Mettler Electronics DECKMATE 2888 Manual

2888
DECKMATE®
Floor Scale
Installation and
Service Manual
14859700A
10/96

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ii
©Mettler-Toledo, Inc. 1996
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.

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PROPRIETARY NOTICE
The information contained in this publication is derived in part from proprietary and patented data of Mettler Toledo.
This publication shall not be copied in whole or in part without prior written approval of Mettler Toledo, nor shall it be
used for any purpose other than that intended. This document is subject to change without notice.
STANDARD WARRANTY: Model 2888 Deckmate®
Mettler Toledo warrants that the equipment covered by this warranty will be free from defects in workmanship and
materials for a period of two years from date of installation or twenty six (26) 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 replacements 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 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. For 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 technician’s 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 2888 Deckmate ® floor scale understructure. Refer to Mettler Toledo Standard
Product Warranty for coverage of other scale system components including scale instrument, printer, and/or other
accessories.
THE COMPANY EXPRESSLY WARRANTS THE EQUIPMENT MANUFACTURED BY IT AS SET FORTH
HEREIN. THE COMPANY MAKES NO OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED (INCLUDING
WITHOUT LIMITATION WARRANTIES AS TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE). IN ADDITION, THIS DOCUMENT SHALL CONSTITUTE THE SOLE AND EXCLUSIVE REMEDIES
OF THE BUYER FOR ANY BREACH BY THE COMPANY OF ITS WARRANTIES HEREIN.
COMPANY LIABILITY UNDER THIS WARRANTY OR ANOTHER WARRANTY WHETHER EXPRESSED OR
IMPLIED IN LAW OR FACT SHALL BE LIMITED TO THE REPAIR OR REPLACEMENT OF DEFECTIVE
MATERIAL AND WORKMANSHIP, AND IN NO EVENT SHALL IT BE LIABLE FOR CONSEQUENTIAL OR
INDIRECT DAMAGES.
This warranty coverage is only applicable to the United States of America. Consult Mettler Toledo for Export Warranty
Terms and Conditions.
APPLICATION GUIDES
The only warranty of Mettler Toledo is for the product it supplies under the Product Warranty Statement listed above.
Weighing application guidelines pertain to Mettler Toledo products.

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Declaration of conformity
Konformitätserklärung
Déclaration de conformité
Declaración de Conformidad
Verklaring de overeenstemming
Dichiarazione di conformitá
We/Wir/Nous/WIJ/Noi: Mettler-Toledo, Inc.
1150 Dearborn Drive
Worthington, Ohio 43085
USA
declare under our sole responsibility that the product,
erklären, in alleiniger Verantwortung, daß dieses Produkt,
déclarons sous notre seule responsabilité que le produit,
declaramos, bajo nuestra sola responsabilidad, que el producto,
verklaren onder onze verantwoordelijkheid, dat het product,
dichiariamo sotto nostra unica responsabilitá, che il prodotto,
Type: Analog Load Cells
Models: 744 and 745 (when used within the technical requirements listed in Test certificate TC2154 and installed as a Load
receptor as listed in Type approval certificate T2206, Table 4.)
to which this declaration relates is in conformity with the following standard(s) or other normative document(s).
auf das sich diese Erklärung bezieht, mitder/den folgenden Norm(en) oder Richtlinie(n) übereinstimmt.
Auquel se réfère cette déclaration est conforme à la (aux) norme(s) ou au(x) document(s) normatif(s).
Al que se refiere esta declaración es conforme a la(s) norma(s) u otro(s) documento(s) normativo(s).
Waarnaar deze verklaring verwijst, aan de volende norm(en) of richtlijn(en) beantwoordt.
A cui si riferisce questa dichiarazione è conforme alla/e sequente/i norma/e o documento/i normativo/i.
CE Conformity / CE-Konformität / Conformité CE
90/384/EU Nonautomatic Balances and Scales / Nichteselbsttätige Waagen / Balances à Functionnement non automatique
Article 1.2.a.
Other Directives and Standards / Andere Richtlinien und Normen / Autres documents
corresponding to local requirements / entsprechend lokalen Anforderungen / correspondant aux exigences locales
R60 OIML International Recommendation , Metrological regulation for load cells
EEx ib IIC T4 el. Safety / el. Sicherheit / s‚curit‚el. (PTB Nr. Ex-95.D.2051)
Darrell Flocken, Manager - Weights & Measures
Office of Weights and Measures
Worthington, Ohio USA
September, 1996 according to EN45014

