# Mettler Toledo | BBK442 | User manual | Mettler Toledo BBK442 User manual

Piece Counting
What Really Counts
Piece Counting
2
How Can You Find the Right Piece Counting
Did you know that even pieces that appear to be identical may have different weights? Different weight is caused
by production tolerances, material stock, tooling machines and operators. The average piece weight must therefore be determined with extreme accuracy using a suitable, precise scale. A small error in this value is multiplied
when counting bulk volumes. The following procedure will help you make the right selection.
1
Determine the average single piece weight:
First you must determine the mean value of the single piece weight. To do this, individually weigh 10 pieces of the
parts to be counted and enter each of the individual piece weights into their own cell in MS Excel®. Calculate the
average weight by adding all 10 weights and then dividing by 10. Using Excel‘s function for standard deviation,
you can then calculate the absolute standard deviation in grams and the relative standard deviation as a percentage.
2
Define the maximum weighing range of your piece counting scales:
Weigh the heaviest pieces to be counted. Multiply this weight by the maximum number of pieces to be counted in
the same process. This will give you the maximum net weight. The maximum gross weight is the sum of the
maximum net weight and the weight of the heaviest tare container. It may not exceed the weighing range of the scale.
3
Now find the right piece counting scales:
Using the information on the weighing range, the smallest piece weight and its standard deviation, you can now
find the right piece counting scale or the right two-scale system in the overview on the following page.
4
Select the performance level of the display, keyboard and software:
• If you require completely simple yet professional operation using one function for each key, then select an
IND435 terminal or one of the compact scales BBA432 or BBK432.
• If you want to easily and safely count many identical portions, then select an IND445/IND449check+ or
a BBA442/BBA449check+/BBK442. You also can enter the tare value using the numeric keyboard.
• Compact scales BBA462, BBK462 as well as IND465/IND449check+ and IND690count also include a
graphic and plain text display for easy administration of up to 1500 memory locations
(IND690count: 999 memory locations). They support printing of different labels or customized labels.
• The IND690count terminal provides easy operability and first-class functionality. The large and bright
BigWeight® graphic display guides the user correctly through the counting process.
Details on the displays, keyboards and interfaces can be found on pages 4–5.
5
Select the right-sized model:
• The BBK4x2 and BBA4x2 models are space-saving compact scales.
• If you would like the display to be at the side, in front of or over the piece container, then select one of
the IND terminals.
• Determine the size and model of the floor scale. Decide whether to install the weighing platform in a pit
or if it is to be directly fixed to the floor.
• Select a Series 4 model if you wish to operate the scale with batteries and/or as a mobile unit, e.g. on a cart.
Possible models and their details are given on pages 6–7.
Weighing
range
6000 lb
3000 kg
IND690/
IND4x5+
PBA330-35BB
+
2158 Vertex
2500 lb
1250 kg
IND690 +
BBK4x2-6Px
+ KCC600s
1000 lb
500 kg
600 lb
300 kg
IND690 +
BBK4x2-3Px
+ KCC300S
IND690
PBA330-6A
+ KE1500s
IND690/
IND4x5+
PBA330-35BB
+
2158 Vertex
IND690/
PBA330-6A
+ 2256 VLC
IND690/
IND4x5+
PBA330-35BB
+
2256 VLC
IND4x5 +
PBA330300BC
IND690 +
BBK4x2-6Px
+ KCC300s
300 lb
150 kg
Counting terminals
– IND690count
– IND465
– IND445
– IND435
Reference scales
– X203S
– X603S
– AB104-S
– AB304-S
BBK4x2-6Px
+
PBA330150CC
120 lb
60 kg
IND690 +
BBK4x2-3Px
+ KB60s
.
Series 4 compact scales
– BBK4x2-3Px
BBK4x2-6Px
+
PBA330-60BB
– BBK4x2-6Px
– BBK4x2-35Sx
70 lb
35 kg
IND690+
X603S
+KA32s
BBK4x2-0.6Px
X603S
.
IND690 +
BBK4x2-3Px
+ KA32s
IND690 +
KA32s
IND690 +
KA32s
BBK4x2-35Sx
BBK4x2-35sx
BBA4x2-35Sx
– BBA4x2-6Px
– BBA4x2-35Sx
30 lb
15 kg
Weighing platforms
– KA32s
12 lb
6 kg
BBK4x2-6Px
BBA4x2-6Px
– PBA330-BB35
– PBA330-BB60
– PBA330-6A
6 lb
3 kg
BBK4x2-3Px
– KE3000
– KES3000
– KCS600
1.2 lb
0.6 kg
0.6 lb
0.3 kg
0.2 lb
0.1 kg
– 2158 Vertex Rocker Pin
– 2256 VLC Floor Scale Footed
IND690 +
AB304-S
IND4x5 +
AB304-S
IND690 +
AB104-S
IND4x5 +
AB104-S
1)
Counts up to 1000 pieces in normal
ambient conditions at a relative standard deviation of < 0.5% of the average piece weight.
