PCB Piezotronics 1203-15A Manual de usuario

Model 1203-15A

LOW PROFILE LOAD CELL

Installation and Operating Manual

For assistance with the operation of this product,

contact PCB Piezotronics, Inc.

Toll-free: 800-828-8840

24-hour SensorLine: 716-684-0001

Fax: 716-684-0987

E-mail: [email protected]

Web: www.pcb.com

The information contained in this document supersedes all similar information that

may be found elsewhere in this manual.

Service –Due to the sophisticated

nature of the sensors and associated

instrumentation provided by PCB

Piezotronics, user servicing or repair is

not recommended and, if attempted,

may void the factory warranty. Routine

maintenance, such as the cleaning of

electrical connectors, housings, and

mounting surfaces with solutions and

techniques that will not harm the

physical material of construction, is

acceptable. Caution should be observed

to ensure that liquids are not permitted

to migrate into devices that are not

hermetically sealed. Such devices

should only be wiped with a dampened

cloth and never submerged or have

liquids poured upon them.

Repair –In the event that equipment

becomes damaged or ceases to

operate, arrangements should be made

to return the equipment to PCB

Piezotronics for repair. User servicing or

repair is not recommended and, if

attempted, may void the factory

warranty.

Calibration –Routine calibration of

sensors and associated instrumentation

is recommended as this helps build

confidence in measurement accuracy

and acquired data. Equipment

calibration cycles are typically

established by the users own quality

regimen. When in doubt about a

calibration cycle, a good “rule of thumb”

is to recalibrate on an annual basis. It is

also good practice to recalibrate after

exposure to any severe temperature

extreme, shock, load, or other

environmental influence, or prior to any

critical test.

PCB Piezotronics maintains an ISO-

9001 certified metrology laboratory and

offers calibration services, which are

accredited by A2LA to ISO/IEC 17025,

with full traceability to SI through

N.I.S.T. In addition to the normally

supplied calibration, special testing is

also available, such as: sensitivity at

elevated or cryogenic temperatures,

phase response, extended high or low

frequency response, extended range,

leak testing, hydrostatic pressure

testing, and others. For information on

standard recalibration services or

special testing, contact your local PCB

Piezotronics distributor, sales

representative, or factory customer

service representative.

Returning Equipment –Following

these procedures will ensure that your

returned materials are handled in the

most expedient manner. Before

returning any equipment to PCB

Piezotronics, contact your local

distributor, sales representative, or

factory customer service representative

to obtain a Return Warranty, Service,

Repair, and Return Policies and

Instructions Materials Authorization

(RMA) Number. This RMA number

should be clearly marked on the outside

of all package(s) and on the packing

Service, Repair, and Return

Policies and Instructions

list(s) accompanying the shipment. A

detailed account of the nature of the

problem(s) being experienced with the

equipment should also be included

inside the package(s) containing any

returned materials.

A Purchase Order, included with the

returned materials, will expedite the

turn-around of serviced equipment. It is

recommended to include authorization

on the Purchase Order for PCB to

proceed with any repairs, as long as

they do not exceed 50% of the

replacement cost of the returned

item(s). PCB will provide a price

quotation or replacement

recommendation for any item whose

repair costs would exceed 50% of

replacement cost, or any item that is not

economically feasible to repair. For

routine calibration services, the

Purchase Order should include

authorization to proceed and return at

current pricing, which can be obtained

from a factory customer service

representative.

Contact Information –International

customers should direct all inquiries to

their local distributor or sales office. A

complete list of distributors and offices

can be found at www.pcb.com.

Customers within the United States may

contact their local sales representative

or a factory customer service

representative. A complete list of sales

representatives can be found at

www.pcb.com. Toll-free telephone

numbers for a factory customer service

representative, in the division

responsible for this product, can be

found on the title page at the front of this

manual. Our ship to address and

general contact numbers are:

PCB Piezotronics, Inc.

3425 Walden Ave.

Depew, NY14043 USA

Toll-free: (800) 828-8840

24-hour SensorLineSM: (716) 684-0001

Website: www.pcb.com

E-mail: [email protected]

PCB工业监视和测量设备 - 中国RoHS2公布表

PCB Industrial Monitoring and Measuring Equipment - China RoHS 2 Disclosure Table

部件名称

有害物质

铅(Pb)

汞

(Hg)

镉

(Cd)

六价铬(Cr(VI))

多溴联苯 (PBB)

多溴二苯醚(PBDE)

