POWERCELL® PDX®

Installation Manual
Load Cell
 Congratulations on choosing the quality and precision of METTLER TOLEDO. Proper use
Service XXL

according to these instructions and regular calibration and maintenance by our factory-
trained service team ensure dependable and accurate operation to protect your investment.
Contact us about a ServiceXXL agreement tailored to your needs and budget.

We invite you to register your product at

www.mt.com/productregistration

so we can contact you about enhancements, updates and important notifications concerning
your METTLER TOLEDO contact.

2 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 Precautions

READ this manual BEFORE WARNING

operating or servicing this
equipment. 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.
FOLLOW these instructions
carefully.

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

DO NOT allow untrained

personnel to operate, clean,
WARNING
inspect, maintain, service, DISCONNECT ALL POWER TO THIS UNIT BEFORE INSTALLING,
or tamper with this equip- SERVICING, CLEANING, OR REMOVING THE FUSE. FAIL-
ment. URE TO DO SO COULD RESULT IN BODILY HARM AND/OR
PROPERTY DAMAGE.

ALWAYS DISCONNECT this

equipment from the power
WARNING
source before cleaning or BEFORE CONNECTING/DISCONNECTING ANY INTERNAL ELECTRONIC COMPONENTS
performing maintenance. 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.
CALL METTLER TOLEDO
for parts, information, and
service.
CAUTION
OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC
SENSITIVE DEVICES.

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 3
Security Advices

CAUTION
DANGER OF BODILY HARM OR PROPERTY DAMAGE!
• When a module is being moved, do not place your fingers or other body
parts between the module and any other surface.

• If it is necessary to place your hands under a module during installation,
make sure that the module is properly blocked so that it cannot move.

CAUTION
FOR SAFTY REASONS DO NOT REPLACE MORE THAN ONE LOAD CELL AT A TIME.

CAUTION
POOR CONTACTS:
• Keep all electrical parts absolutely dry on the inside and as dry as possible
on the outside.

• If the cable ends will be exposed to the weather for a long period (not
connected to the load cell), apply dielectric compound, cover the cable
ends with plastic, and secure the open end with duct tape.

CAUTION
RISK OF COMMUNICATION FAILURES DUE TO EXPOSED STRANDS OF WIRES
• Make sure that no stray conductors are left unsecured. Exposed strands of
wires can lead to communication failures if they bridge the connection in
the terminal block.

Disposal of Electrical
and Electronic Equipment
In conformance with the European Directive 2002/96 EC on Waste Electrical and Electronic Equipment
(WEEE) this device may not be disposed of in domestic waste. This also applies to countries outside
the EU, per their specific requirements.

Please dispose of this product in accordance with local regulations at the collecting point specified for
electrical and electronic equipment.

If you have any questions, please contact the responsible authority or the distributor from which you
purchased this device.

Should this device be passed on to other parties (for private or professional use), the content of this
regulation must also be related.

Thank you for your contribution to environmental protection.

4 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 Contents

1 Introduction...................................................................................... 6
1.1 General............................................................................................. 6

2 Components..................................................................................... 7
2.1 Introduction....................................................................................... 7
2.2 Receiver Variant 1 “Standard”.............................................................. 8
2.3 Dimensions....................................................................................... 9
2.4 Receiver Variant 2 “Retrofit”............................................................... 10
2.5 Dimensions..................................................................................... 11
2.5 Cables............................................................................................ 12

3 Installation..................................................................................... 13
3.1 Foundation Requirements................................................................. 13
3.2 Positioning Base Plates.................................................................... 13
3.3 Installing Locating Pins.................................................................... 14
3.4 Installing Lower Receivers................................................................. 14
3.5 Installing Upper Receivers................................................................. 16
3.6 Inserting Locating Tools.................................................................... 16
3.7 Installing Scale Modules................................................................... 17
3.8 Removing Locating Tools.................................................................. 18
3.9 Installing Load Cells......................................................................... 18
3.10 Cabling........................................................................................... 20
3.11 Shimming....................................................................................... 22
3.12 Installation Summary....................................................................... 25

4 Service Parts.................................................................................. 26
4.1 Item Numbers.................................................................................. 26
4.2 MTMS Part Numbers......................................................................... 28

5 Specifications................................................................................ 30
5.1 General........................................................................................... 30

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 5
 1 Introduction
Introduction

1.1 General

The POWERCELL® PDX® load cell provides unequalled accuracy and reli-
ability. This innovative load cell builds on the success of the industry-leading
POWERCELL brand, which is operating reliably in every corner of the world.
Its weighing performance is kept stable through “in-cell” measurement and
correction of errors caused by weather, low voltage, and radio and telephone
interference. The POWERCELL PDX load cell has the unique advantage of
proactively recognizing and reporting potential weighing errors and problems
before they lead to under-reported income, overload fines, and complaints
from customers or suppliers. By resisting lightning damage up to 80,000
amperes, the load cell provides 24/7 operation and reduces your mainte-
nance budget and unnecessary out-of-pocket expenses. Cables resist water,
lightning, and rodents, and, if they are damaged, they can be replaced
without recalibrating the scale.
This manual explains the preferred procedure for installing POWERCELL PDX
load cells in a scale.

Figure 1-1: POWERCELL PDX Load Cell

6 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 2 Components

2.1 Introduction

All POWERCELL PDX load cell components are made of high-quality material
and are designed and tested to function for a long time. They include the
following features:

• Rugged enclosure for protection from the environment (mud, stones,

water, ice, etc.).

• Thick heavy-duty boots to prevent buildup of stones, dirt, snow, and

ice.

• Super heavy-duty cables to eliminate electromagnetic interference and

rodent damage. Cables can be replaced without recalibration.

• Larger load cell buttons to increase the service life.