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INTRODUCTION
This publication is provided as a guide for the trained technician for installing, calibrating,
and servicing the 2888 Deckmate. Repair or adjustment by unauthorized persons voids the
METTLER TOLEDO warranty.
For information regarding your METTLER TOLEDO distributor, Sales, and Service
location, please contact: METTLER TOLEDO
6600 Huntley Road
Columbus, Ohio 43229
[phone]
ORDERING INFORMATION
It is most important that the correct part number is used when ordering parts. Parts orders are
machine processed, using only the part number and quantity as shown on the order. Orders are not
edited to determine if the part number and description agree.
METTLER TOLEDO RESERVES THE RIGHT TO MAKE REFINEMENTS OR
CHANGES WITHOUT NOTICE.

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PRECAUTIONS WARNING
ONLY PERMIT QUALIFIED PERSONNEL TO
SERVICE THIS EQUIPMENT. EXERCISE
CARE WHEN MAKING CHECKS, TESTS AND
ADJUSTMENTS THAT MUST BE MADE WITH
POWER ON. FAILING TO OBSERVE THESE
PRECAUTIONS CAN RESULT IN BODILY
HARM.
WARNING
FOR CONTINUED PROTECTION AGAINST
SHOCK HAZARD CONNECT TO PROPERLY
GROUNDED OUTLET ONLY.
DO NOT REMOVE THE GROUND PRONG.
WARNING
DISCONNECT ALL POWER TO THIS UNIT
BEFORE REMOVING THE FUSE OR
SERVICING.
CAUTION
BEFORE CONNECTING/DISCONNECTING ANY INTERNAL
ELECTRONIC COMPONENTS OR INTERCONNECTING WIRING
BETWEEN ELECTRONIC EQUIPMENT ALWAYS REMOVE POWER
AND WAIT AT LEAST THIRTY (30) SECONDS BEFORE ANY
CONNECTIONS OR DISCONNECTIONS ARE MADE. FAILURE TO
OBSERVE THESE PRECAUTIONS COULD RESULT IN DAMAGE TO
OR DESTRUCTION OF THE EQUIPMENT OR BODILY HARM.
CAUTION
OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC
SENSITIVE DEVICES.
READ this manual BEFORE
operating or servicing this
equipment.
FOLLOW these instructions
carefully.
SAVE this manual for future
reference.
DO NOT allow untrained
personnel to operate, clean,
inspect, maintain, service, or
tamper with this equipment.
ALWAYS DISCONNECT
this equipment from the
power source before cleaning
or performing maintenance.
CALL METTLER TOLEDO
for parts, information, and
service.

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CONTENTS
Chapter 1: Specifications
General Description ...................................................................................................................... 1-1
Power Supply Requirements........................................................................................................ 1-1
Accuracy........................................................................................................................................ 1-1
Model / Ram Numbers.................................................................................................................. 1-2
Load Cells...................................................................................................................................... 1-3
Platform Assembly........................................................................................................................ 1-4
Support Frames............................................................................................................................. 1-5
Portable Assembly........................................................................................................................ 1-6
Access Ramps............................................................................................................................... 1-7
Chapter 2: Inspection and Site Selection
Inspection...................................................................................................................................... 2-1
Site Selection................................................................................................................................. 2-1
Chapter 3: Installation
Locate............................................................................................................................................ 3-1
Remove Platform.......................................................................................................................... 3-1
Anchor Frame................................................................................................................................ 3-1
Junction Box Wiring..................................................................................................................... 3-3
Reinstall Platform.......................................................................................................................... 3-4
Mode of Operation........................................................................................................................ 3-4
Chapter 4: Optional Ramp Installation
Chapter 5: Calibration
Shift Adjust.................................................................................................................................... 5-1
Scale Calibration........................................................................................................................... 5-2
Chapter 6: Routine Care and Maintenance
General.......................................................................................................................................... 6-1
Site Inspection............................................................................................................................... 6-1
Platform Inspection....................................................................................................................... 6-1

