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Forest Products Industrial Weighing and Measuring
Upgrading Your Vehicle Scale Can Boost Your Profits Are you still getting the most out of your vehicle scale? As a scale grows older, you can spend increasing amounts of time and money trying to keep it weighing accurately. Make your scale a more profitable part of your operation by giving it a new lease on life with a POWERCELL® PDX® upgrade. A well-maintained vehicle scale can provide many years of service. If an older weighbridge and foundation are structurally sound, there might be no need to replace them. But just because an older weighbridge is still in good condition, there is no guarantee that the load cells under it are not outdated. Load cell technology has made tremendous strides recently. The most significant advance has been POWERCELL PDX load cell technology, which provides benefits that were undreamed of just a few years ago. If your scale has experienced increased maintenance costs and unplanned downtime, you might be able to revive the scale’s performance simply by upgrading the load cells. METTLER TOLEDO offers complete kits to upgrade scales with the
latest POWERCELL PDX technology. These conversion kits can be installed under existing weighbridges to replace older weighing components such as mechanical lever systems, analog load cells, hydraulic load cells, and previous generations of POWERCELL load cells. Custom-designed receivers, plates, and hardware make installation quick and easy. Upgrading to POWERCELL PDX technology can give new life to a scale that is suffering from decreasing accuracy and increasing maintenance costs. It provides the benefits of cutting-edge load cell technology without the cost of a new scale. Increased Accuracy How can you be sure your scale is weighing accurately? An annual calibration
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Load Cell Upgrades
check can tell you how accurate a scale is on the day the service is performed. But conventional load cells rarely maintain that accuracy throughout the entire year. Each POWERCELL PDX load cell has a built-in digital compensation system that helps maintain the highest weighing accuracy. The system tracks environmental conditions such as temperature, hysteresis, linearity, creep, and vibration. Using a series of algorithms, it adjusts the load cell output to compensate for changes in those conditions. While the accuracy of conventional load cells can change significantly from season to season, POWERCELL PDX load cells deliver the same accurate weighing in all environments. Reduced Maintenance As scales age, they often need increasing amounts of maintenance to keep them weighing accurately. This is especially true of older weighing technologies that require frequent adjustments and use leak-prone junction boxes. POWERCELL PDX technology is engineered to eliminate unplanned service
Publisher / Production Mettler-Toledo AG MarCom Industrial Heuwinkelstrasse CH-8606 Nänikon Switzerland Subject to technical changes © 02/2013 Mettler-Toledo AG Printed in Switzerland
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and the downtime that it causes. Gone are the time-consuming adjustments typical of analog systems. And gone are the hard-to-seal junction boxes that can be maintenance nightmares. Instead, you get a watertight load cell network that resists damage from floods, corrosion, lightning, and rodents.
scale operator to know how well or how poorly they are performing. By upgrading to POWERCELL PDX technology, you get the benefit of predictive diagnostics. This unique system constantly monitors the performance of each load cell. It verifies network health, putting the diagnostic information at your fingertips 24 hours a day.
Predictive Diagnostics Most older weighing technologies keep you in the dark. There is no way for a
If the predictive diagnostics system detects an inconsistency, it alerts you before weighing errors and downtime can affect
Before
After
POWERCELL PDX upgrade kits can be installed under most existing weighbridges with minimal alterations.
your profits. With POWERCELL PDX load cells, problems that were hidden by older technologies can now be identified and fixed quickly. Powerful Terminals A POWERCELL PDX upgrade includes a high-performance IND560 or IND780 terminal. By combining advanced capabilities with simple operation, these terminals enable you to do more with your scale and get it done more quickly. An upgrade can pay for itself with the money it saves by improving weighing accuracy and lowering maintenance costs. Find out if a POWERCELL PDX upgrade is right for you. Let METTLER TOLEDO help you evaluate the cost of an upgrade and analyze the return on investment it can provide.
Complete POWERCELL® PDX® Upgrade A POWERCELL PDX upgrade includes everything needed to convert a structurally sound weighbridge’s obsolete weighing system to POWERCELL PDX technology. It includes the following: • • • • • • • •
R etrofit with POWERCELL PDX load cells L oad cell receivers and mounting hardware N ew cables (with no junction boxes) IND560 or IND780 terminal with advanced diagnostics S trikeShield™ lightning protection system K now-how and project management T esting, calibration, and certification Industry-leading warranty
POWERCELL® PDX® Load Cell System Upgrade Kit
www.mt.com/UpgradeToPDX-for4
POWERCELL® PDX® Load Cell System Conversion Kit
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EasyClean 400
Greater Process Reliability and Sensor Life Extended up to 30% Maintaining sensors at peak condition is important for performance and for process assurance. An automatic sensor cleaning and calibration unit frees your maintenance staff for more important tasks. It can also significantly increase sensor life.