Standard Deviation is calculated as
described under point 1 on page 2.
IND690 +
X203S
IND4x5 +
X203S
2)
0.0000002 lb
0.000002 lb
0.000002 lb
0.00002 lb
0.00002 lb
0.0002 lb
Average Piece Weight 1)
0.0002 lb
0.002 lb
Average Piece Weight 2)
0.002 lb
0.02 lb
0.02 lb
0.2 lb
Counts up to 1000 pieces in normal
ambient conditions at a relative standard deviation of 0.5–1% of the average piece weight.
Standard Deviation is calculated as
described under point 1 on page 2.
3
Piece Counting
The Right Solution for Every Job
IND690count: the robust and intelligent counting system
• The robust and versatile IND690count stainless steel terminal is IP69k-protected and is therefore also suitable
for use in the harshest industrial environments – with a matching, robust industrial GA46 printer contained
in stainless steel housing for printing barcodes.
• The large, bright, high-contrast ”BigWeight®“ display allows counting results to be easily read without tiring
your eyes – even at large distances and in poorly lit conditions.
• Up to four weighing platforms can be connected, this allows high-resolution, precise weighing ranges of
0.1 mg to 6000 kg/0.0000002 lb to 12,000 lb using just one IND690count terminal.
• The integrated database provides 999 flexible storage locations for part data.
• The IND690count terminal can be connected to a warehouse management system via Ethernet TCP/IP, Profibus DP,
DeviceNet, USB, Bluetooth, WLAN, RS232, RS422, RS485, digital inputs/outputs and RFID, making it the central
tool for registering incoming/outgoing goods and for inventory management.
Intelligent commissioning and portioning using BBK462, BBA462 and IND465
• The bright graphic display avoids misunderstandings, as it guides the user through the counting process using
plain text instructions.
• An integrated database with 1,500 flexible storage locations allows part data to be managed easily.
• Barcode scanners are used to ensure error-free, efficient part selection.
• Monotonous work, such as filling many identical packaging units, can be done efficiently. The filling guide informs
the user when the target has been reached. Underfilling or overfilling is therefore avoided.
• Free design of barcode print-outs on labels, e.g., with name of company, address, alphanumerical part ID, date,
time, variables, lot ID and order number.
• Can be integrated into existing systems using Ethernet TCP/IP and digital inputs/outputs.
• A second scale can be connected for larger volumes or for exact piece weight sampling.
Correct Order filling using BBK442, BBA442, IND445, BBA449check+, IND449check+
• Tedious work, such as filling many identical packaging units, is simplified, as the filling guide informs the user
when the target has been reached. The BBA449check+ has the colorWeight® function. It supports the operator
with a color change of the display if the target weight is reached. Underfilling or overfilling is therefore avoided.
• Comes with a database of 99 flexible storage locations for target counts with tolerances and tare values.
• Flexible print-outs with name of company, address, and numerical part ID. The part ID can be entered using the scale
• A second scale can be connected for large volumes or for exact piece weight sampling to BBK442, BBA442 and IND445.
• The tare values can be entered on the keyboard.
Simple, safe and professional: BBK432, BBA432, IND435
• Secure entry due to allocation of one single function to each key minimizes operator error.
• Keys and display have been optimized simply and without compromise for counting.
• A second scale can be connected for large volumes or for exact piece weight sampling.
4
MonoBloc provides the highest rate of counting
precision and repeatability – for reliable results.
The BBK4x2 scales and K-Line weighing platforms
are equipped with unique MonoBloc technology
for maximum repeatability and precision of weighing
and counting results.
Their high measuring resolution allows for a high
weighing range at a very high rate of precision,
linearity and repeatability. Generally, this means:
MonoBloc is 10–20 times more accurate than
strain gauge technology.
METTLER TOLEDO
METTLER TOLEDO
RefOpt: User-friendly, precise determination
of piece weights
Using the “automatic reference optimization“ function,
you can count easily, efficiently and correctly.
The scale continuously optimizes the piece weight.
METTLER TOLEDO
USB
EtherNet
DeviceNet
RS232
WLAN
Interfaces
Depending on the model, the METTLER TOLEDO
counting systems and counting scales can be
integrated into a modern materials management
system. With Ethernet TCP/IP, Profibus DP, USB,
Bluetooth, DeviceNet and RFID, all types of connection
are covered and all data can flow freely.