• Two connectors for operation without junction boxes.

Figure 2-1: POWERCELL PDX Load Cell Components

Depending on the region and related logistics, the components will arrive
within the scale shipment or as a separate package.

METTLER TOLEDO offers two types of receivers for the POWERCELL PDX
load cell: Standard and Retrofit. The selection of components depends on
the receiver type.

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 7
 2.2 Receiver Variant 1 “Standard”
Components

The “standard” receiver is a new design. It combines the strength of our

previous receivers with easy installation and maintenance.

This solution requires three threaded holes (M12 x 1.75) in the base plate
for the locating pins. The force from the scale is introduced through the top
surface of the upper receiver. Shims can be added only under the lower
receiver or under the base plate.

2.2.1 Assembly

Upper receiver with O-ring

Item # 61043499

POWERCELL PDX load cell

(includes rubber boot)
30 ton: Item # 42904883
50 ton: Item # 42904891

Rubber boot
Item # 42904785

Lower receiver
Item # 61043498

Shims
1/4” (6 mm): Item # 61043489
1/8” (3 mm): Item # 61043490
1/16” (1.5 mm): Item # 61043491

Locating pins
Item # 61043497

Base plate
By others

Figure 2-2: Assembly for Receiver Variant 1 “Standard”

8 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 2.2.2 Dimensions

Top receiver plate (cross section)

The thickness of the top receiver plate
depends on the scale design.

Ø 69.85-mm hole required for receiver.

Depth = 13 mm

Load cell stack-up (cross section)

Dimension without shims.

Height from top surface of the base plate

to the bottom surface of the top receiver
plate = 177.6 mm.

Overall height = 190.6 mm

Maximum Ø = 109.6 mm (load cell)

Base plate (top view)

Size and thickness depends on the
foundation design and stability.

3 x M12x1.75 threaded holes required

for locating pins.
Minimum depth = 13 mm
(120° separation)

Figure 2-3: Dimensions for Receiver Variant 1 “Standard”

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 9
 2.3 Receiver Variant 2 “Retrofit”
Components

The “retrofit” receivers are designed to make POWERCELL PDX load cells
compatible with scales that are built for use with POWERCELL 760 or MTX
load cells (designs using a 69.85-mm-diameter hole). The receivers are
not compatible with other POWERCELL load cells that use smaller-diameter
receivers.

This solution requires holes in the base plate for the lower receiver (Ø 69.85 mm)
and a roll pin (Ø 12.7 mm). The force from the scale is introduced through
the shoulders of both upper and lower receivers. Shims can be added under
both the upper and lower receivers, but not to exceed 9 mm at either receiver.
If additional shimming is necessary, shim under the base plate(s).

2.3.1 Assembly

Shims
0.06” (1.5 mm): Item # 68000301
0.12” (3 mm): Item # 68000554
0.18” (4.5 mm): Item # 61024613

Upper retrofit receiver with O-ring

Item # 61043569

POWERCELL PDX load cell

(includes rubber boot)
30 ton: Item # 42904883
50 ton: Item # 42904891

Rubber boot
Item # 42904785

Lower retrofit receiver

Item # 61043571

Shims
0.06” (1.5 mm): Item # 68000301
0.12” (3 mm): Item # 68000554
0.18” (4.5 mm): Item # 61024613

Locating pin
Item # 72207803

Base plate
By others

Figure 2-4: Assembly for Receiver Variant 2 “Retrofit”

10 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 2.3.2 Dimensions

Top receiver plate (cross section)

The thickness of the top receiver plate
depends on the scale design.

Ø 69.85-mm hole required for receiver.

With chamfer = 3.5 mm x 45°
Minimum depth = 25 mm

Load cell stack-up (cross section)

Dimension without shims.

Height from top surface of the base plate to

the bottom surface of the top receiver plate
= 207.9 mm.

Overall height = 251.5 mm

Maximum Ø = 109.6 mm (load cell)

Base plate (top view)

Size and thickness depends on the foun-
dation design and stability.

Ø 69.85-mm hole required for receiver.

With chamfer = 3.5 mm x 45°
Minimum depth = 25 mm

Ø 12.7-mm hole required for locating pin.

Minimum depth = 20 mm

Figure 2-5: Dimensions for Receiver Variant 2 “Retrofit”

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 11
 2.4 Cables
Components

The POWERCELL® PDX® network is designed to minimize cable length and

promote easy installation. No junction boxes are needed. POWERCELL PDX
load cell cables are installed using quick-connect connectors, which produce
an audible “click” when installed properly. Because each POWERCELL PDX
load cell has two interface ports, the host terminal can be connected to the
most conveniently accessible load cell in the network, and the “daisy chain”
starts at that load cell. Each load cell is cabled to the next, until the last load
cell in the network is connected. The cables can be connected to either port
on the load cells. A termination connector and protective boot are secured to
the last port of the last load cell to complete the chain. Corrosion-resistant,
glass-to-metal connectors ensure a good cell-to-cell connection and resist
environmental elements. The METTLER TOLEDO IND780 terminal can sup-
port a network with as many as 24 nodes (with an auxiliary power supply).
With the IND780 terminal, these load cells can be parsed into four logically
independent platforms.

Always refer to drawing TC100884x when installing a POWERCELL PDX

load cell system. The “x” in the drawing number is a place holder for the
revision number. The latest copy of this drawing is available from METTLER
TOLEDO.

Home run cable

Termination connector

Cell-to-cell cables

Figure 2-6: POWERCELL PDX Load Cell Network

NOTE: The cables that are required depend on the length and width of the
scale and the position of conduits.

Recommended and minimum bend radii for these cables:

• Recommended: 4” (10 cm).

• Minimum: 2” (5 cm).