Keeping sensors in prime condition can extend their lifetime by 30% and provide greater assurance of process reliability. Conditions in the pulp and paper industry mean the time spent on measurement point maintenance can be extensive. With the EasyClean 400, thorough sensor cleaning and accurate calibration are completely automated.
By cleaning and calibrating pH electrodes dependably, the EasyClean 400 frees your maintenance staff to concentrate on more important and skill-intensive tasks. To find out how EasyClean systems can help your operations, go to www.mt.com/EasyClean-for4
Your benefits
Completely unattended maintenance Automatic cleaning and calibration of pH measurement points.
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Greater production efficiency Eliminates downtime caused by insufficiently maintained sensors.
Configurable to your requirements Calibration time and cleaning time/duration are fully programmable.
EasyClean 400 automatic sensor cleaning and calibration unit
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Vehicle Scale Options
Choosing the Right Vehicle Scale Can Pay Off in the Long Run Choosing the right scale today can pay off with years of dependable operation. The METTLER TOLEDO product line has the flexibility to deliver a vehicle scale that meets even the most specialized needs. No matter what type of vehicle weighing application you have, METTLER TOLEDO can help you find the right solution.
Steel Deck
Concrete Deck
Both types of driving surfaces have similar initial costs, maintenance requirements, and longevity. Steel decks can be used immediately after installation. Concrete decks provide better traction when wet.
Above Ground
Pit
Above-ground scales make service simpler and less expensive. Pits are useful for applications that have space limitations or require greater access under the scale.
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Single Platform
Multiple Platform
Single-platform scales provide gross vehicle weights. Multipleplatform scales capture individual axle weights. Both types of scales are suitable for legal-for-trade weighing applications.
POWERCELL
Analog
POWERCELL® PDX® load cells with predictive diagnostics combine high accuracy and low maintenance. Analog load cells are an option for applications with lower traffic volumes, but they require high-maintenance junction boxes.
Orthotropic
I-Beam
The METTLER TOLEDO orthotropic design provides proven strength and durability for even the heaviest traffic. I-Beam designs are available for applications with lower volumes of traffic.
www.mt.com/vehicle-for4
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On-line Videos
New Vehicle Weighing Videos: See Technology in Action Learn about how the latest METTLER TOLEDO technology is making vehicle weighing more accurate and reliable than ever. Visit our ever-growing video library on mt.com and get the inside story about how this technology pays off with a longer service life, less downtime, and greater weighing accuracy.
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Vehicle Scale Plant Tour Video Visit our North American vehicle scale manufacturing plant. Tour the facility and see how we give you the maximum return on your investment by building quality into our products. www.mt.com/vehicle-videos-for4
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How It’s Made: POWERCELL PDX Load Cell Video Take a look inside the POWERCELL PDX load cell. See how a combination of innovative design and precise manufacturing produces a load cell that is revolutionizing vehicle weighing. www.mt.com/vehicle-videos-for4
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Quick and Easy Service Video Discover why the POWERCELL PDX load cell is your most potent weapon in the fight against downtime. This video shows how quick and easy replacement ensures that you spend your time weighing vehicles, not servicing your scale. www.mt.com/vehicle-videos-for4
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Lightning Protection Video Find out how POWERCELL PDX load cells are designed and tested to survive the destructive power of lightning. They continue to perform after lightning strikes that put other scales out of commission. www.mt.com/vehicle-videos-for4
Module Masher Video See the module masher in action. This unique test stand verifies the durability of METTLER TOLEDO truck scales by applying the equivalent of 20 years of traffic within a few months. www.mt.com/vehicle-videos-for4
Environmental Protection Video Learn how POWERCELL PDX load cells stand up to harsh environments. They are designed to weigh accurately and reliably despite continued exposure to hot, cold, and wet conditions. www.mt.com/vehicle-videos-for4
Junction Box Video Find out how POWERCELL PDX load cells have revolutionized vehicle weighing by eliminating junction boxes. These load cells provide exceptionally reliable weighing without the costly maintenance that junction boxes require. www.mt.com/vehicle-videos-for4
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Vehicle Scales
Say Goodbye to Junction Boxes and Hello to Greater Reliability POWERCELL® PDX® load cells are revolutionizing vehicle weighing. With their unique design, they eliminate the weak link in any vehicle scale: the junction box. The result is unmatched weighing accuracy and reliability.
POWERCELL PDX load cells connect to one another in a simple network that transmits individual load cell signals to the scale terminal. Compare them with conventional vehicle scale load cells. Each group of up to four conventional load cells is wired to a junction box, which is then wired to the next junction box in the system and so on until all load cells are connected. The bigger the scale, the bigger the tangle of boxes and wires. And the bigger the problem.
