OR REPLACEMENT OF DEFECTIVE MATERIAL AND WORKMANSHIP, AND IN NO
EVENT SHALL IT BE LIABLE FOR CONSEQUENTIAL OR INDIRECT DAMAGES.
This warranty coverage is applicable only to the United States of America.
Export Products: The Company warrants equipment destined for export or sold for export to be free from defects in
workmanship and material for a period of one year from date of installation or 18 months from date of shipment to the Buyer,
whichever occurs first. Should any such defect be found within that period, parts will be furnished free of charge (ex works)
point of origin or final distribution center. If the Buyer requests the performance of warranty work provided for under the
foregoing warranty outside of the contiguous United States, the Buyer shall be required to pay for labor, travel time, living,
and travel expenses of any personnel required to perform such warranty work.
APPLICATION GUIDES
The only warranty of METTLER TOLEDO is for the product it supplies under the Product Warranty Statement listed above.
Weighing application guidelines pertain to METTLER TOLEDO products.




Precautions

WARNING
PERMIT ONLY QUALIFIED PERSONNEL TO SERVICE THIS
EQUIPMENT. EXERCISE CARE WHEN MAKING CHECKS,
TESTS, AND ADJUSTMENTS THAT MUST BE MADE WITH
POWER ON. FAILING TO OBSERVE THESE PRECAUTIONS
CAN RESULT IN BODILY HARM.


CAUTION
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.


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
BEFORE CONNECTING OR DISCONNECTING ANY INTERNAL ELECTRONIC
COMPONENTS OR INTERCONNECTING WIRING BETWEEN ELECTRONIC
EQUIPMENT, ALWAYS REMOVE POWER AND WAIT AT LEAST THIRTY (30)
SECONDS. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN
BODILY HARM OR DAMAGE TO OR DESTRUCTION OF THE EQUIPMENT.


CAUTION
OBSERVE PRECAUTIONS FOR HANDLING
ELECTROSTATIC SENSITIVE DEVICES.




CONTENTS
1 Introduction.................................................................................................... 1-1
General ..............................................................................................................................1-1
Model Numbers...................................................................................................................1-1
Model/RAM Numbers...........................................................................................................1-2
Load Cells ..........................................................................................................................1-3
Load Cell Specifications .......................................................................................................... 1-3
Approvals ...........................................................................................................................1-3
2 Inspection and Site Selection .......................................................................... 2-1
Inspection...........................................................................................................................2-1
Site Selection .....................................................................................................................2-1
3 Installation..................................................................................................... 3-1
Safety Considerations..........................................................................................................3-1
Assembly and Installation....................................................................................................3-1
Modes of Operation .............................................................................................................3-3
Analog Mode ......................................................................................................................... 3-3
RAAD Mode ........................................................................................................................... 3-4
IDNet Mode ........................................................................................................................... 3-5
Home Run Cable Connection................................................................................................3-6
4 Calibration..................................................................................................... 4-1
General ..............................................................................................................................4-1
Analog Junction Box............................................................................................................4-1
RAAD Junction Box..............................................................................................................4-2
IDNet Junction Box..............................................................................................................4-2
5 Routine Care and Maintenance........................................................................ 5-1
General ..............................................................................................................................5-1
Site Inspection....................................................................................................................5-1
Scale 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 ........................................................................................................6-4
7 Service Parts.................................................................................................. 7-1
0990 Monorail Scale...........................................................................................................7-1

8 Reference Material ......................................................................................... 8-1
Reference Drawings ............................................................................................................8-1
Recommended Spare Parts ..................................................................................................8-1












Chapter 1: Introduction
General


1 Introduction


General
The Model 0990 monorail overhead track scale is a complete weighing assembly that
can be installed as part of a new or existing rail system. It provides accurate weighing
in overhead rail systems used in meat processing operations.
The 0990 monorail is available in 1,250-lb and 2,500-lb capacities. Each can be
constructed of carbon steel or stainless steel with two live rail lengths (2 feet and 4
feet). The live rail is the weighing portion of the rail assembly, the portion on which the
trolley wheel rolls. The assembly also includes a backing bar to support the live rail and
suspension components to transfer the load to the load cells. A monorail scale can be
loaded up to 100% of its rated capacity anywhere along the length of the live rail.