R F I D
METTLER TOLEDO
Battery powered
Selected models also available with optional rechargeable battery for mobile use.
5
Piece Counting
The Right Models and Sizes for
Combine small, medium and large platforms with modular compact scales and the powerful IND counting
terminals. Position the terminal in the ideal location for your needs: to the side, the front or on a mount.
Connect the compact BBK and BBA models to bench and floor scales to form two-scale systems.
Compact Scales Small Sizes
NTEP-approved
BBA4x2: Class III, 7,500d
BBK4x2: Class II, 60,000d
Housing
Die-cast aluminum
Measuring method
BBK4x2 MonoBloc/BBA4x2 Strain Gauge
Power supply
110V AC or built-in rechargeable battery
Dimensions (in/mm) 10.40 × 13.20 × 4/265 × 335 × 100
Platform size (in/mm) 6.50 × 6.50/165 × 165
1
Platform size (in/mm) 7.90 × 9.50/200 × 240
2
Interfaces
Ethernet TCP/IP, USB, digital I/O,
up to 3× RS232, RS485, connection for
second scale (depending on application level)
Model
Weighing range
Resolution Platform
size
BBK432-3PL
6 lb × 0.00002 lb
3 kg × 0.01g
1
BBK442-3PD
6 lb × 0.00002 lb
3 kg × 0.01g
1
BBK462-3PT
6 lb × 0.00002 lb
3 kg × 0.01g
1
BBK432-6PL
12 lb × 0.00005 lb
6 kg × 0.02g
2
BBK442-6PD
12 lb × 0.00005 lb
6 kg × 0.02g
2
BBK462-6PT
12 lb × 0.00005 lb
6 kg × 0.02g
2
BBA432-3PL
6 lb × 0.0005 lb
3 kg × 0.2g
2
BBA442-3PD
6 lb × 0.0005 lb
3 kg × 0.2g
2
BBA462-3PT
6 lb × 0.0005 lb
3 kg × 0.2g
2
BBA432-6PL
12 lb × 0.00005 lb
6 kg × 0.5g
2
BBA442-6PD
12 lb × 0.00005 lb
6 kg × 0.5g
2
BBA462-6PT
12 lb × 0.00005 lb
6 kg × 0.5g
2
AB Balances
Reference balances for small parts
Model
Weighing range Resolution
AB104-S
110 g
0.0001 g
AB304-S
320 g
0.0001 g
Platform size (in/mm) Ø 3.15/80
6
Compact Scales Large Sizes
NTEP-approved
BBA4x2: Class III, 7,500d
BBK4x2: Class II, 60,000d
Housing
Die-cast aluminum
Measuring method
BBK4x2 MonoBloc/BBA4x2 Strain Gauge
Power supply
110V AC or built-in rechargeable battery
Dimensions (in/mm) 14.17 × 14.56 × 4.53/360 × 370 × 115
Platform size (in/mm) 9.45 × 13.78/240 × 350
3
Interfaces
thernet TCP/IP, USB, digital I/O,
up to 3 × RS232, RS485, connection for
second scale (depending on application level)
Model
Weighing range
Resolution Platform
size
BBK432-15SL
30 lb × 0.0001lb
15 kg × 0.05 g
3
BBK442-15SD
30 lb × 0.0001lb
15 kg × 0.05 g
3
BBK462-15ST
30 lb × 0.0001lb
15 kg × 0.05 g
3
BBK432-35SL
70 lb × 0.0001lb
35 kg × 0.1g
3
BBK442-35SD
70 lb × 0.0001lb
35 kg × 0.1g
3
BBK462-35ST
70 lb × 0.0001lb
35 kg × 0.1g
3
BBA432-15SL
30 lb × 0.002 lb
15 kg × 1g
3
BBA442-15SD
30 lb × 0.002 lb
15 kg × 1g
3
BBA462-15ST
30 lb × 0.002 lb
15 kg × 1g
3
BBA432-35SL
70 lb × 0.005 lb
35 kg × 2g
3
BBA442-35SD
70 lb × 0.005 lb
35 kg × 2g
3
BBA462-35ST
70 lb × 0.005 lb
35 kg × 2g
3
BBA432-60SL
120 lb × 0.01lb
60 kg × 5g
3
BBA442-60SD
120 lb × 0.01lb
60 kg × 5g
3
BBA462-60ST
120 lb × 0.01lb
60 kg × 5g
3
X203S/X603S Balances
Reference balances for small parts
Model
Weighing range Resolution
X203S
210 g
0.001 g
X603S
610 g
0.001 g
Platform size (in/mm) 5 × 5/127 ×127
K Line High Precision
High-precision bench and floor scales for use in harsh industrial
environments. Can be used as reference scales or bulk scales.