12 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 3 Installation

Installation Procedure

METTLER TOLEDO recommends the following procedure for installing

POWERCELL PDX load cells. Some installation steps can vary slightly
depending on the scale design. It is the technician’s responsibility to install
the load cells correctly.
METTLER TOLEDO has achieved the best results by positioning the whole
scale before anchoring the base plates to the foundation. That procedure,
which requires using locating tools, is described in this chapter.
A summary of the essential installation steps is provided at the end of this
chapter.

3.1 Foundation Requirements

All base plates for the load cells must be level and in the same plane for
accurate and repeatable weighing. Shims can be added under the receivers to
level the scale. METTLER TOLEDO recommends that the top of the foundation
at the base plate locations be level and in one plane (within ± 3 mm).

Snap a chalk line on the foundation to mark the location of each side of the
scale from approach coping to approach coping.

• These chalk lines will be used to align the modules as they are set in
place.
• Check the distance between the approach copings against the
foundation drawing to ensure that there is sufficient room for the scale.
• Check the diagonal measurements to ensure that the foundation is
square. If the foundation is not square, it could prevent you from
installing the scale or cause weighing errors after the scale is
installed. Refer foundation problems to the customer or customer’s
contractor for correction.

3.2 Positioning Base Plates

Roughly position the base plates on the foundation at the chalk lines. Refer
to the scale’s general layout drawing for the correct position of the load cell
axes.

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 13
 3.3 Installing Locating Pins
Installation

Variant 1 “Standard”
Install three locating pins (socket-head pins) in each base plate.
• Grease the threads of the pins with Loctite® 242® threadlocker.
• Insert the M12x1.75 threaded ends into the base plate.
• Firmly tighten the pins with a 6-mm “Allen” or hex-head wrench.

Variant 2 “Retrofit”
Install a roll pin in each base plate.
• Insert the tapered end first.
• Tap the pin with a small hammer until it is completely vertical.
• Do not hammer the pin completely into/through the base plate hole
until the receiver has been installed.

Variant 1 Variant 2

Figure 3-1: Locating Pin Installation

3.4 Installing Lower Receivers

Variant 1 “Standard”
Place one lower receiver on each base plate, aligning the holes with the
locating pins.
• Make sure there are no stones or debris between the receiver and base
plate

Variant 2 “Retrofit”
Use anti-seize compound to grease the lower receivers and insert one into
each of the base plates, aligning the notch with the roll pin.
• Make sure that all receivers are snug in the base plate by visually
inspecting for a gap. If you find a gap, place a piece of hard wood
above the receiver and gently hammer it until the receiver is seated
properly.

Figure 3-2: Lower Receiver (Variant 2)

14 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 3.4.1 Measuring and Shimming

Shims are used to balance (or equalize) the scale mechanically, removing
any inconsistencies in the level of the foundation or scale.
Use a transit to check the elevation of the receiver at each base plate loca-
tion.
• Make sure that all receivers are at the same height and the scale will not
be above or below the horizontal plane formed by the approaches. To
check this accurately, rest the measuring rod on the top surface of the
receiver at each base plate location.
• Use a spirit level to verify that all base plates are level in both planes.
• If the plates are not level, grind the concrete (below the base plate in
the locations where the plates are too high) and/or add shims until the
plates are level in both directions.
• Do not exceed the following shimming thickness at the lower receivers:
Variant 1 “standard” = maximum 12 mm (bottom receiver only)
Variant 2 “retrofit” = maximum 18 mm (split between the top and bot-
tom receivers)
If you need to shim more than these amounts, shim between the base
plate and foundation.
Notes:
• When shimming, always ensure that the top of the scale and the approach
are in the same plane to ± 4 mm.
• The scale should be shimmed as closely as possible to the correct height
in order to achieve the best repeatability and accuracy. Shimming to
within 1 mm saves time during calibration because it ensures that the
scale load is well distributed across all the load cells.

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 15
 3.5 Installing Upper Receivers
Installation

Use anti-seize compound to grease the upper (top) receivers and insert a
receiver into each load cell receiver plate on the scale.
• The large O-ring on the receiver will hold it in place. Make sure the
receiver is inserted correctly by verifying that it is not tilted.
• The receiver should rest firmly on the receiver block. If it does not,
make sure that it is not skewed and then gently tap the receiver into
place with a block of wood and a hammer.

3.6 Inserting Locating Tools

METTLER TOLEDO recommends using locating tools because this is the most
accurate method of positioning the scale and base plates. It ensures that
the load cells are positioned vertically and reduces installation time. Other
methods, such as adjusting by sight or by spirit level, generally deliver poor
results because they do not guarantee that the load cells will be correct in
all axes.

Variant 1 “Standard”
Insert a locating tool into each lower receiver. Check for proper seating by
looking for a gap in the receiver shoulder and the base plate.

Variant 2 “Retrofit”
Insert a locating tool into each lower receiver, aligning the notch with the
locating pin. Check for proper seating.

Variant 1 Variant 2

Figure 3-3: Locating Tools

NOTE: The locating tools for receiver variant 2 are slightly longer than the
POWERCELL PDX load cells with receivers. This will cause the deck of the
scale to be higher when the scale is installed for positioning the base plates
(described in the next step).

16 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 3.7 Installing Scale Modules

CAUTION
DANGER OF BODILY HARM OR PROPERTY DAMAGE!
• When a module is being moved, do not place your fingers or other body
parts between the module and any other surface.
• If it is necessary to place your hands under a module during installation,
make sure that the module is properly blocked so that it cannot move.