Model Numbers
The following table shows how standard model numbers are determined for currently
available 0990 monorail scales.
XXXX X X X X X XX
Model Rail Length Load Cell Material Junction Box Load Cell
Type
Load Cell
Cable Length
Load Cell
Capacity
0990 0 = 24 inches
1 = 48 inches
0 = Carbon steel
1 = Stainless steel
0 = None
1 = Standard analog
3 = IDNet
4 = Large analog
6 = Large IDNet
0 = TLC H44
1 = THC H44
2 = Future
3 = Future
0 = 15 feet
1 = 30 feet
01 = Future
02 = 1,250 lb
03 = 2,500 lb
11 = Future
12 = Future
13 = Future

(9/04) 1-1
METTLER TOLEDO 0990 Monorail Overhead Track Scale Installation and Service Manual


Model/RAM Numbers

RAM Number Description Capacity Shipping
Weight
09900011102 Monorail / 2 feet / CS / Analog / H44 THC / 30 feet / 1,250 lb 1,250 lb 170 lb
09900011103 Monorail / 2 feet / CS / Analog / H44 THC / 30 feet / 2,500 lb 2,500 lb 170 lb
09901011102 Monorail / 4 feet / CS / Analog / H44 THC / 30 feet / 1,250 lb 1,250 lb 200 lb
09901011103 Monorail / 4 feet / CS / Analog / H44 THC / 30 feet / 2,500 lb 2,500 lb 200 lb
09900001102 Monorail / 2 feet / CS / No J-Box / H44 THC / 30 feet / 1,250 lb 1,250 lb 167 lb
09900001103 Monorail / 2 feet / CS / No J-Box / H44 THC / 30 feet / 2,500 lb 2,500 lb 167 lb
09901001102 Monorail / 4 feet / CS / No J-Box / H44 THC / 30 feet / 1,250 lb 1,250 lb 197 lb
09901001103 Monorail / 4 feet / CS / No J-Box / H44 THC / 30 feet / 2,500 lb 2,500 lb 197 lb
09900111102 Monorail / 2 feet / SS / Analog / H44 THC / 30 feet / 1,250 lb 1,250 lb 170 lb
09900111103 Monorail / 2 feet / SS / Analog / H44 THC / 30 feet / 2,500 lb 2,500 lb 170 lb
09901111102 Monorail / 4 feet / SS / Analog / H44 THC / 30 feet / 1,250 lb 1,250 lb 200 lb
09901111103 Monorail / 4 feet / SS / Analog / H44 THC / 30 feet / 2,500 lb 2,500 lb 200 lb
09900101102 Monorail / 2 feet / SS / No J-Box / H44 THC / 30 feet / 1,250 lb 1,250 lb 167 lb
09900101103 Monorail / 2 feet / SS / No J-Box / H44 THC / 30 feet / 2,500 lb 2,500 lb 167 lb
09901101102 Monorail / 4 feet / SS / No J-Box / H44 THC / 30 feet / 1,250 lb 1,250 lb 197 lb
09901101103 Monorail / 4 feet / SS / No J-Box / H44 THC / 30 feet / 2,500 lb 2,500 lb 197 lb

(9/04) 1-2
Chapter 1: Introduction
Load Cells


Load Cells
Model 0990 monorail scales include stainless steel, cantilever-beam load cells with
integral, four-conductor, shielded cables. Individual load cell capacities are listed
below:
Scale Capacity Capacity of Each
Load Cell
Minimum Approved
Graduation Size
1,250 lb
2,500 lb
1,250 lb
2,500 lb
0.5 lb
1.0 lb


Load Cell Specifications

Model Number 757
Rated Capacity (RC) 1,250 lb, 2,500 lb
Rated Output 2 mV/V
Maximum Excitation Voltage* 15 VDC or VAC rms
Recommended Excitation Voltage 15 VDC
Input Terminal Resistance 350 ohms minimum
Output Terminal Resistance 350 2 ohms
Temperature Range (compensated) +14F to +104F (-10C to +40C)
Safe Overload 150% RC
Safe Side Load 100% RC
Zero Balance 1.0% RC
*The power supply to the load cells is provided by the METTLER TOLEDO indicator.