By their very nature, junction boxes are hard to seal. They must be opened periodically for inspection and service. Afterward, the service technicians have to tighten the screws and connectors by hand. Even if technicians do their best to seal the boxes, lids get bent, screws get lost, and gaskets deteriorate over time. It doesn’t take long for an imperfect seal to
be penetrated by water from rain, power washing, or flooding. The POWERCELL PDX load cell network has no junction boxes to leak. All electronics are protected inside hermetically sealed load cell enclosures. The load cells are never opened, so there is no need to
Whether manufacturers call them gathering boxes, totalizers, or sectional controllers, the problem is the same. Junction boxes remain the number one cause of failure in vehicle scales. Water Damage One of the biggest challenges is protecting the junction box’s sensitive electronics from the damaging effects of water. Each junction box contains electronic equipment that receives the load cell signals and sums them to produce a combined weight signal. To ensure the integrity of this signal, you need to protect the electronic equipment by maintaining a watertight seal around the junction box lid and cable connections.
POWERCELL PDX Load Cell Network (No Junction Boxes)
Conventional Load Cell Wiring (Junction Boxes Required) POWERCELL PDX load cells connect to one another in a simple network that revolutionizes vehicle scale reliability by eliminating troublesome junction boxes.
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worry about resealing them. If an enclosure is ever punctured, the built-in predictive diagnostics system automatically alerts the scale operator. This breach-detection feature enables you to replace a punctured load cell before moisture penetrates it and damages the electronics. POWERCELL PDX cable connectors have the same glass-to-metal design used in military and medical applications where reliable performance is essential. When you connect a cable to a load cell, an audible click tells you that the connector is locked securely in place, sealing out water. The load cells, cables, and connectors are all watertight, effectively sealing the entire network against moisture to IP68 standards.
be time-consuming and expensive. Junction boxes are notoriously difficult to troubleshoot. The service technician has to gain access to the boxes and test them to locate the faulty component. Replacing a defective junction box requires opening the box, disconnecting all the load cell cables, removing the box, wiring the load cells to the replacement box, shift adjusting the corners, sealing the box, and recalibrating the scale. This procedure can easily mean 4 to 8 hours of downtime for your scale. By eliminating junction boxes, the POWERCELL PDX load cell network eliminates the frequent failures and timeconsuming repairs. Its unique predictive diagnostics system constantly monitors load cell performance to verify the health of the network. The system can detect potential problems with a load cell or cable and alert you before they cause weighing errors. Unlike conventional analog systems, there are no weeks or months of lost revenue caused by undetected errors.
POWERCELL PDX cable connectors lock securely with an audible click to form a watertight seal.
guesswork or laborious testing to figure out what is wrong. If there is a defective load cell or cable, it can be replaced quickly without recalibrating the scale. Say goodbye to junction boxes and the costly failures they cause. POWERCELL PDX load cells deliver accurate, reliable weighing for the life of your vehicle scale. www.mt.com/powercell-for4
Troubleshooting is quick and easy. The predictive diagnostics system tells the service technician what the trouble is and where it is located. There is no
Junction boxes are frequent causes of failure and difficult to troubleshoot.
POWERCELL PDX Load Cells Outperform Other Technologies
Troubleshooting and Repair What happens when a junction box fails? A conventional analog load cell system hides the failure from you. Defective load cells, junction boxes, and wiring simply pass weighing errors on to the scale terminal. Your vehicle scale can continue giving incorrect weight readings for months before somebody notices the errors. Once you notice a problem, fixing it can
POWERCELL PDX Load Cell Network
Conventional Load Cell Wiring
• No junction boxes
• Junction boxes are the #1 cause of scale failure
• Electronics protected in hermetically sealed load cells
• Electronics located in hard-to-seal junction boxes
• Watertight cable connectors
• Hand-wired cable connections
• Predictive diagnostics system alerts you at the first sign of a problem
• Problems can go undetected for long periods of time
• Predictive diagnostics system identifies the source of a problem
• Time-consuming troubleshooting needed to identify the source of a problem
• Maintenance and repair are quick and easy
• Maintenance and repair are time-consuming
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Vehicle Scale Software Streamlines Your Weighing Operation METTLER TOLEDO vehicle scale software can save time and money by streamlining your weighing operation. This easy-to-configure software makes it possible to tailor a solution specifically for your application. With the right software solution, you can automate processes to eliminate time-consuming manual data entry and operation.
Multiple Scales Control as many as six vehicle scales plus traffic lights, gates, and other peripheral equipment.
Unattended Weighing Enable truck drivers to process their own vehicle weighing transactions quickly and easily.
Invoicing Simplify billing by automatically generating invoices directly from the OverDrive database.
Video Server Monitor activity at your truck scales and store digital images for each weighing transaction.
To learn more about vehicle scale software from METTLER TOLEDO, visit our webpage at www.mt.com/OverDrive-for4
www.mt.com/ind-forest-for4 For more information Mettler-Toledo AG CH-8606 Greifensee Switzerland Tel. + 41 44 944 22 11 Fax + 41 44 944 30 60