The installation procedure of the scale depends on the scale design. Refer
to the scale’s installation manual for the recommended method of placing
and coupling the scale modules.
1. Slowly lower the module onto the locating tools, lowering the approach
end first.
2. Check the module’s alignment with the chalk line snapped on the foun-
dation.
3. Inspect the locating tools to make sure they are seated properly. If there
is a gap between the shoulder and the receiver, use a large hammer to
tap the side of the base plate (on the side with the gap) until the locating
tool seats firmly. You will hear a definite “crash” sound when it seats.
4. Test all positions. When you are satisfied that all base plates are aligned
properly, proceed to the next step.

Strike Here

Figure 3-4: Adjusting the Locating Tool

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 17
 3.8 Removing Locating Tools
Installation

CAUTION
FOR SAFTY REASONS DO NOT REPLACE MORE THAN ONE LOAD CELL AT A TIME.

Remove a locating tool and replace it with a load cell, using the procedure
described in the following two steps. Repeat the procedure until all load cells
have been installed.
1. Jack up the module and remove the locating tool.
2. Fill the lower receiver with multi-purpose grease (item # 68004326,
included with the load cell kit).
3. If you need to adjust the height of the deck, add or remove shims at
this time. Do not exceed the following recommended maximum
shimming at a load cell or the receiver could become dislodged:
12 mm for Variant 1 (do not place any shims at the upper receiver)
18 mm for Variant 2 (do not place more than 9 mm of shims at the
upper or lower receiver)
NOTE: If additional shimming is needed, place shims between the founda-
tion and the base plate. This type of shim must be sourced locally; it is not
supplied with the scale.
Final shimming should be determined by viewing each load cell’s output after
addressing the load cells, but before calibrating the scale.

3.9 Installing Load Cells

METTLER TOLEDO recommends positioning the load cells with the serial
numbers in sequence so that the lowest number is installed at the first loca-
tion and the highest number at the final location (see Figure 3-5).

Load Cell with 1 3 5 7

Lowest Serial
Number
Termination Connector

2 4 6 8 Load Cell with

Highest Serial
Home Run Cable Number
(to Scale Terminal)

Figure 3-5: Cable Routing for POWERCELL PDX Load Cell Network

18 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 1. Apply multi-purpose grease to the load surface of the cell buttons at the
top and bottom of the POWERCELL PDX load cell.
2. Place the hex end of the load cell into the lower receiver, ensuring that
that the two hex surfaces mate.
3. Make sure the cable connectors point toward the outside of the scale and
are oriented 30° out and away for the best cable routing.
4. Make sure the hex surface of the load cell is aligned properly with the hex
surface of the lower receiver. To check alignment, rotate the load cell with
your hand. The load cell should rotate freely several degrees.
5. Gently lower the module onto the load cell, ensuring that the top end of
the load cell is seated inside the receiver socket.
NOTE: To keep the load cell connectors clean, leave the caps on the con-
nectors until you are ready to install the cables.

Grease

Figure 3-6: Installing the Load Cell

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 19
 3.10 Cabling
Installation

CAUTION
POOR CONTACTS:
• Keep all electrical parts absolutely dry on the inside and as dry as possible
on the outside.

• If the cable ends will be exposed to the weather for a long period (not
connected to the load cell), apply dielectric compound, cover the cable
ends with plastic, and secure the open end with duct tape.

3.10.1 General Information

• Determine how the cabling will be routed. The load cell in the most
convenient position can take the home run cable input. A daisy-chain
network must be created from this point with a terminating connector
on the last load cell.
• Route the cables through conduits to connect the daisy chain.
• Secure the cables to the modules with wire ties so the cables are off
the ground.

Dress the cables to form a drip loop at a point before the cables connect to
the load cells.
• Water collecting on a cable will travel along the cable to its lowest point
before reaching connectors or seals.
• It is important that the load cell cable allows the load cell to move freely.
The drip connection should behave like a spring.
• A straight connection (no drip loop) could cause premature cable failure
by putting excessive pulling-stress on the cable end.

Figure 3-7: Dressing the Load Cell Cables

20 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 3.10.2 Connecting the Home Run Cable

1. Connect the home run cable to the POWERCELL PDX load cell as
described in the procedure for connecting load cell cables.
2. Connect the home run cable to the terminal as described in the terminal’s
manual.
Notes:
• See the wiring diagram for maximum home run cable length.
• Use only home run cables approved by METTLER TOLEDO (see Chapter
4 for available cable lengths).

CAUTION
RISK OF COMMUNICATION FAILURES DUE TO EXPOSED STRANDS OF WIRES
• Make sure that no stray conductors are left unsecured. Exposed strands of
wires can lead to communication failures if they bridge the connection in
the terminal block.

3.10.3 Connecting Load Cell Cables

POWERCELL PDX cables are not integrally attached to the load cells. This
allows easy replacement of a damaged cable or load cell (where permitted)
without the need for recalibration.
1. Inspect each load cell and cable connector.
• Dielectric compound is applied inside the load cell connector at
the factory. This compound provides an additional moisture
barrier for the contacts.
• Remove the transportation caps from the connectors on the load
cell and cable.
• Inspect both connectors to determine if they are free from foreign
material or dirt. Remove any foreign objects. Ensure that the pins
in the load cell are straight. The connector must be correctly and
completely seated so the gasket will seal out all moisture.

CAUTION
PROBLEMS WITH CONNECTING CABLES
• Do not apply dielectric compound to new load cells or cable connectors
(it is already applied at the factory).

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 21
 2. Connect the cable connector to the load cell.
Installation

• To secure the connection, press the connector inward and turn

the connector ring clockwise. There will be an audible click when
the connector is properly closed.
Tip: Simultaneously push in (toward the load cell) and twist the
connector to get it to seat/unseat properly.
• Do not use wrenches or pliers on the load cell or cables. If the
fit is correct and free of foreign material, you should be able
to assemble the connection easily by hand (insert the cable
connector and then twist the connector ring).
• The connector is keyed in the proper orientation. The key inside
the lower connector is positioned 180° opposite of the top
connector (see Figure 3-8).
• If your view is obstructed, twist the cable to feel the position of
the key. Once the key is aligned, the connector will slip in easily
(don’t force it).
• The two connectors on the POWERCELL PDX load cell are
interchangeable and can take either an incoming or outgoing
cable.