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Chapter 7: Troubleshooting
General....................................................................................................................................................7-1
Isolate the Problem ................................................................................................................................7-1
Check Wiring...........................................................................................................................................7-2
Check Load Cells....................................................................................................................................7-2
Check Mechanical Components............................................................................................................7-3
Load Cell Replacement Procedure........................................................................................................7-4
Chapter 8: Service Parts
Load Cell and Suspension Parts............................................................................................................8-1
Static Platform Parts...............................................................................................................................8-2
Portable Scale Parts................................................................................................................................8-3
Chapter 9: Reference Material
Reference Drawings................................................................................................................................9-1
Recommended Spare Parts....................................................................................................................9-1
Load Cell Data.........................................................................................................................................9-1

Chapter 1: Specifications
General Description
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1-1
1 Specifications
General Description The model 2888 Deckmate ® floor scale is a fully electronic low profile
floor scale suited for top-of-floor drum weighing application.
Specifications include:
• Platform Size— 30 in. x 30 in. x 1.31 in. (76.2 cm x 76.2 cm x 3.3
cm) deck with “ live” side rails
• Gross Capacity—1,000 lb (500 kg)
• 4 Load Cells—500 lb each
• End Loading — 1,000 lb (500 kg)
• Standard Support Frame or Portable Assembly
Power Supply
Requirements Load cell power supply is provided by the Mettler Toledo Digital
Indicator.
Accuracy
Model 2888 Deckmate floor scales meet or exceed the National
Institute of Standards and Technology (NIST) Handbook 44
requirements for Class III 5000 divisions.

METTLER TOLEDO 2888 Deckmate Floor Scales Installation and Service Manual
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Model /Ram
Numbers
Model Standard Platform 30 In x 30 In (76.2 Cm X 76.2 Cm), 1,000 Capacity Shipping Weight (lb)
2888002001 Mild Steel Tread Plate Deck. 125
2888012001 Mild Steel Smooth Plate Deck 125
2888022001 Stainless Steel Tread Plate Deck 125
2888032001 Stainless Steel Smooth Plate Deck 125
Model Portable Assembly 30 in x 30 in (76.2 cm x 76.2 cm), 1,000 Capacity Shipping Weight (lb)
2888 P02001 Mild Steel Tread Plate Deck. 325
2888 P12001 Mild Steel Smooth Plate Deck 325
2888 P22001 Stainless Steel Tread Plate Deck 325
2888 P32001 Stainless Steel Smooth Plate Deck 325

Chapter 1: Specifications
Load Cells
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1-3
Load Cells
Four 500 lb Stainless Steel Hermetically Sealed Load Cells are provided
in all 2888 Deckmate platforms, which allow for a 100 % end
loading (loading across either end of the scale) of 1,000 lb / 500 kg.
Each cell is complete with an integral 4-conductor, shielded, color coded
cable and attached to a stainless steel junction box. The load cell
suspension utilizes a stainless steel rocker pin between the cell and a fixed
receiver in the frame (see Figure 1-a).
BUMPER GAP
OVERLOAD GAP
LOAD CELL
MOUNTING BOLTS
ROCKER PIN
Figure 1-a: Load Cell Suspension Detail

METTLER TOLEDO 2888 Deckmate Floor Scales Installation and Service Manual
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1-4
Platform Assembly
Deckmate scales utilize a channel reinforced deck with “live” side
rails design, which provides mounting for the four load cells, protection
for the load cell cables, and mounting for the junction box. The platform
is available in mild steel or stainless steel with either tread or smooth plate
deck. The stainless steel platform with smooth plate deck has a glass bead
blast finish (see Figure 1-b).
Figure 1-b: Platform Assembly
DECK
DATA PLATE
JUNCTION BOX LOAD CELL -- TYPICAL
EACH CORNER
SIDE RAILS