Approvals
NTEP Certification
Model 757 load cells meet or exceed NIST Handbook-44 requirements for Class III
5,000 divisions (multiple cell). A Certificate of Conformance was issued under the
National Type Evaluation Program (NTEP) of the National Conference of Weights and
Measures (certificate number 96-006).
(9/04) 1-3
Chapter 2: Inspection and Site Selection
Inspection


2 Inspection and Site Selection


Inspection
When the 0990 monorail scale is delivered, visually inspect it for any damage that
might have occurred during shipping and handling. Inspect the following:
1. Scale support frame (check for warping)
2. Load cell and suspension components
3. Load cell cables
4. Load cell summing junction box
5. Live rail and approach rails
If you find any damage, contact your freight carrier immediately.


Site Selection
Many problems associated with monorail scale installations are caused by improper
site conditions. Before installing the scale, check the proposed location for the following
conditions:
1. The section of rail in which the scale will be installed should be straight and level
enough to maintain good weighing.
2. The rail at each end of the scale assembly should be capable of supporting the
entire weighing capacity of the scale.
3. There should be easy access to the scale for maintenance.
4. There should be no heavy vibrations or wind currents at or near the scale.
5. The scale should not be subjected to excessive or unusual loading due to the
location or type of equipment used.
If the site is acceptable, proceed with the installation. If not, choose a new location or
select another scale.

(9/04) 2-1
Chapter 3: Installation
Safety Considerations


3 Installation


Safety Considerations
All welding should be performed by a certified welder per American Welding Society
(AWS) guidelines.
A safety support system (safety chain or wire rope) with a capacity greater than or
equal to the scale capacity is required.

WARNING
FAILURE TO INSTALL AND USE A SECONDARY SAFETY SUPPORT SYSTEM COULD
RESULT IN BODILY HARM OR PROPERTY DAMAGE.

Never place a load on the monorail scale that exceeds the scales rated capacity.


Assembly and
Installation
The 0990 monorail scale is shipped as a kit of parts. Figure 3-1 shows a monorail
scale with a 2-foot live rail. To assemble the scale, refer to the assembly drawing for
your specific scale and use the following procedure:
1. Attach the backing bar to the live rail, using 1/2-13 UNC flat-head socket screws.
Torque the screws to 60 ft-lb.
2. Attach the approach rail support blocks to the base weldment, using 1/2-13 UNC
socket-head cap screws. Torque the screws to 100 ft-lb for carbon steel scales or
75 ft-lb for stainless steel scales.
3. Attach the approach rails to the support blocks, using 1/2-13 UNC flat-head socket
screws. Do not tighten the screws at this time.
4. Mount the load cells to the base weldment, using 1/2-13 UNC socket-head cap
screws. Torque the screws to 100 ft-lb for carbon steel scales or 75 ft-lb for
stainless steel scales.

WARNING
FAILURE TO TORQUE MOUNTING SCREWS TO THE CORRECT SPECIFICATIONS
COULD RESULT IN BODILY HARM OR PROPERTY DAMAGE.

(9/04) 3-1
METTLER TOLEDO 0990 Monorail Overhead Track Scale Installation and Service Manual
NOTE: Sleeve bearings fit snugly
into the live rail bore. Take care to
insert them squarely into the rail.

NOTE: The approach rails are
replaceable parts. Welding rails to
the building superstructure or
adjacent rails will complicate future
replacement.
5. Attach the live rail assembly to the load cells, using the load support pins and
hardware. Make sure that there is 1/16 inch of clearance between the live rail and
the approach rails (see Figure 3-2). Torque the load support pins to 200 ft-lb.
6. Tighten the approach rail screws to 60 ft-lb.
7. Align the approach rails with the existing monorail.
8. When the rails are aligned and level, attach the 0990 monorail scale assembly to
a nearby superstructure using appropriately sized mounting struts.

Support Block
Load Cell 1
Approach Rail
Base Weldment
Load Cell 2
Backing Bar

Figure 3-1: Monorail Scale Assembly (with 2-Foot Live Rail)



Figure 3-2: Clearance Between Live Rail and Approach Rails

Support Block
Load Support Pin
Load Support Pin
Live Rail
Approach Rail
1/16" 1/16"
Approach Rail Approach Rail Live Rail
(9/04) 3-2
Chapter 3: Installation
Modes of Operation


Modes of Operation

Analog Mode
A Model 0990 monorail scale can be used with an analog junction box for summing
the load cell outputs. An analog junction box must be used with a compatible analog
indicator. See Figure 3-3 and Table 3-1 for the correct cable connections. Load cells are
numbered as indicated in Figure 3-1.
NOTE: Use 24-gauge instrument
cable (P/N 510624370) for 50 feet
or less. Use 20-gauge instrument
cable (P/N 510620370) for
distances longer than 50 feet.