Notch

Notch

Top Connector Bottom Connector

Figure 3-8: Load Cell Cable Connectors

3. Push the rubber connector boot forward over the load cell connector to
protect the connector from dirt and ice.
• Make sure the connection is free of any foreign material except
the dielectric compound that has been applied by METTLER
TOLEDO.
• Leave enough slack in the cable so that the load cell can move
freely. If the cable is too tight, it can break when the scale moves.

3.11 Shimming

When all cables have been connected, address the load cells electronically
(according to the technical manual for a compatible scale terminal such as
IND560 or IND780). After addressing the load cells via the terminal, follow
the mechanical shimming procedure.
The shimming procedure used during installation should have provided the
optimal mechanical installation. Now it is possible to make small corrections
by verifying the output of each load cell.

NOTE: Do not electronically shift adjust the scale (load cells) until you are
sure you have mechanically shimmed all load cells according to the fol-
lowing steps.

22 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 3.11.1 Prerequisites

Before starting the shimming sequence, the following conditions must be

fulfilled:
• Each load cell is addressed in accordance to the terminal’s technical
manual.
• The load cells have warmed up for approximately 1/2 hour. That allows
the electronics to reach their optimal operating temperature. If the scale
has not warmed up sufficiently, you will notice some drift in the load
cell output.
• In the scale terminal, the values of the shift constant for each load cell
should be 1 (not adjusted). Failure to make sure that these values are
set to 1 will significantly lengthen the calibration time.
• During installation you should have shimmed the base plates so that the
scale is level with the approach. If the scale is still below the approach,
shim the receivers until the scale is the required height.
• Make sure that you know the proper location of each cell in your scale
and that cells 1, 2, 3, and 4 are supporting the first (or starting) module
of the scale.

Cell # 1 3 5 7 9
O O O O O
Approach First Module Middle Middle Terminal Approach
Ramp (4) Cells Module Module Module Ramp
O O O O O
Cell # 2 4 6 8 10
Section # (1) (2) (3) (4) (5)

Figure 3-9: Recommended Load Cell Numbering

3.11.2 Load Distribution

Due to the differences in weight loading, the pairs of cells under middle
modules will transmit double the weight of the pairs at the approach ends of
the scale. That is because cells 3 and 4 are carrying half the weight of both
the starter module and the middle module, while cells 1 and 2 are carrying
only half the weight of the starter module. The weight on cells 3 and 4 is
about double that on cells 1 and 2.
Ideally, the pairs of cells in a section should have the same load and cor-
responding output (for example, 1–2, 3–4, 5–6, etc.).
Both the 30t and 50t POWERCELL PDX load cells will transmit 0.1 kg
per count as their minimum value; however, the terminal will allow you to
decrease the sensitivity if you wish.

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 23
 3.11.3 Shimming Sequence
Installation

Each load cell in the section pair should see the same amount of weight.
Otherwise, the scale is not mechanically balanced and requires shimming.
Shimming should be done with test weights or a service vehicle to ensure
the best results.
Shimming to a lower percentage than the 20% mentioned below improves
calibration and scale performance.
Example: A typical 18-meter concrete weighbridge weighs about 33 tons. If
the bridge were evenly balanced, you would see 2750 kg on each of the end
load cells and 5500 kg on the middle cells. If you were to use a test mass
of 3 tons to perform a shift test, the end cells would increase their output to
5750 kg (2750 kg + 3000 kg) and the middle cells would increase their
output to 8500 kg (5500 kg + 3000 kg).

Ideal values with Cell 1 Cell 3 Cell 5 Cell 7

shift test load applied: 5750 8500 8500 5750

Cell 2 Cell 4 Cell 6 Cell 8

5750 8500 8500 5750

Observed values with
Cell 1 Cell 3 Cell 5 Cell 7
shift test load applied:
5000 8500 8500 5750

Cell 2 Cell 4 Cell 6 Cell 8

5900 8600 8500 5750

The difference between the highest and lowest observed values would be
3600 kg (8600 kg – 5000 kg). Twenty percent of the difference would
be 720 kg (3600 kg * 0.2). Cell 1 indicates the lowest amount of weight
because it is not being loaded as much as its peers, so it should be shimmed
until the weight indicates a higher value not to exceed 5720 kg (the actual
value of 5000 kg + the target shift value of 720 kg). Add mechanical shims
and retest this cell with the test load. You should notice that the load on cell
1 increased and the loads on cells 2, 3 and 4 may have decreased. Perform
this test again until the scale meets your desired condition.
If you didn’t reach your target value, jack up the module and add another
shim. If you exceeded your target value when shimming, replace the shim
that you used with the next thinner size.
NOTES:
• Remember that most of the time an uneven load is caused by an uneven
foundation. In some cases, the scale might also be uneven (more fre-
quently with concrete scales because they are stiffer).
• If you don’t mechanically shim the scale, you might experience problems
with repeatability and with calibration. Neither problem is related to the
load cells.
• Performing mechanical shimming will speed up calibration.

24 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 3.11.4 Calibration and Shift Adjustment

Instructions for programming and calibrating the scale terminal can be found
in the terminal’s manual. Capacity and increment size vary depending on
local law. Higher capacities and resolution are available on request.
NOTES:
• Both the 30t and 50t POWERCELL PDX load cells transmit 0.1 kg per
count (“d”).
• You will usually see double the indication on the middle load cells
because one load cell pair is supporting two modules.
• If you notice a change when driving in one direction and then in another,
you need to check that all your load cells have a value of 1 and then
repeat the shimming procedures.