NTEP-approved
Class III 10,000d
Class II 32,000d
Weighing ranges
6–6,000 lb/3–3,000 kg
Resolution
0.00002–0.1lb/0.01–50 g
Platform sizes
13.8 × 11 to 59 × 59 in
IND449check+ Weighing Terminal
NTEP-approved
class III 10,000d for strain gauge cells
class II 100,000 with approved balance
Housing
Stainless steel
Protection
IP69k
Measuring method Strain gauge
Power supply
110V AC or built-in rechargeable battery
Optional Interfaces Ethernet TCP/IP, USB, digital I/O, RS232, RS485
2158 Vertex Rocker Pin Floor Scale
Carbon steel painted or stainless steel floor scales for use as
bulk scales in harsh industrial environments.
NTEP-approved
Class III 5,000d
Weighing ranges
1,000–20,000 lb
Resolution
5,000d, 10,000d (option, non-approved)
Platform sizes
3 × 3 to 5 × 7 ft or custom dimensions
2256 VLC Floor Scales
Floor scales for use in harsh industrial environments.
NTEP-approved
Class III 5,000d
Weighing ranges
1,000–10,000 lb/450–4,500 kg
Resolution
0.2–2 lb/0.1–1kg
Platform sizes
3 × 3 to 5 × 7 ft
PBA330 and CBUx Bench Scales
Scales that can be used as bench, stand, and floor-mounted
for use as bulk scales.
NTEP-approved
PBA330 class III 5,000d
CBUx class III 10,000d
Weighing ranges
12–1,200 lb/6–600 kg
Resolution
0.002 to 0.2 lb/1–200 g
Platform sizes
9 × 9 to 24 × 32 in
240 × 240 to 600 × 800 mm
IND4x5 Weighing Terminal
NTEP-approved
class III 10,000d for strain gauge cells
class II 100,000d with approved balance
Housing
Die cast aluminum
Protection
IP65
Measuring method Strain gauge
Power supply
110V AC or built-in rechargeable battery
Connection
Can connect up to 2 scales
Optional Interfaces Ethernet TCP/IP, USB, digital I/O,
RS232, RS485
BBA449check+ Compact Scale
NTEP-approved
Class III 5,000d
Housing
Stainless Steel
Protection
IP69k
Measuring method Strain gauge
Power supply
110V AC or built-in rechargeable battery
Platform size A
9,4 × 11.8 in
Platform size QA 9 × 9 in
Platform size B
15.7 × 19.7 in
Platform size QB 12 × 12 in
Platform size BB
11.8 × 15.7 in
Model
Weighing range Resolution
Pf. size (in)
BBA449 003Z
6 lb × 0.001lb
3 kg × 0.0005 g A
BBA449 006Z
12 lb × 0.002 lb
6 kg × 0.001g
A, QA
BBA449 015Z
15 lb × 0.002 lb
6 kg × 0.001g
A, QB
BBA449 030Z
30 lb × 0.005 lb
15 kg × 0.002 g BB, QB, B
BBA449 060Z
60 lb × 0.01 lb
30 kg × 0.005 g BB, QB, B
BBA449 150Z
150 lb × 0.02 lb
60 kg × 0.01g
B
Optional Interfaces Ethernet TCP/IP, USB,
WLAN, digital I/O, RS232, RS485
IND690count Weighing Terminal
NTEP-approved
class III 10,000d for strain gauge cells
class II 100,000d for K-Line, BBK, AB, X
Housing
Stainless steel
Protection
IP69k
Measuring method MonoBloc and strain gauge
Connection
Can connect up to 4 scales
Optional Interfaces Ethernet TCP/IP, Profibus DP, DeviceNet,
WLAN, Bluetooth, USB, RFID, digital I/O, RS232,
Current Loop, RS485/422, analog output
7
Piece Counting
Reliable Numbers for Incoming Goods
Facilitate Seamless Production
Precise weighing and counting
from 1 mg to 6000 kg
METTLER TOLEDO has a range of
scales that cover all counting and
weighing requirements for incoming
goods. The incoming goods area
of a company is often very hectic.
Depending on the situation, many
deliveries are often accepted and
checked at the same time. Packages
have different sizes, ranging from
containers, through pallets, right
down to smaller packages and even
letters with small consignments.