Figure 3-3: Analog Junction Box Detail

Load Cell Wiring Instrument Cable Wiring*
Function Color Function Color
+Excitation Green +Excitation White
+Sense Not Used +Sense Yellow
+Signal White +Signal Green
Shield Yellow Shield Orange
-Signal Red -Signal Black
-Sense Not Used -Sense Red
-Excitation Black -Excitation Blue
*Instrument cable color code based on METTLER TOLEDO cable number 510624370

Table 3-1: Analog Junction Box Wiring Codes

A
U
X

I
N
P
U
T

+
E
X
E

+
S
I
G

S
H
L
D

-
S
I
G

-
E
X
E

+
E
X
E

+
S
I
G

S
H
L
D

-
S
I
G

-
E
X
E

+
E
X
E

+
S
I
G

S
H
L
D

-
S
I
G

-
E
X
E

+
E
X
E

+
S
I
G

S
H
L
D

-
S
I
G

-
E
X
E

LC2
LC1
LC4
LC3
ANALOG JBOX
A/N 13640300A
+EXE
+SEN
+SIG
SHLD
-SIG
-SEN
+EXE
+SEN
+SIG
SHLD
-SIG
-SEN
Individual Load Cell Trimming
Potentiometer
NOTE: Turn all potentiometers fully
clockwise prior to calibration.
To LC2
To Indicator
To LC1
NOTE: Do not cut load cell cables.
Cutting a cable will affect compensation
and void the warranty.
(9/04) 3-3
METTLER TOLEDO 0990 Monorail Overhead Track Scale Installation and Service Manual

RAAD Mode
A Model 0990 monorail scale can be used with a RAAD junction box for summing load
cell outputs. A JAGUAR or JAGXTREME indicator must be used with the RAAD
junction box. The indicator serves as the host for the RAAD junction box, allowing you to
use the indicators keypad to adjust scale parameters. See Figure 3-4 and Table 3-2 for
cable connections. Load cell wiring for RAAD mode is the same as for analog mode.
Load cells are numbered as indicated in Figure 3-1.


WARNING!
DO NOT USE THE RAAD JUNCTION BOX IN LOCATIONS
CLASSIFIED AS HAZARDOUS BY THE NATIONAL
ELECTRICAL CODE (NEC) ARTICLE 500.
















ON 1 2 3 4 5
W1 W2 W3 W4
TB1 TB3 TB4 TB6 TB2 TB5
SW
#3 #4 #2 #1
+VA +VC +VB +VA
NOTE: A DigiTOL POWERCELL card
must be installed in the JAGUAR or
JAGXTREME indicator.
NOTE: If more than one junction box is
used, connect the junction boxes in a
daisy chain. Connect Terminal TB5 on the
first junction box to Terminal TB2 on the
next junction box in the series.
The addresses of the DigiTOL cards in the
second RAAD box must be reset to the
factory settings and then re-addressed to
the correct load cell number.
Switch Positions (SW)
SW1: On if Load Cell 1 is used
SW2: On if Load Cell 2 is used
SW3: On if Load Cell 3 is used
SW4: On if Load Cell 4 is used
SW5: On if last J-box in series
To Cell 2 To Jaguar To 2nd J-Box To Cell 4 To Cell 3 To Cell 1
NOTE: For 2 mV/V load cells, jumpers
W1, W2, W3, and W4 must be ON
(shorting the pins).
C
O
M

A

C
O
M

B

G
N
D

G
N
D

G
N
D

+
V
C

+
V
B

+
V
A

C
O
M

A

C
O
M

B

G
N
D

G
N
D

G
N
D

+
V
C

+
V
B

+
V
A

-
E
X
C

-
S
I
G

S
H
L
D

+
S
I
G

+
E
X
C

-
E
X
C

-
S
I
G

S
H
L
D

+
S
I
G

+
E
X
C

-
E
X
C

-
S
I
G

S
H
L
D

+
S
I
G

+
E
X
C

-
E
X
C

-
S
I
G

S
H
L
D

+
S
I
G

+
E
X
C

Figure 3-4: RAAD Junction Box Detail

RAAD TB2 Terminal Function Jaguar Terminal
1 +20 VDC (+VA) 8
2 +20 VDC (+VB) 7
3 +20 VDC (+VC) 6
4 Ground 5
5 Ground 4
6 Ground 3
7 COM B 2
8 COM A 1
Table 3-2: RAAD Junction Box Wiring
(9/04) 3-4
Chapter 3: Installation
Modes of Operation

IDNet Mode
The IDNet junction box can output an IDNet data format compatible with METTLER
TOLEDO IDNet weight displays. See Figure 3-5 and Table 3-3 for cable connections. For
detailed information about the indicator capabilities and operating instructions, refer to
the appropriate service manual. Load cells are numbered as indicated in Figure 3-1.