住房

PCB板

电气连接器

压电晶体

环氧

铁氟龙

电子

厚膜基板

电线

电缆

塑料

焊接

铜合金/黄铜

本表格依据 SJ/T 11364 的规定编制。

O：表示该有害物质在该部件所有均质材料中的含量均在 GB/T 26572 规定的限量要求以下。

X：表示该有害物质至少在该部件的某一均质材料中的含量超出 GB/T 26572 规定的限量要求。

铅是欧洲RoHS指令2011/65/ EU附件三和附件四目前由于允许的豁免。

CHINA RoHS COMPLIANCE

DOCUMENT NUMBER: 21354

DOCUMENT REVISION: D

ECN: 46162

Component Name

Hazardous Substances

Lead

(Pb)

Mercury

(Hg)

Cadmium

(Cd)

Chromium VI

Compounds

(Cr(VI))

Polybrominated

Biphenyls

(PBB)

Polybrominated

Diphenyl

Ethers (PBDE)

Housing

PCB Board

Electrical

Connectors

Piezoelectric

Crystals

Epoxy

Teflon

Electronics

Thick Film

Substrate

Wires

Cables

Plastic

Solder

Copper Alloy/Brass

This table is prepared in accordance with the provisions of SJ/T 11364.

O: Indicates that said hazardous substance contained in all of the homogeneous materials for this part is below the limit

requirement of GB/T 26572.

X: Indicates that said hazardous substance contained in at least one of the homogeneous materials for this part is above

the limit requirement of GB/T 26572.

Lead is present due to allowed exemption in Annex III or Annex IV of the European RoHS Directive 2011/65/EU.

PCB Load & Torque, Inc. Toll-Free in USA 866-684-7107 716-684-0001 www.pcbloadtorque.com

GENERAL PURPOSE LOW PROFILE LOAD CELL OPERATION MANUAL

TABLE OF CONTENTS

1.0 INTRODUCTION..................................................................................................................2

2.0 SAFETY PRECAUTIONS....................................................................................................2

3.0 OVERVIEW..........................................................................................................................2

3.1 Dimensions .......................................................................................................................................2

3.2 Standard Components......................................................................................................................3

3.3 Optional Components .......................................................................................................................3

4.0 MECHANICAL INSTALLATION..........................................................................................3

4.1 Mounting Bases ................................................................................................................................3

4.2 Mounting Load Cell to a Standard Base or Custom Fixture .............................................................3

4.3 Threaded Tension Rods....................................................................................................................4

4.4 Mounting Optional Connector Protectors..........................................................................................4

4.4.1 Included Components in Kit (084A90)...................................................................................4

4.4.2 Required Tools........................................................................................................................4

4.4.3 Installation of Connector Protector.........................................................................................4

5.0 ELECTRICAL INSTALLATION ...........................................................................................5

5.1 Electrical Drawing / Western Regional Std.......................................................................................5

5.2 Cable & Grounding Considerations ..................................................................................................5

6.0 CALIBRATION.....................................................................................................................5

6.1 Calibration Certificate Description.....................................................................................................5

6.1.1 Measured Output.....................................................................................................................6

6.1.2 Hysteresis................................................................................................................................6

6.1.3 Best Fit Output........................................................................................................................6

6.1.4 Strain Gage Measurements .....................................................................................................6

6.1.5 Shunt Calibration Standard Resistor.......................................................................................6

6.1.6 Static Error Band (SEB)..........................................................................................................6

7.0 MOMENT COMPENSATION...............................................................................................6

8.0 FATIGUE & OVERLOAD.....................................................................................................6

9.0 SHUNT CALIBRATION DESCRIPTION..............................................................................7

9.1 Resistor Value...................................................................................................................................7

9.2 Shunt Calibration Process.................................................................................................................7

9.3 Estimating Shunt Resistor for a Given Load.....................................................................................7

10.0 MAINTENANCE.................................................................................................................7

11.0 TROUBLE SHOOTING......................................................................................................8

11.1 Mechanical Trouble Shooting .........................................................................................................8

11.2 Electrical Trouble Shooting.............................................................................................................8

11.2.1 Estimating Bridge Balance using an Ohm Meter..................................................................8

12.0 CALIBRATION / REPAIR SERVICES...............................................................................8

12.1 RMA / Purchase Order....................................................................................................................9

13.0 WARRANTY ......................................................................................................................9

PCB Load & Torque, Inc. Toll-Free in USA 866-684-7107 716-684-0001 www.pcbloadtorque.com

GENERAL PURPOSE LOW PROFILE LOAD CELL OPERATION MANUAL

1.0 INTRODUCTION

General purpose low profile load cells manufactured by PCB

Load & Torque, Inc. are suitable for a wide range of general

force measurement applications, including weighing,

dynamometer use, and static material test machines. These

load cells are designed for use in compression and tension

loading, while being resistant to extraneous bending and side

loading forces.

In addition to our general purpose load cells, we offer a

complete line of fatigue-rated load cells which are specifically

designed for highly cyclic testing. Applications include

material testing, component life cycle testing, and structural

testing. All fatigue-rated load cells are guaranteed against

fatigue failure for 100 million fully reversed cycles, and are

extremely resistant to extraneous bending and side loading

forces.