3.12 Installation Summary

METTLER TOLEDO recommends using the installation procedure in this

chapter for POWERCELL PDX load cells. Some installation steps can vary
depending on the scale design.
The following steps are essential:
• Check foundation to ensure that base plate locations are level and in
one plane.
• Mark positions of base plates and place base plates on foundation (do
not attach them yet). If base plates are already attached to foundation,
make sure they are positioned correctly.
• Insert locating pins or roll pins into base plates.
• Grease lower receivers and set them into base plates. Check for proper
seating.
• Check elevation of lower receivers and add shims if necessary.
• Grease upper receivers and set them into the scale. Check for proper
seating.
• Apply load cell lubricant to top and bottom buttons of load cells.
• Position each load cell with its hex end in the lower receiver. Make sure
the cable connector points toward the outside of the scale.
• Gently lower the module onto the load cell. Make sure that the top end
of the load cell is seated inside the receiver socket.
• Connect all cables and ensure correct seating.
• Commission the electronics of scale according to technical manual.
• Add shims until the output of each load cell is within the required
range.
For programming and calibration, refer to the terminal’s manual.

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 25
 4 Service Parts
Service Parts

4.1 Item Numbers

Item Number Description Spare Part Service Likely to be

Part Replaced2
(Included)1
POWERCELL PDX Load Cells (includes rubber boot)
42904883 30t POWERCELL PDX Load Cell, H44 + OIML C3 X
42904884 30t POWERCELL PDX Load Cell, OIML C4 X
42904885 30t POWERCELL PDX Load Cell, OIML C6 X
42904891 50t POWERCELL PDX Load Cell, H44 + OIML C3 X
42904892 50t POWERCELL PDX Load Cell, OIML C4 X
42904785 Rubber Boot (supplemental) X
Receivers and Shims (new PDX style)
61043498 Lower Receiver, Standard X X
61043499 Upper Receiver, Standard X X
61043497 Locating Hex Pin, Lower Receiver (3 per receiver) X
61043489 Receiver Shim, 1/4” (6 mm) X
61043490 Receiver Shim, 1/8” (3 mm) X
61043491 Receiver Shim, 1/16” (1.5 mm) X
Receivers and Shims (POWERCELL and MTX retrofit style)
61043569 Upper Receiver, Retrofit, 45t X X
61043571 Lower Receiver, Retrofit, 45t X X
72207803 Locating Roll Pin, Lower Receiver (not new) X
68000554 Receiver Shim, 0.12” (3 mm) X
68000301 Receiver Shim, 0.06” (1.5 mm) X
61024613 Receiver Shim, 0.18” (4.5 mm) X
Auxiliary Materials
61043093 Locating Tool (new PDX style)
61007565 Locating Tool (POWERCELL and MTX retrofit style)
68004326 Multi-purpose Grease (not new) X
68004320 Dielectric Compound (not new) X

26 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 Item Number Description Spare Part Service Likely to be
Part Replaced2
(Included)1
Cell-to-Cell Cables
61043480 POWERCELL PDX Load Cell Cable, 2 meters X X
61043523 POWERCELL PDX Load Cell Cable, 4 meters X X
61043481 POWERCELL PDX Load Cell Cable, 5 meters X X
61043482 POWERCELL PDX Load Cell Cable, 7 meters X X
61043483 POWERCELL PDX Load Cell Cable, 8 meters X X
61043484 POWERCELL PDX Load Cell Cable, 9 meters X X
61043485 POWERCELL PDX Load Cell Cable, 10 meters X X
61043486 POWERCELL PDX Load Cell Cable, 11 meters X X
61043487 POWERCELL PDX Load Cell Cable, 12 meters X X
61043488 POWERCELL PDX Load Cell Cable, 24 meters X X
61043496 Termination Connector X X
Home Run Cables
61044730 POWERCELL PDX Home Run Cable, 10 meters X X
61044731 POWERCELL PDX Home Run Cable, 20 meters X X
61044732 POWERCELL PDX Home Run Cable, 30 meters X X
61044733 POWERCELL PDX Home Run Cable, 40 meters X X
61044734 POWERCELL PDX Home Run Cable, 50 meters X X
61044735 POWERCELL PDX Home Run Cable, 60 meters X X
61044736 POWERCELL PDX Home Run Cable, 70 meters X X
61044737 POWERCELL PDX Home Run Cable, 80 meters X X
61044738 POWERCELL PDX Home Run Cable, 90 meters X X
61044739 POWERCELL PDX Home Run Cable, 100 meters X X
61044740 POWERCELL PDX Home Run Cable, 110 meters X X
61044741 POWERCELL PDX Home Run Cable, 120 meters X X
61044742 POWERCELL PDX Home Run Cable, 130 meters X X
61044748 POWERCELL PDX Home Run Cable, 140 meters X X
61044749 POWERCELL PDX Home Run Cable, 150 meters X X
61044750 POWERCELL PDX Home Run Cable, 160 meters X X
61044751 POWERCELL PDX Home Run Cable, 170 meters X X
61044752 POWERCELL PDX Home Run Cable, 180 meters X X
61044753 POWERCELL PDX Home Run Cable, 190 meters X X
61044754 POWERCELL PDX Home Run Cable, 200 meters X X
61044755 POWERCELL PDX Home Run Cable, 210 meters X X
61044757 POWERCELL PDX Home Run Cable, 220 meters X X
61044758 POWERCELL PDX Home Run Cable, 230 meters X X
61044759 POWERCELL PDX Home Run Cable, 240 meters X X
61044760 POWERCELL PDX Home Run Cable, 250 meters X X
61044761 POWERCELL PDX Home Run Cable, 260 meters X X
61044762 POWERCELL PDX Home Run Cable, 270 meters X X
61044763 POWERCELL PDX Home Run Cable, 280 meters X X
61044764 POWERCELL PDX Home Run Cable, 290 meters X X
61044765 POWERCELL PDX Home Run Cable, 300 meters X X
1
These are reference part numbers for parts that ship with the POWERCELL PDX load cell system and are required for installation.
2
These are spare parts that are subject to potential wear and replacement over the life of the scale.

