Vertex 2158 Analog User manual

2158 Analog
2160 DigiTOL
2162 IDNet
VertexFloor Scales
Service Manual
A14691400A
(11/96)

©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.

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

METTLER TOLEDO Publication Problem Report
If you find a problem with our documentation, please complete and fax this form to [phone]
Publication Name:
Publication Part Number: Publication Date:
PROBLEM(S) TYPE: DESCRIBE PROBLEM(S): INTERNAL USE ONLY
oTechnical Accuracy oText oIllustration
oCompleteness oProcedure/step oIllustration oDefinition oInfo. in manual
What information is oExample oGuideline oFeature
missing? oExplanation oOther (please explain below)
oInfo. not in
manual
oClarity
What is not clear?
oSequence
What is not in the right
order?
oOther Comments
Use another sheet for
additional comments.
Your Name: Location:
Phone Number: ( )
Mettler-Toledo, Inc. Printed in U.S.A. 14981600A
Fax this completed form to MarCom at [phone]

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
2158, 2160, and 2162 VERTEX®Scales
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 Models 2158, 2160, and 2162 VERTEX® 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.

INTRODUCTION
This publication is provided as a guide for the trained technician for installing, calibrating,
and servicing the 2158, 2160, and 2162 VERTEX®. Repair or adjustment by unauthorized
persons voids the METTLER TOLEDO®warranty.
Information regarding your nearest METTLER TOLEDO Distributor, Sales, and Service
location, please contact: METTLER TOLEDO
6600 Huntley Road
Columbus, Ohio 43229-1012
ph: [phone]
Information regarding METTLER TOLEDO Technical Training may be obtained by writing,
calling, or faxing to: METTLER TOLEDO
1150 Dearborn Drive
Worthington, Ohio 43085-6712
ph: [phone]
fax: [phone]
WARNING!
This equipment generates, uses, and can radiate radio frequency energy and if not installed and
used properly, i.e., in accordance with the instructions manual, may cause harmful interference
to radio communications. It has been tested and found to comply with the limits for a Class A
computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide
reasonable protection against such interference when operated in a commercial environment.
Operation of this equipment in a residential area is likely to cause interference which case the
user at his own expense will be required to take whatever measures may be required to correct
the interference.
METTLER TOLEDO RESERVES THE RIGHT TO MAKE REFINEMENTS OR
CHANGES WITHOUT NOTICE.

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 installing,
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.

CONTENTS
Chapter 1: Specifications....................................................................................1-1
Power Supply Requirements .......................................................................................1-1
Accuracy....................................................................................................................1-1
Load Cells.................................................................................................................1-2
End Loading...............................................................................................................1-3
Platform Assembly.....................................................................................................1-3
Support Frames..........................................................................................................1-4
Chapter 2: Inspection and Site Selection .............................................................2-1
Inspection..................................................................................................................2-1
Site Selection............................................................................................................2-1
Chapter 3: Installation (Top-of-Floor)
Locate.......................................................................................................................3-1
Remove Platform .......................................................................................................3-1
Anchor Frame ............................................................................................................3-1
Route/Attach Instrument Cable....................................................................................3-3
Junction Box Wiring...................................................................................................3-4
Modes of Operation....................................................................................................3-5
Reinstall Platform....................................................................................................3-11
Chapter 4: Optional Ramp Installation .................................................................4-1
Chapter 5: Optional Scale Guard Installation........................................................5-1
Chapter 6: Optional Forklift Frame Installation .....................................................6-1
Chapter 7: Quick-Pit Installation (In-Floor) ..........................................................7-1
Chapter 8: Calibration ........................................................................................8-1
Shift Adjust................................................................................................................8-1
Scale Calibration.......................................................................................................8-3
Chapter 9: Routine Care and Maintenance...........................................................9-1
General.....................................................................................................................9-1
Site Inspection...........................................................................................................9-1
Platform Inspection....................................................................................................9-1
Chapter 10: Troubleshooting.............................................................................10-1

General....................................................................................................................10-1
Isolate the Problem ..................................................................................................10-2
Check Wiring............................................................................................................10-2
Check Load Cells......................................................................................................10-3
Check Mechanical Components.................................................................................10-4
Load Cell Replacement Procedure .............................................................................10-4
Chapter 11: Service Parts................................................................................. 11-1
Chapter 12: Reference Material........................................................................ 12-1
Reference Drawings..................................................................................................12-1
Recommended Spare Parts .......................................................................................12-1
Load Cell Data..........................................................................................................12-1