WARNING!
DO NOT USE THE IDNet JUNCTION BOX IN LOCATIONS
CLASSIFIED AS HAZARDOUS BY THE NATIONAL
ELECTRICAL CODE (NEC) ARTICLE 500.





















Terminal
Cell + Exc.
Green
- Exc.
Black
+ Sig.
White
- Sig.
Red
#1 4 4 9 9
#2 3 3 8 8
#3 2 2 7 7
#4 1 1 6 6
ST2
ST3
P P8 7
P1 P2
SA1
8
7
6
5
4
3
2
1
1
2
3
4
5
7
-
S
I
G


+
S
I
G

8
9
-
E
X
C





+
E
X
C

-
S
E
N


+
S
E
N

W3
LC1
LC2
LC4
LC3
6
W2 W5
W1
Figure 3-5: IDNet Junction Box Detail and Wiring

(9/04) 3-5
METTLER TOLEDO 0990 Monorail Overhead Track Scale Installation and Service Manual

Jumper Status Description
W1 Closed (ON) Matching the gain at 2 mV/V load cells
W2 Closed (ON) No external sensing (-SEN)
W3 Closed (ON) No external sensing (+SEN)
W4 Closed (ON) Internal reference voltage = 3.5 Volts
W5 Open (OFF) Excitation voltage for load cells = 4.0 Volts
W6 Closed (ON) Internal supply voltage = 7.1 Volts
W7 2-3 Protocol IDNet
W8 1-2 Interface 20 mA
W9 Open (OFF) Supply voltage IDNet
SA1 Closed (ON) Trim potentiometers circuit disabled
NOTE: For 2 mV/V load cells, jumpers
W1, W2, W3, and W4 must be ON
(shorting the pins).
Table 3-3: IDNet Default Factory Settings


Home Run Cable
Connection
Cord Grip Cap
Nut
Spherical Washer
Junction Box
Enclosure
Home Run Cable
Rubber Grommet
Body Insert


Figure 3-6: Cord Connection Details

Connect the home run cable from the scale indicator to the junction box (refer to Figure
3-6):
1. Wire the home run cable to the PCB according to Figure 3-3 for Analog, Figure 3-4
for RAAD, or Figure 3-5 for IDNet.
2. Place the desiccant bag inside the junction box.
3. Reinstall the junction box lid. Make sure that the rubber gasket is clean and
correctly positioned. Tighten all screws and make sure all cord grip caps are
secure.

(9/04) 3-6
Chapter 4: Calibration
General


4 Calibration


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.

Calibrate the scale according to the procedure described in the manual for the scale
indicator. The scale should be calibrated using certified test weights that can be traced
to the National Institute of Standards and Technology (NIST).


Analog Junction Box
Hang the test weight from the scale, using the type of hanger/trolley that will be used to
convey product across the scale. The test weight should equal or exceed the largest
load that will be weighed on the scale (minimum of 50% of scale capacity).
1. Remove the cover from the junction box and turn the load cell trim potentiometers
fully clockwise.
2. Apply power to the indicator and calibrate the scale.
3. Span the scale by placing the weight in the center of the live rail.
4. After initial calibration is complete, place the test weight alternately at each end of
the live rail. Record the weight reading at each position.
5. Place the weight at the end of the live rail at which the highest weight reading was
recorded. Turn the corresponding trim potentiometer counterclockwise until the
reading agrees with the reading recorded at the other end of the live rail.
6. Repeat Steps 4 and 5 until the readings at both ends of the live rail are equal.
7. Recheck the calibration. If the span is off, adjust the span using the procedure
described in the indicator manual.
8. Place a desiccant bag inside the junction box and reinstall the cover.
(9/04) 4-1
METTLER TOLEDO 0990 Monorail Overhead Track Scale Installation and Service Manual


RAAD Junction Box
Perform the shift adjust procedure at the indicator, with the indicator in Setup mode. For
shift adjustment instructions, refer to the indicator manual.