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 27
 4.2 MTMS Part Numbers
Service Parts

Item Number Description Trade Name /

Part Number
POWERCELL PDX Load Cells (includes rubber boot)
42904883 30t POWERCELL PDX Load Cell, H44 + OIML C3 42904883-MTMS
42904884 30t POWERCELL PDX Load Cell, OIML C4 42904884-MTMS
42904885 30t POWERCELL PDX Load Cell, OIML C6 42904885-MTMS
42904891 50t POWERCELL PDX Load Cell, H44 + OIML C3 42904891-MTMS
42904892 50t POWERCELL PDX Load Cell, OIML C4 42904892-MTMS
42904785 Rubber Boot (supplemental)
Receivers and Shims (Variant 1 Standard)
61043498 Lower Receiver, Standard TA207197
61043499 Upper Receiver, Standard TA207633
61043497 Locating Hex Pin, Lower Receiver TN207198
61043489 Receiver Shim, 1/4” (6 mm) TA207315-1
61043490 Receiver Shim, 1/8” (3 mm) TA207315-2
61043491 Receiver Shim, 1/16” (1.5 mm) TA207315-3
Receivers and Shims (Variant 2 Retrofit)
61043569 Upper Receiver, Retrofit, 45t TA314817
61043571 Lower Receiver, Retrofit, 45t TA314818
72207803 Locating Roll Pin, Lower Receiver MZ0904000063
68000554 Receiver Shim, 0.12” (3 mm) TA200833-1
68000301 Receiver Shim, 0.06” (1.5 mm) TA200833-2
61024613 Receiver Shim, 0.18” (4.5 mm) TA200833-3
Auxiliary Materials
61043093 Locating Tool (Variant 1 Standard) TA207484
61007565 Locating Tool (Variant 2 Retrofit)
68004326 Multi-purpose Grease TN203217
68004320 Dielectric Compound TN203256

28 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 Item Number Description Trade Name /
Part Number
Cell-to-Cell Cables
61043480 POWERCELL PDX Load Cell Cable, 2 meters TA000233-002
61043481 POWERCELL PDX Load Cell Cable, 5 meters TA000233-005
61043482 POWERCELL PDX Load Cell Cable, 7 meters TA000233-007
61043483 POWERCELL PDX Load Cell Cable, 8 meters TA000233-008
61043484 POWERCELL PDX Load Cell Cable, 9 meters TA000233-009
61043485 POWERCELL PDX Load Cell Cable, 10 meters TA000233-010
61043486 POWERCELL PDX Load Cell Cable, 11 meters TA000233-011
61043487 POWERCELL PDX Load Cell Cable, 12 meters TA000233-012
61043488 POWERCELL PDX Load Cell Cable, 24 meters TA000233-024
61043496 Termination Connector TN000235
Home Run Cables
61044730 POWERCELL PDX Home Run Cable, 10 meters TA000237-010
61044731 POWERCELL PDX Home Run Cable, 20 meters TA000237-020
61044732 POWERCELL PDX Home Run Cable, 30 meters TA000237-030
61044733 POWERCELL PDX Home Run Cable, 40 meters TA000237-040
61044734 POWERCELL PDX Home Run Cable, 50 meters TA000237-050
61044735 POWERCELL PDX Home Run Cable, 60 meters TA000237-060
61044736 POWERCELL PDX Home Run Cable, 70 meters TA000237-070
61044737 POWERCELL PDX Home Run Cable, 80 meters TA000237-080
61044738 POWERCELL PDX Home Run Cable, 90 meters TA000237-090
61044739 POWERCELL PDX Home Run Cable, 100 meters TA000237-100
61044740 POWERCELL PDX Home Run Cable, 110 meters TA000237-110
61044741 POWERCELL PDX Home Run Cable, 120 meters TA000237-120
61044742 POWERCELL PDX Home Run Cable, 130 meters TA000237-130
61044748 POWERCELL PDX Home Run Cable, 140 meters TA000237-140
61044749 POWERCELL PDX Home Run Cable, 150 meters TA000237-150
61044750 POWERCELL PDX Home Run Cable, 160 meters TA000237-160
61044751 POWERCELL PDX Home Run Cable, 170 meters TA000237-170
61044752 POWERCELL PDX Home Run Cable, 180 meters TA000237-180
61044753 POWERCELL PDX Home Run Cable, 190 meters TA000237-190
61044754 POWERCELL PDX Home Run Cable, 200 meters TA000237-200
61044755 POWERCELL PDX Home Run Cable, 210 meters TA000237-210
61044757 POWERCELL PDX Home Run Cable, 220 meters TA000237-220
61044758 POWERCELL PDX Home Run Cable, 230 meters TA000237-230
61044759 POWERCELL PDX Home Run Cable, 240 meters TA000237-240
61044760 POWERCELL PDX Home Run Cable, 250 meters TA000237-250
61044761 POWERCELL PDX Home Run Cable, 260 meters TA000237-260
61044762 POWERCELL PDX Home Run Cable, 270 meters TA000237-270
61044763 POWERCELL PDX Home Run Cable, 280 meters TA000237-280
61044764 POWERCELL PDX Home Run Cable, 290 meters TA000237-290
61044765 POWERCELL PDX Home Run Cable, 300 meters TA000237-300

