7 Common Ways Your Hopper Scales’ Load Cells Can Malfunction and How to Avoid Them
If you work in agriculture, mining, or manufacturing, you know how vital hopper scales are to your operation. When it comes to weighing and handling material, accuracy is key, which means you also need reliable load cells. While load cells are engineered to be rugged and precise, they can fail if exposed to stressors in the field. But when you understand why they malfunction, you can watch for signs of trouble, prevent downtime, maintain accuracy, and save on repair costs.
At Accurate/Western Scale, we supply hopper scales and tank scales, and offer professional scale load cell repair services to keep your weighing systems operating reliably. For now, let’s look at the seven common ways hopper scale load cells malfunction and how to avoid them.
1. Overloading the Load Cell
Applying more weight than a load cell is rated for is one of the most common causes of failure. Every hopper scale has a specified capacity—exceed it, and the load cell can suffer permanent deformation, leading to inaccurate or no readings at all. Always ensure your loads stay within capacity guidelines.
2. Moisture and Corrosion Damage
Moisture can be disastrous for load cells. Water—especially when it contacts sensitive electronics or seeps through seals—can cause shorts, corrosion, and long-term degradation of internal components. Older hopper scales are especially vulnerable as seals and housings wear over time. Regular inspections and proper sealing help mitigate this risk.
3. Chemical Exposure
Chemicals—whether spilled during operation or present in the environment—can corrode load cells or damage wiring and electronics. This type of damage often requires full replacement of the affected component. As with moisture, preventing chemical ingress and protecting the weighing area is key.
4. Electrical Surges and Power Issues
Electrical events such as lightning strikes, power surges, or unstable electrical feeds can damage your hopper scales’ load cells and associated electronics. Grounding, surge protection, and proper electrical setup reduce the likelihood of electrical damage. Even with protection, severe events can still cause failures that require professional-scale load cell repair.
5. Mechanical Damage and Misalignment
Load cells take the brunt of the force applied to a hopper scale. Physical impacts, improper installation, or misalignment (where the load isn’t applied evenly) can deform the load cell or weaken its structure. To prevent this, ensure proper installation and avoid impact during movement or service.
6. Temperature Extremes and Creep
Rapid temperature changes or extended exposure to extreme heat or cold can affect load cells, strain gauges, and electronics, leading to signal drift or output irregularities. Sustained loads at high temperatures can also cause “creep,” where the load cell slowly drifts from its zero point over time. Choose load cells rated for your operating conditions and monitor performance in varying environments.
7. Zero Drift and Signal Problems
A load cell that won’t return to zero (even without a load applied) or gives unstable readings often signals internal issues. This may stem from an imbalance in the zero connection, damage to strain gauges, or wiring defects. In many cases, this requires calibration or scale load cell repair by experienced technicians.
Signs Your Scale Load Cells Need Repair
If your hopper scale is showing any of the following, it may be time to schedule scale load cell repair:
- Scale won’t calibrate
- Scale can’t reset or zero out
- Inconsistent or fluctuating weight readings
- No display or readings at all
- Readings drift over time
A malfunctioning load cell doesn’t just affect accuracy—it can stop your entire operation.
Why Timely Load Cell Service Matters
Ignoring early signs of load cell issues can lead to larger problems, from inaccurate inventory tracking to regulatory compliance risks and costly downtime. Whether your hopper scales are outdoors in tough conditions or used in high-volume industrial applications, routine inspection and prompt scale load cell repair help extend the life of your equipment.
When You Need Hopper Scale Cell Load Repair, Trust the Experts
Don’t wait for a complete failure. If you’re experiencing load cell issues on your hopper scales or tank scales, it’s time to call in the pros. At Accurate Western Scale, we offer a range of services, including scale load cell repair and hopper scale calibration.
If it’s time for repairs or maintenance, contact Accurate Western Scale today for dependable service designed to keep your weighing systems accurate and operational.