IDNet Junction Box
Perform the shift adjust procedure using the load cell trim potentiometers mounted on
the PCB inside the IDNet junction box (see Figure 4-1).
















-
S
I
G


+
S
I
G

1
2
3
4
5
7
8
9
-
E
X
C





+
E
X
C

-
S
E
N


+
S
E
N

W3
LC1
LC2
LC4
LC3
ST2
ST3
P7 P8
P1 P2
SA1
8
7
6
5
4
3
2
1
6
W2 W5
W1
LC4
LC3
LC2
LC1
Potentiometer Pair LC1
Potentiometer Pair LC4
Potentiometer Pair LC3
Potentiometer Pair LC2
Hook Switches
Figure 4-1: IDNet Potentiometer Adjustment

1. Place the test weight alternately at each end of the live rail. Record the weight
reading at each position. If the readings are within the desired tolerance, no shift
adjustment is needed. Otherwise, perform Steps 2 to 4.
2. Activate the trim potentiometers by opening the eight hook switches (if they are not
already open) on the PCB (see Figure 4-1). Once activated, the switches remain
open. Do not close the switches, even after completing the shift adjustment.
3. Place the test weight at the end of the live rail at which the highest weight reading
was recorded. Turn the corresponding trim potentiometers (each load cell has two)
counterclockwise to decrease the reading (clockwise increases the reading).
4. Check the weight readings again, with the test weight positioned at each end of the
live rail. Repeat Step 3 until the readings at both locations are the same or within
the specified scale tolerances.
5. Make sure all cable connectors and cord grip caps are tight. Then place a
desiccant bag in the box, leave all hook switches open, and reinstall the junction
box lid.
(9/04) 4-2
Chapter 5: Routine Care and Maintenance
General


5 Routine Care and Maintenance


General
Once the scale has been installed, have an authorized METTLER TOLEDO representative
inspect and calibrate it periodically. If the scale is used for legal-for-trade purposes,
consult the local weights and measures authorities for minimum inspection
requirements. Contact your local authorized METTLER TOLEDO service representative for
information about periodic inspection and calibration services.


Site Inspection
Make sure that the scale site remains in good condition. Check for alterations in the
surrounding rail support, excessive vibrations, and possible overloading conditions.


Scale Inspection
During periodic inspections of the scale, check the following:
1. Are there any unusual wear points, paths, or marks on the live or approach rails?
2. Is the monorail scale attached securely to the superstructure?
3. Is the junction box lid properly sealed and are all cable connectors tight?
4. Is there any moisture or foreign material around or inside the junction box?
5. Is the instrument cable damaged or binding the scale?
6. Is there any debris or material build-up under or around the live rail that could
prevent it from moving freely?
7. Are all screws and load support pins torqued according to the specifications in
Chapter 3?

WARNING
FAILURE TO TORQUE MOUNTING SCREWS TO THE CORRECT SPECIFICATIONS
COULD RESULT IN BODILY HARM OR PROPERTY DAMAGE.

8. Are there signs of unusual wear on the load cells, live and approach rails, or
suspension components (bearing rings, etc.)?
9. Check repeatability and shift of the scale.
(9/04) 5-1
Chapter 6: Troubleshooting
General


6 Troubleshooting


General
If the scale does not operate properly, find out as much about the problem as possible.
Try to determine whether the problem is constant or intermittent. Mechanical and
electrical influences can cause malfunctions, so be patient and use sound logic when
troubleshooting.
When troubleshooting a Model 0990 monorail scale, examine the scales physical
location. Check for the presence of water, corrosive materials, binding at the live rail,
high vibrations, air currents, or physical damage to the live rail or approach rails. Also
check the instrument cable for damage, and check all connections for loose or improper
wiring.
WARNING
PERMIT ONLY QUALIFIED PERSONNEL TO SERVICE THIS
EQUIPMENT. EXERCISE CARE WHEN MAKING CHECKS,
TESTS, AND ADJUSTMENTS THAT MUST BE MADE WITH
POWER ON. FAILING TO OBSERVE THESE PRECAUTIONS
CAN RESULT IN BODILY HARM.

CAUTION
BEFORE CONNECTING/DISCONNECTING ANY INTERNAL ELECTRONIC
COMPONENTS OR INTERCONNECTING WIRING BETWEEN ELECTRONIC
EQUIPMENT, ALWAYS REMOVE POWER AND WAIT AT LEAST THIRTY (30)
SECONDS. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN
BODILY HARM OR DAMAGE TO OR DESTRUCTION OF THE EQUIPMENT.