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 29
 5 Specifications
Specifications

Parameters Unit of Measure Specification

Trade Name POWERCELL PDX
Model Number SLC820
Load Cell Type Column Compression, Digital Weight Processor (DWP)
Rated Capacity (R.C.) 1 t (klb, nominal) 30 (66) 50 (110)
Sensitivity at R.C. d @ R.C. 300,000 500,000
Communication Controller Area Network (CAN), Encrypted
Communication Rate kbit/sec 125
Effective System Update Rate (14 cells) Hz 40
Effective System Update Rate (24 cells) Hz 15
Weighing Performance
Cable Length, Cell to Cell (typical) m (ft) 5, 12 (16, 39)
Cable Length, Home Run (maximum) m (ft) 100, 200, 300 (328, 656, 984)
Warm-up Time from Cold Start minutes 15
Effect of Cable Length on System Accuracy kg 0
Temperature Effect on Minimum Dead Load Output Vmin/ºC (…/ºF) 0.8/5ºC (0.8/9ºF)
Compensated2 ºC (ºF) -10 to +40 (+14 to +104)
Temperature Range Operating ºC (ºF) -30 to +55 (-22 to +131)
Safe Storage ºC (ºF) -40 to +80 (-40 to +176)
Humidity Effect, Continuous 100% RH 0
Barometric Pressure Effect on Zero Load Output Vmin/kPa <1
Linearity3 ppm R.C. < 100
Metrology Hysteresis ppm R.C. < 160
Combined Error
3 ppm R.C. < 300
Class C3 C4 C6 C3 C4
Temperature Effect on Span3, 4 ppm R.C./ºC <±13.3 <±10.0 <±6.6 <±13.3 <±10.0
Creep at R.C.4 10s to 30m ppm R.C. <±167 <±125 <±83 <±167 <±125
Zero Return4 30 min at R.C. ppm R.C. <±167 <±125 <±83 <±167 <±125
Nonrepeatability ppm R.C. <± 50
Zero Balance %R.C. < 0.1
Predictive Diagnostics (System)
Breach Detection Loss of Hermetic Seal
Maximum Overload Maximum Overload
Load Cell Temperature Minimum, Maximum, Actual
Asset Management Serial Number
Load Cell Voltage Minimum, Maximum, Actual
Communication Signal Level High, Low
Tilt Angle Current Position, Maximum Recorded
1 R.C. = Rated or full capacity as specified on the data plate.
2 Certified according to approval agency or notified body (third party).
3 The combined error of span, linearity error, and hysteresis will not exceed 80% of the error limits for OIML R60.
4 TC of span, creep, and creep return for HB44 typically meet OIML C3 performance.

30 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell Order number 61044072 01/11
 Parameters Unit of Measure Specification
Metrological Approvals
Number TC7579; T2206; R60/2000-NL1-09:08
Class C3 C4 C6 C3 C4
nmax 3000 4000 6000 3000 4000
European/OIML Approval5 Y 6383 12,500 20,000 8772 12,500
Vmin kg 4.7 2.4 1.5 5.7 4.0
pLC 0.8 (Terminal = 1)
Humidity Symbol CH (Hermetic Seal)
Min. Dead Load kg 50
Number NTEP 08-090
Class III L-M
NTEP Approval5 nmax 10,000
Vmin (typical) kg 1.8 2.2
Min. Dead Load kg (lb) 50 (110)
Hazardous Area
(in process)
Electrical
Supply Voltage Regulated Typical V DC 12 or 24 (external supply)
in the Load Cell Minimum/Maximum V DC 12/24
Lightning Protection6 Max. Tested (IEEE4-95) A > 80,000
Insulation Resistance @ 50VDC M_ > 2000
Breakdown Voltage V AC > 500
Mechanical
Spring Element 17-4 PH Stainless Steel (magnetic)
Enclosure Electropolished 304 Stainless Steel
Low-Profile 17-4 PH Forged and Machined Stainless Steel,
Receivers Hardened
Anti-Rotation 6-Point Hexagonal
Material Cable Entry Fittings Stainless Steel, Laser Welded
Cable, Load Cell Braided Stainless Steel, Oil Resistant, 9mm, 5 Con-
ductors, Internal/External Shielded with Drain Wires
Cable, Home Run Braided Stainless Steel, Oil Resistant, 9mm, 5 Con-
ductors, Internal/External Shielded with Drain Wires
Connectors Quick-Connect, Stainless Steel, Glass-to-Metal
Type Hermetic (submersible)
Protection IP Rating IP68 (1m - 7 days submersion), IP69K test
reports on file
NEMA Rating NEMA 6P (submersible)
Load Limit Safe %R.C. 200
Ultimate %R.C. 300
Safe Dynamic Load %R.C. 70
Direction of Loading Compression
Deflection @ R.C., typical mm (in) 0.51 (0.020) 0.71 (0.028)
Horizontal Restoring Force %A.L./mm7 1.82
Shipping Weight, nominal kg (lb) 3.0 (6.6) 3.2 (7.0)
5 See certificate for complete information.
6 Tested by Elektro Swiss AG (40,000A) and Lightning Technologies, Inc. (80,000A).
7 Percent of the vertical applied load (A.L.) per mm of displacement..

01/11 Order number 61044072 ­METTLER ­TOLEDO Installation Manual POWERCELL® PDX® Load Cell 31
To protect your METTLER TOLEDO product’s
future:
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of value of all METTLER TOLEDO products for
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Tel. + 41 44 944 22 11
Fax + 41 44 944 30 60

Subject to technical changes

© 01/2011 Mettler-Toledo AG
Printed in Switzerland
Order number 61044072