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3 - Reliability – Technology vs. Price It can be difficult to think about a new scale being unreliable because you don’t expect a new piece of equip- ment to fail. However, truck scales face a number of challenges, often resulting in frequent repairs. Because scale downtime can be detrimental to business operations, think about reliability up front. Designs and features that protect against scale failures can be well worth the initial investment to give you peace of mind later on. Causes of Scale Downtime Extensive long-term service data over time provide statistical analysis on scale failures and long-term system performance. This analysis indicates that approximately 75% of maintenance and repair costs for legacy truck scales is based in the load cell system. The conclusion is the selection of the load cell and environ- mental protection is the most critical technology decision to be made in the selection of a new truck scale system.
The following list names the most common historical sources of scale repairs across all makes and models. The forthcoming sections of this guide explain many of these components and situations in more detail.
Environmental impacts • Lightning damage • Frost-heave, ice damage or debris buildup • Water damage
Junction boxes and cable connections • Moisture in a junction box • Failed connections in a junction box • Damage to a load cell cable (rodents, accidental severing, etc.) Load cells • Moisture ingress damaging internal components • Physical damage and corrosion • Physical wear due to misalignment or poor preventive maintenance • Leaking hydraulic fluid (hydraulic systems)
5% Accessories
Calibration or recertification required • Expired Weights and Measures certification • Change in major components • Change in location (portable scales) • Weighbridge misalignment requiring adjustment
5% Weighbridge
4% Software
Protection from Environmental Challenges
Flooding and Moisture An extreme situation such as a flood can easily show the value of water protection. A scale with inadequate protection may require the replacement of numerous expensive parts. However, some scales have been de- signed with conditions like flooding in mind. Help prevent damage by choosing load cells that can offer hermetic (airtight) seals created from precision manufacturing technologies, such as laser welding. Additionally, load cells and cable connections can carry an Ingress Protection (IP) code rating to note their resistance to the ingress of dust and water. The level of protection is signified with a two-digit number. • IP68 The number 6 indicates that the enclosure is dust tight, providing complete protection from dust. The number 8 indicates that the component is suitable for continuous immersion in water. • IP69K This rating indicates that the enclosure is suitable for high-pressure, high-temperature washdown applications. However, the components most vulnerable to water or other moisture damage are typically not load cells but junction boxes. Junction boxes include access panels that are difficult to seal. Temperature Temperature changes can also present challenges to a truck scale. Over time, thermal cycles can cause the scale to require more frequent calibrations and service. Some load cells can experience signal fluctuations due to temperature, causing the scale’s accuracy to suffer.
10% Terminal
76% Load Cell System
Costs over the life of the scale Though many companies focus their sales presentation on the weighbridge, it is typically a low-maintenance item when compared to other parts of the scale. Many truck scale buyers wish to focus sales discussions more on the load cell systems once they learn that older load cell systems have been the main source of ongoing maintenance, repair costs, and downtime. There- fore, choosing the right load cell system has the greatest potential to save the owner money over the life of the scale.
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