(9/04) 6-1
METTLER TOLEDO 0990 Monorail Overhead Track Scale Installation and Service Manual


Isolate the Problem
Determine whether the problem is in the scale or the indicator.
1. Remove power from the system, and then disconnect the indicator from the scale.
2. Connect the indicator to a load cell simulator (analog simulator available from
METTLER TOLEDO).
3. Reapply power and test the indicator. If the problem persists, consult the indicator
manual for further troubleshooting assistance.
4. If the problem is NOT present with the load cell simulator attached to the indicator,
remove power, disconnect the simulator, and reconnect the scale. If the problem
persists, continue troubleshooting the scale.


Check Wiring
1. Remove power from the system.
2. Remove the lid from the junction box and check the interior for moisture and foreign
material.
3. Make sure that all wiring connections are tight and that no insulation material is
touching the terminal contacts.
4. Check all cable connections to make sure they are wired correctly. The wiring color
codes are given in Table 6-1:
Load Cell Wiring Instrument Cable Wiring*
Function Color Function Color
+Excitation Green +Excitation White
+Sense Not Used +Sense Yellow
+Signal White +Signal Green
Shield Yellow Shield Orange
-Signal Red -Signal Black
-Sense Not Used -Sense Red
-Excitation Black -Excitation Blue
*Instrument cable color code based on METTLER TOLEDO cable no. 510624370
Table 6-1: Load Cell Wiring Color Codes
5. Check all cable connectors and cord grip caps on the junction box.
6. Tighten any loose connectors.
(9/04) 6-2
Chapter 6: Troubleshooting
Check Load Cells


Check Load Cells
1. Remove power from the system. Fully disconnect each load cell and check for
proper input/output resistances (see Table 6-2).
Measuring Points Resistance
Any lead to shield or ground Infinity
+Exc (Green) to -Exc (Black) 350 ohms minimum
+Sig (White) to -Sig (Red) 348 to 352 ohms
Table 6-2: Load Cell Measuring Points
2. If resistance is within specification, perform a shorted-signal symmetry test.
Short the signal leads together and place one multimeter lead on the shorted
signals and one lead on the +Excitation wire. Note the resistance value.
Remove the lead from the +Excitation wire and place it on the -Excitation wire.
The two resistance values should be approximately equal.
3. If the load cells pass the shorted-signal test, reconnect them and reapply power to
the scale. Confirm that the proper excitation voltage is reaching the load cells by
placing multimeter leads on the excitation positions of each load cell terminal.
4. If proper excitation voltage is reaching the load cells, check the output signal from
each cell by disconnecting the signal leads and measuring voltage output. If one
cell has a particularly high or low dead-load output, it is suspect. The maximum
output possible from any cell is 30 mV at 15 VDC excitation and loaded to gross
capacity.
5. If any load cell has an unusual signal, remove all load from that cell by raising the
platform.
With the power on, measure the output from the suspect load cell. The no-load
zero output should be 1.0% of the full scale output. For example, if the
excitation voltage is 15 VDC, then the full scale output would be 30 mV and
the no-load zero output should be within 0.3 mV.
NOTE: Remove signal leads
from terminals to measure
output.
6. If a load cell fails any of the above tests, replace it.

(9/04) 6-3
METTLER TOLEDO 0990 Monorail Overhead Track Scale Installation and Service Manual


Check Mechanical
Components
Because the design of the 0990 monorail scale is so simple, there are only a few
mechanical components to troubleshoot. Make sure that the live rail can move freely
and is not touching the approach rails. If the live rail is touching the approach rails,
check the following:
1. Check the ends of the live rail and its suspension components for unusual wear.
Replace any worn or damaged components.
2. Make sure that the load cells are positioned correctly. If not, loosen the mounting
screws, position the load cells correctly, and then tighten the mounting screws.
3. Check the approach rail fasteners for proper torque (see Chapter 3 for torque
specifications).