The weighing technology used for
incoming goods must therefore cover
a wide range from 0.000002 to
12,000 lb. In certain circumstances,
as many as 10,000 pieces must be
counted within one package. Precise
weighing down to the last and even
lightest piece requires a precision
bench scale. Counting pieces that are
delivered on pallets or in bulk containers require high capacity scales.
BigWeight® display –
never get fatigued
The bright, high-contrast graphic
display of the IND690count,
provides the user with legible instructions and information. The patented BigWeight® function is unique.
It allows you to avoid reading errors
and premature fatigue. The keys,
which are uniquely labeled for piece
counting, enable efficient work
and help prevent operator errors.
8
Robust industrial equipment
In the shipping and receiving area,
awkward and heavy packages
are transported manually, with a
fork-lift truck, a hand-truck
or even a crane. METTLER TOLEDO
scales withstand these conditions due to their high overload
protection. Their terminals are
protected up to IP69k and continue
to work reliably even in dusty
or damp environments.
Several printers connectable
Several label printers can be connected to the IND690. This increases
efficiency if you need several label
sizes. The layout and configuration of
the label size can be stored directly
on the printer. You don’t need an
additional IT system just for printing.
Network capable
The data recorded via the barcode
readers can be transferred to an
IND690count terminal via RS232,
USB or Bluetooth. The data is then
transferred via Ethernet TCP/IP or
Profibus to the ERP system or the
PLC. The IND690count terminal then
assumes the function of a local
network node with user guidance.
Greater efficiency with a database
The IND690count has a database with 999 storage
locations for the part ID, piece weight, tare weight
and target weight with tolerances. The stored values
can be called up by barcode reader or keyboard.
The database can be easily edited and stored
on the computer using the “COUNT Tool“ software
Always the correct scale, with
multiple connection capabilities
Always count and weigh on the right
scale and at the right place.
Up to four scales can be connected to
an IND690count terminal.
9
Piece Counting
Every Piece is Important –
in the Warehouse, When Taking Inventory,
Order Filling and Shipping Goods
User-friendly order filling
with colorWeight®
Even if there is a large number of
bags, order filling remains easy
and efficient. The BBA449check+
supports the operator with the
colorWeight®functionintargetweighing. The back-lit display of
this counting scale can change its
color from light blue to green,
yellow or red. The limits for the color
change can be set with the key
board. It can change to one of the
three colors after the preset number
of parts is reached. The customer
can determine which color he wants
to allocate to which status.
The scale can also signal the filling
status to a machine with digital I/O.
Target count not reached.
Still far away from target.
Target count not reached.
Close to target.
Target count reached, OK.
Overfill.
Target count exceeded.
10
Network capable
or keyboards can be transferred to
the scale. The data is transferred via
Ethernet TCP/IP to a computer or
the ERP system. The compact scales
BBA4x2, BBK4x2 or the IND4x5
terminal assume the role of local network nodes.
Mobile counting in the order picking warehouse
be operated on a cart. Compact scales BBK462
and BBA462 have 1500 storage locations for
target weight, tolerance, identification, piece weight
and tare weight. Barcode readers, a keyboard or
printer can be also connected. This keeps the scale
mobile throughout the day and allows it to be
used independently in the order picking warehouse.
Greater efficiency with a database
The IND465, BBA462 and BBK462
models have a database with
1500 storage locations. The storage
locations offer enough space for
the part ID, piece weight, tare weight
and target weight with tolerances.
The stored values can be called up
The database can be easily edited,
managed and stored on the computer using the “Smart Manager”
program. It can also be used to
The “Smart Manager” even allows
import/export of data files for
use with MS Excel®.
Printers
a multitude of various label,
strip and ticket printers. The print
possibilities vary depending
on the built-in application.
11
High-resolution
Two-scale System
Piece weights vary from piece to piece. It depends on the machine, the day or the
operator who has produced the parts. A small error when determining the average
piece weight is multiplied when counting larger quantities. Therefore, when there
is a large variation, the average piece weight must be determined using a greater
number of reference pieces. You also require a high-resolution and high-precision
reference scale.
For very small parts, the AB104-S and AB304-S platforms are used. The AB104-S and
AB304-S can be connected as reference scales or stand-alone scales to the IN690count,
IND465, IND445, IND435 and IND449check+ counting terminals. They act as pure
reference scales together with compact scale models BBK432, BBK442 and BBK465.
This allows you to use all the features that make the METTLER TOLEDO scales so userfriendly and efficient with the highest resolution and precision.
www.mt.com/counting
USA
Mettler-Toledo, Inc.
1900 Polaris Parkway
Columbus, Ohio 43240
Tel. (800) 523 5123
Subject to technical changes
Printed in USA
ISP-0708-LIT
Mettler-Toledo, Inc.