Chapter 1: Specifications
Power Supply Requirements
(11/96)
1-1
1 Specifications
Power Supply
Requirements Load cell power supply is provided by the Mettler Toledo Digital
Indicator.
Accuracy Models 2158, and 2160 Vertex floor scales meet or exceed the National
Institute of Standards and Technology (NIST) Handbook 44
requirements for Class III scales. Standard Vertex scales meet 5000
division accuracy, a certificate of conformance, No. 91-097 (2158), and
94-010 (2160) were issued under the National Type Evaluation Program
(NTEP) of the National Conference of Weights and Measures. The
Model 2162 Vertex floor scale has not been submitted for approval.
Applied Weight Allowable Error
0 - 500 Divisions
501 - 2000 Divisions
2001 - 4000 Divisions
4001 - 10,000 Divisions
± 1/2 Division
± 1 Division
± 1-1/2 Divisions
± 2-1/2 Divisions
NIST - 44 Acceptance Tolerances
+3.0
+2.5
+2.0
+1.5
+1.0
+0.5
0
-0.5
-1.0
-1.5
-2.0
-2.5
-3.0
500d 2000d 4000d 10,000d
Number
of
Divisions
Figure
1
-a: Class III Weighing Tolerances

METTLER TOLEDO 2158/2160/2162 Vertex Floor Scales Service Manual
(11/96)
1-2
Applied Weight Allowable Error
0 - 500 Divisions
501 - 2000 Divisions
2001 - 10000 Divisions
± 1/2 Division
± 1 Division
± 1-1/2 Divisions
Load Cells Stainless steel cantilever beam load cells are provided in all 2158, 2160,
and 2162 Vertex floor scales with integral 4-conductor, shielded, color
coded cable (See note). All load cells 2,500 lb and less have a built-in
overload stop to prevent damage due to accidental overloads. The load
cell suspension utilizes a rocker pin inserted between the cell and a fixed
receiver in the frame (see Figure 1-c). Individual load cell capacities
used in the Models 2158, 2160, and 2162 include:
Scale Platform Capacity of Each Minimum Approved
Capacity Load Cell Graduation Size
(lb) (lb) (lb)
1000 500 0.2
2500 1250 0.5
5000 2500 1.0
10000 5000 2.0
20000 10000 5.0
Figure
1-b
: OIML Weighing Tolerances (Model 2158 only)
OIML Tolerance Chart
+2.5
+2.0
+1.5
+1.0
+0.5
0
-0.5
-1.0
-1.5
-2.0
-2.5
500d 2000d 4000d 10,000d
Number
of
Divisions
Note: Scales 4’ x 6’ and smaller use
7.5’ long cables. Scales larger than 4’
x 6’ and all 20k capacity scales use
15’ long cables. Do Not mix cables of
different lengths within a platform.

Chapter 1: Specifications
End Loading
(11/96)
1-3
End Loading
Models 2158, 2160, and 2162 may be loaded up to 100% of the
platform's full rated capacity or two times the individual load cell rating
(whichever is less) across any end of the scale.
Platform Assembly
Vertex scales utilize a single channel reinforced platform design with
removable plate to access the junction box assembly. Standard mild steel
units have a safety tread plate deck surface. Stainless steel scales utilize
a platform structure very similar to the mild steel unit. Standard
stainless steel units have a smooth deck surface with a glass bead blast
finish. Threaded holes are provided in all platform structures for lifting
eyebolts to ease platform installation and removal.
Bumper Gap 0.12
Platform
Frame
Lower Receiver O-Ring
Rocker Pin
Load Cell Load Cell Mounting Screws
Figure 1-c: Load Cell/ Suspension Details

METTLER TOLEDO 2158/2160/2162 Vertex Floor Scales Service Manual
(11/96)
1-4
Support Frames
“Standard”
Above-Floor Frame Standard Vertex platforms utilize a formed angle frame with all sides
turned under the scale for a fully captured assembly (see Figure 1-d).
Vertex scales are primarily used for top-of-floor installations and can be
used with optional ramps with access to all four sides of the scale. In
addition, optional scale guards can be mounted around the perimeter of
the standard frame to provide protection in high-traffic areas. Standard
Vertex frames may be used for in-floor applications, however, a Quick-
Pit frame is recommended.
Vertex Scale PlatformVertex Scale Frame
Floor Line
Figure 1-d: Vertex Frame

Chapter 1: Specifications
Support Frames
(11/96)
1-5
"Quick-Pit" In-Floor Frame The Quick-Pit frame option provides a unitized scale assembly
eliminating the need for additional pit coping when in-floor installations
are required. The upper flange of the rugged C-channel frame acts as the
pit coping around the perimeter of the weigh platform.
• Pits are correct depth
• Pits are always square
• No field assembly or welding of coping
• Ease of construction, no pit forming required
• Ability to move the scale in the future
Forklift Channel Frame The Forklift Channel frame is used when scale portability is required.
The rugged C-channel construction and fork blade guides ensure safe
lifting and transport.
Truck Dock Frame The Truck Dock frame option offers maximum scale protection in high-
traffic above-floor applications. The heavy duty C-channel frame is
compatible with all standard ramps to allow access to any side of the
scale.
Vertex Scale
Vertex Quick Pit Frame
3/8” Typical
Floor
Figure 1-e: Quick Pit Frame
Floor
Frame Support
Leg
Fork Blade Guides
Figure 1-f: Forklift Channel Frame