Load Cell Replacement
1. Remove power to the indicator and disconnect the instrument cable.
2. Make sure that the live rail and approach rails are empty.
3. Disconnect the load cell cable from the terminal strip inside the junction box.
Loosen the cord grip connector and pull the load cell cable out of the junction box.
4. Remove the load cell mounting screws and the defective load cell.
5. Place the new load cell in position and secure it with the mounting screws. Torque
the mounting screws to 100 ft-lb for carbon steel scales or 75 ft-lb for stainless
steel scales.
6. Wire the replacement load cell cable to the proper terminal strip in the junction box.
Be sure to tighten the cord grip connector around the load cell cable.
7. Attach the live rail to the load cells, using the load support pins and hardware.
Make sure that there is 1/16 inch clearance between the live rail and approach
rails. Torque the load support pins to 200 ft-lb.
8. Check the calibration and shift adjustment with a certified test weight. Make any
adjustments as required.

WARNING
FAILURE TO TORQUE MOUNTING SCREWS TO THE CORRECT SPECIFICATIONS
COULD RESULT IN BODILY HARM OR PROPERTY DAMAGE.

(9/04) 6-4
Chapter 7: Service Parts
0990 Monorail Scale


7 Service Parts


0990 Monorail Scale
Refer to Figure 7-1 and Table 7-1 when ordering parts for a current 0990 monorail
scale.

(9/04) 7-1
METTLER TOLEDO 0990 Monorail Overhead Track Scale Installation and Service Manual


2
11


Figure 7-1: 0990 Monorail Scale Assembly

1
1
3
11
12
4
5
9
2
3
7
8
7
11
15
14
7
6
13
10
(9/04) 7-2
Chapter 7: Service Parts
0990 Monorail Scale

Ref. No. Part Number Description Qty.
1 TB600489-2
TB600490-2
Model 757 Load Cell, 1,250 lb (30-foot cable)
Model 757 Load Cell, 2,500 lb (30-foot cable)
2
2 TN800647
TN800648
1/2-13 Socket Head Cap Screw x 1.75 inches long, Black Oxide
1/2-13 Socket Head Cap Screw x 1.75 inches long, Stainless Steel
12
3 TN400056-10
TN400057-10
Support Block, Carbon Steel
Support Block, Stainless Steel
2
4 TA400048-10
TA400041-10
TA400053-10
TA400058-10
Base Weldment, Carbon Steel (for 2-foot rail)
Base Weldment, Stainless Steel (for 2-foot rail)
Base Weldment, Carbon Steel (for 4-foot rail)
Base Weldment, Stainless Steel (for 4-foot rail)
1
5 TN400046-10
TN400039-10
Departure Rail, Mild Steel (2 feet long)
Departure Rail, Stainless Steel (2 feet long)
1
6 TN400045-10
TN400038-10
Approach Rail, Mild Steel (2 feet long)
Approach Rail, Stainless Steel (2 feet long)
1
7 MZ0901010464 1/2-13 Flat Head Socket Screw x 1 inch (required for 2-foot live rail)
1/2-13 Flat Head Socket Screw x 1 inch (required for 4-foot live rail)
11
15
8 TA400047-10
TA400040-10
TA400055-10
TA400042-10
Live Rail, Mild Steel (2 feet long)
Live Rail, Stainless Steel (2 feet long)
Live Rail, Mild Steel (4 feet long)
Live Rail, Stainless Steel (4 feet long)
1
9 TA400043-10
TA400036-10
TA400054-10
TA400035-10
Backing Bar, Mild Steel (2 feet long)
Backing Bar, Stainless Steel (2 feet long)
Backing Bar, Mild Steel (4 feet long)
Backing Bar, Stainless Steel (4 feet long)
1
10 TN400034 Load Support Pin 2
11 TN400052 Neoprene Spacer 6
12 TN400050 Load Pin Ring Bearing 2
13 TN400049 Sleeve Bearing 2
14 TN400051 Sleeve Bushing 2
15 TN800595 Capacity Label 2
-- TB100391 Analog Junction Box Assembly
Consists of: *13640300A Analog PCB (*May have a letter prefix)
TA800218 Desiccant Bag
1
Table 7-1: 0990 Monorail Scale Assembly
(9/04) 7-3
Chapter 8: Reference Material
Reference Drawings


8 Reference Material


Reference Drawings

Scale Material Assembly Drawing
0990 Carbon Steel TB400060
0990 Stainless Steel TB400059



Recommended Spare
Parts
For part numbers, refer to the service parts list (Chapter 7).

Quantity Description
1 Load cell (capacity of cell required depends on scale capacity)
1 Junction box circuit board
1 Junction box desiccant bag


(9/04) 8-1

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