Chapter 1: Specifications
Support Frames
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1-5
Support Frames
“Standard Platform”Standard Deckmate platforms utilize a support frame under the platform
for maintaining position of the platform. (see Figure 1-c). The model
2888 platforms are used for top-of-floor installations and can be used
with optional ramps for access to one or both ends of the platform (see
Figure 1-c).
MOUNTING HOLES
TYPICAL EACH CORNER
RAMP MOUNTING BAR
AT BOTH ENDS OF SCALE
ROCKER PIN RECEIVER
TYPICAL EACH CORNER
BUMPER BRACKET
( 2) EACH CORNER
Figure
1-c
: Support Frame

METTLER TOLEDO 2888 Deckmate Floor Scales Installation and Service Manual
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1-6
Portable Assembly
The support frame for the portable assembly provides support for the
2888 platform and the ability to easily move the platform from one
weighing location to another. (see Figure 1-d).
SCALE DECK
30 in (76.2 cm) x 30 in (76.2 cm)
INDICATOR MOUNTING
BRACKET
HANDLE
BATTERY PACK
MOUNTING BRACKET
INDICATOR COLUMN
RAMP ( 0PTIONAL)
PORTABLE FRAME
SWIVEL CASTER
EACH CORNER
4.38 in (11.12 cm) ---- WEIGHING HEIGHT
5.75 in (14.60 cm) ---- TRANSPORT HEIGHT
46.12 in
(117.14 cm)
33.62 in
85.40 cm
BUBBLE LEVEL
1.31 in (3.33 cm) toTop of Deck ----WEIGHING HEIGHT
Figure 1-d: Portable Platform

Chapter 1: Specifications
Access Ramps
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1-7
Access Ramps Mild Steel and Stainless Steel access ramps are available for the model
2888 floor scales. The access ramps will provide access to the scale deck
from one or both ends of the platform. The ramps for the static scale
platform are attached to a mounting bar located at the ends of the
platform. The ramps for portable assembly are hinged to allow the ramps
to fold up over the deck when moving the platform.
Model
Number Standard Platform Ramp 30 In (76.2 Cm) Ramp Width Ramp Angle Shipping Weight (Lb)
88-110001 6 in (152 mm) Lg. Mild Steel Tread Plate 11.6° 15
88-110002 6 in (152 mm) Lg. Mild Steel Smooth Plate 11.6° 15
88-110003 12 in (305 mm) Lg. Mild Steel Tread Plate 5.8° 25
88-110004 12 in (305 mm) Lg. Mild Steel Smooth Plate 5.8° 25
88-110101 6 in (152 mm) Lg. Stainless Steel Tread Plate 11.6° 15
88-110102 6 in (152 mm) Lg. Stainless Steel Smooth Plate 11.6° 15
88-110103 12 in (305 mm) Lg. Stainless Steel Tread Plate 5.8° 25
88-110104 12 in (305 mm) Lg. Stainless Steel Smooth Plate 5.8° 25
Model
Number Portable Assembly Ramp 30 In (76.2 Cm) Hinged Ramp Width Ramp Angle Shipping Weight (Lb)
88-130001 12 in (305 mm) Lg. Mild Steel Tread Plate 5.8° 25
88-130002 12 in (305 mm) Lg. Mild Steel Smooth Plate 5.8° 25
88-130003 18 in (457 mm) Lg. Mild Steel Tread Plate 3.8° 30
88-130004 18 in (457 mm) Lg. Mild Steel Smooth Plate 3.8° 30
88-130101 12 in (305 mm) Lg. Stainless Steel Tread Plate 5.8° 25
88-130102 12 in (305 mm) Lg. Stainless Steel Smooth Plate 5.8° 25
88-130103 18 in (457 mm) Lg. Stainless Steel Tread Plate 3.8° 30
88-130104 18 in (457 mm) Lg. Stainless Steel Smooth Plate 3.8° 30

Chapter 2: Inspection and Site Selection
Inspection
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2-1
2 Inspection and Site Selection
Inspection Upon delivery of the 2888 DECKMATE, visually inspect the scale for
any damage which may have occurred during shipment and handling.
Inspect the following areas:
1. Platform assembly for any damage
2. Load cell and suspension assemblies
3. Load cell cables
4. Load cell summing junction box
5. Overall platform assembly
If any damage is noted, contact your freight carrier immediately.
Site Selection Many problems associated with floor scale installations are caused by
improper site conditions. Before installing the scale, check the proposed
location for the following conditions:
• Is the floor or support at the location of the scale level?
• Is the floor/support at each corner of the scale area able to maintain
support throughout the entire weighing capacity of the scale?
• Is there proper drainage away from the scale area?
• Are there any heavy vibrations or wind currents present at or near the
scale?