METTLER TOLEDO 2158/2160/2162 Vertex Floor Scales Service Manual
(11/96)
1-6
Access Ramps Access ramps are available for all styles of 2158, 2160, and 2162 Vertex
floor scales. Vertex ramps can accommodate single or multi-directional
traffic. Ramps are available in 36" or 60” lengths by the width of the
scale. The maximum ramp angles are:
Capacity Ramp Length Ramp Angle
1k-5k 36" 4.4°
1k-5k 60" 2.6°
10k 36" 4.9°
20k 36” 5.9°

Chapter 2: Inspection and Site Selection
Inspection
(11/96)
2-1
2 Inspection and Site Selection
Inspection Upon delivery of the 2158, 2160, or 2162 Vertex scale, visually inspect
the scale for any damage which may have occurred during shipment and
handling. Inspect the following areas:
1. Frame assembly for any warpage or bent angles
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:
1. Is the area level to within 1/ 4" from the highest to the lowest
corner?
2. Is the floor/support at each corner of the scale area able to
maintain support throughout the entire weighing capacity of the
scale?
3. Is there proper drainage away from the scale area?
4. Are there any heavy vibrations or wind currents present at or near
the scale?
5. Will the scale be subjected to excessive or unusual loading due to
the location or type of equipment used? If the site passes, proceed
with installation. If not, choose a new location or select another
scale.

Chapter 3: Installation (Top-of-Floor)
Locate
(11/96)
3-1
3 Installation (Top-of-Floor)
Locate Place the 2158, 2160, or 2162 Vertex in the desired location after
inspecting the site per Chapter 2 of this manual.
Remove Platform Remove scale platform from the frame by using lifting eye bolts in the
holes provided in the deck (a quantity of two 3/4"-10 UNC eye bolts
required). Ensure that the eye bolts are snug and fully threaded into the
deck before lifting.
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 provided with each Vertex
scale for securing frame to floor. The 1/2" anchors themselves 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 (Part
No. 58-030025) or fabricated using Figure 3-b as a guide.
Secure the frame to the floor using the eight flat head anchor bolts
provided.

METTLER TOLEDO 2158/2160/2162 Vertex Floor Scales Service Manual
(11/96)
3-2
Frame
(2) Countersunk Holes for
1/2” Flat Head Screws
Typical Each Corner
Fixed Receiver
Figure 3-a: Frame Corner Detail (top view)
1.25”
6.88”
6.25”
1.25”
1.19”
45°
1.19”
6.25”
6.88”
1.88”
(2) 1.06 Dia. Holes
Figure 3-b: Leveling Shim Detail

Chapter 3: Installation (Top-of-Floor)
Route/Attach Instrument Cable
(11/96)
3-3
Route/Attach
Instrument Cable Remove the junction box access cover plate from platform.
A loose coil of instrument cable is located inside the platform channel, on
either side of the J-Box assembly.
Thread the instrument cable through the hole provided in the scale frame
and platform, continuing through the inside of the platform channel,
stopping at the junction box (see Figure 3-c).
Scale Platform
Frame
Instrument Cable Access Hole
(Typical two holes per corner)
Conduit
Quick-Pit
Top of Floor
Ramp
Top of Floor
Frame
Alternate instrument cable
access hole in ramp application Ramp Attachment Hole
Vertex (with ramp)
Scale Platform
Instrument Cable Access Hole
(Typical two holes per corner)
Vertex (without ramp)
Frame
Ramp Attachment Hole
Top of Floor
Instrument Cable
Figure 3-c: Instrument Cable Access Locations

METTLER TOLEDO 2158/2160/2162 Vertex Floor Scales Service Manual
(11/96)
3-4
Remove the junction box lid. Loosen the instrument cable connector,
thread the cable through the connector (pull enough cable to reach the
“input” terminal), reinstall and tighten (see Figure 3-e).
Junction Box Wiring
Wire the instrument cable to the terminal marked "INPUT" for model
2158 and 2160 (see pages 3-5 through 3-8 ).
Place desiccant bag inside junction box.
Reinstall junction box lid. Make sure that the rubber gasket is clean and
correctly located. Tighten all screws and check that all cord grip caps
are tight.
Reinstall the platform access plate.
In-Correct
Load
Cell
Correct
Load
Cell
Figure 3-d: Cable Incorrect and Correct
Cord Grip Cap
Nut
Spherical Washer Junction Box Enclosure
Instrument Cable
Rubber Grommet
Body Insert
Figure 3-e: Cord Connector Details