Chapter 3: Installation
Locate
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3-1
3 Installation
Locate Place the 2888 Deckmate in the desired location after inspecting the site
per Chapter 2 of this manual.
Remove Platform Remove scale platform from the frame by lifting the platform straight up
from the frame.
Anchor Frame Locate the anchor holes in all four corners of the frame. There are a total
of 8 anchor holes (2 per corner). (see Figure 3-a).
Drill the anchor holes using the frame as a guide. Eight 1/2"-13 UNC x
1-1/2" long flat head socket cap screws are required to secure the frame
to floor. The 1/2" anchors and 1/2-13 flat head screws are to be
provided by others or can be purchased from Mettler Toledo. Drill
anchor holes to a diameter and depth per the supplier's instructions.
All corners of the frame must be in contact with the floor and be level
within plus or minus 1/16". If the scale is out-of-level or gaps exist
between the frame and floor, shimming is required.
Corner shims (1/16" thick) can be purchased from Mettler Toledo or
fabricated using Figure 3-b as a guide.

METTLER TOLEDO 2888 Deckmate Floor Scales Installation and Service Manual
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3-2
CORNER ANCHORING
HOLES
( 2 ) 1/2 -13 DROP IN ANCHORS
6.00 in
(152mm)
2.75 in
(69.9 mm)
1.62 in
(41.1mm)
( 2 ) .75 in (19.0 mm)
DIA. HOLE
5.62 in
(142.7 mm)
2.00 in
(50.8 mm)
2.75 in
(69.8 mm)
Figure 3-a
: Frame Anchoring - Typical Each Corner
Figure 3-b: Leveling Shim Detail

Chapter 3: Installation
Junction Box Wiring
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3-3
Junction Box
Wiring Remove the junction box cover plate from the top of the side rail of the
platform. Thread the instrument cable through the connector on the end
of the junction box and terminate the cable to the terminals provided (see
figure 3-c). After terminating cable check all connections and place
desiccant bag inside junction box. Reinstall junction box cover. Make
sure the rubber gasket is clean and correctly located. Tighten all screws
and check that all cord grip caps are tight.
Load Cell Wiring Instrument Cable Wiring
Function Color Function Color
+ Excitation Green + Excitation White
+ Sense Yellow
+ Signal White + Signal Green
Shield Yellow Shield Orange
– Signal Red – Signal Black
– Sense Red
– Excitation Black – Excitation Blue
(Based on Mettler Toledo
cable number 510624370)
LC 2 LC 4
LC1 LC3
Load Cell Orientation
(Top View of Platform)
J Box Cover
to LC 2
to LC 1
to LC 4
to LC 3
to INDICATOR
Individual Load Cell
Trimming Potentiometer
LC 1 LC 2 LC 3 LC 4
- SIG
+ SIG
- SEN
- EXC
+ SEN
+ EXC
SHLD
- SIG
+ SIG
- EXC
+EXC
SHLD
Figure 3-c: 2888 Analog Junction Box Details and Wiring Codes
Note: Turn all potentiometers fully
clockwise prior to calibration.

METTLER TOLEDO 2888 Deckmate Floor Scales Installation and Service Manual
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3-4
Reinstall Platform
Clear all debris from the scale area. Ensure that all four load pin
receivers in the frame are clean and free of all foreign material.
Replace the platform into the frame. Make sure there is slack in the
cable between the frame and platform and that no cable pinching occurs.
Oscillate the platform to ensure that the rocker load pins are seated in the
receivers and no binding exists.
Calibrate the scale per the Mettler Toledo Indicator Manual.
Mode of Operation
The model 2888 uses an analog junction box for summing the load cell
outputs. Only analog compatible indicators will work with the model
2888. The correct cable connection can be seen in Figure 3-c.