The nominal full scale output of the general purpose low

profile load cells is 4.0 mV/V for non-fatigue-rated (1200

series) and 2.0 mV/V for fatigue-rated (1400 series).

The following document explains how to properly install the

low profile load cell, including detailed procedures on

specified torques installation, adapter thread class 3 and

tension pre-load specifications.

2.0 SAFETY PRECAUTIONS

Failure of the load cell structure or fasteners used in the load

cell installation may cause personal injury and equipment

damage.

It is important to provide adequate clearances and safety

guards or shields properly surrounding test fixtures where

fatigue rated load cells are used.

It is important to review the manufactured data when selecting

rod ends and fasteners for load cell installation. Failure might

occur due to combine measurement axis and extraneous loads

if installation specifications are not followed. All test fixtures

designed for use with low profile load cells should be

carefully evaluated for potential failure modes of the fixtures.

It is important to use threaded fasteners properly when

assembling test fixtures used with the load cells. Fixtures with

inadequately designed bolted joints, or improperly tightened

threaded fasteners can fail before the parts under test have

completed the planned fatigue test cycles.

3.0 OVERVIEW

General purpose low profile load cells come in a variety of

capacities to handle loads ranging from 250 lbf to 200,000 lbf.

3.1 Dimensions

The following figure and tables give the general outline

dimensions of the general purpose low profile load cells with

optional tension base.

Model Series

1203/1403 1204/1404 1208/1408 1211/1411

Dimensions

(see Figure 1)

(in) (mm) (in) (mm) (in) (mm) (in) (mm)

2.50 63.5 3.50 88.9 4.50 114.3 6.50 165.1

1.37 34.8 1.75 44.5 2.50 63.5 3.50 88.9

1.13 28.7 1.75 44.5 2.00 50.8 3.00 76.2

1.25 31.8 1.63 41.4 2.25 57.2 3.25 82.6

∅

∅∅

∅

4.12 104.6 6.06 153.9 8.00 203.2 11.00

279.4

2.54 64.6 3.53 89.7 4.85* 123.2* 6.10* 154.9*

∅

∅∅

∅

3.50 88.9 5.13 130.2 6.50 165.1 9.00 228.6

∅

∅∅

∅

1.25 31.8 2.42 61.4 3.50 88.9 5.38 136.5

∅

∅∅

∅

1.25 31.8 2.25 57.2 3.50 88.9 4.50 114.3

45º 30º 22.5º 22.5º

0.25 6.4 0.37 9.4 0.48 12.2 0.75 19.1

0.03 0.76 0.03 0.76 0.03 0.76 0.03 0.76

1/4-28x1 3/4

screw 12 pt.

Qty. 8

3/8-24x2 1/4

screw 12 pt.

Qty. 12

1/2-20x3 1/2

screw 12 pt.

Qty. 16

3/4-16x4 1/2

screw 12 pt.

Qty. 16

5/8-18 1 1/4-12 1 3/4-12 2 3/4-8

Thread Depth 0.88 22.4 1.37 34.8 2.12 53.8 2.56 65.0

5/8-18 1 1/4-12 1 3/4-12 2 3/4-8

Thread Depth 0.88 22.4 1.37 34.8 1.71 43.4 3.15 80.0

*Indicates dimension with connector protector.

“R6” dimensions given for PT02E-10-6P connector.

Figure 1 - Dimensions

Table 2 – Dimension Values

Dim. Description

Total Height

Load Cell Height

Tension Base Height

Load Cell Body

Height

∅

∅∅

∅

Load Cell Diameter

Max. Clearance

Radius

∅

∅∅

∅

Bolt Circle Diameter

∅

∅∅

∅

Top Loading Surface

Diameter

∅

∅∅

∅

Bottom Loading

Surface Diameter

Angle Between

Screws

Screw Head Height

Bottom Loading

Surface Height

Screw for Tension

Base

Load Cell Mounting

Thread

Tension Base

Mounting Thread

Table 1 – Dimension

Descriptions

∅

∅∅

∅

∅∅

∅

∅∅

∅

∅∅

∅

PCB Load & Torque, Inc. Toll-Free in USA 866-684-7107 716-684-0001 www.pcbloadtorque.com

GENERAL PURPOSE LOW PROFILE LOAD CELL OPERATION MANUAL

3.2 Standard Components

The following figure describes the standard components of the

general purpose low profile load cells.

3.3 Optional Components

The following figure describes the optional components of the

general purpose low profile load cells.

NOTE: Connector protectors are standard on 8” and 11”

models.

Table 3 describes the available optional components

NOTE: Pre-tension studs include the threaded stud and the

jam nut.

NOTE: The use of the tension base greatly increases the

performance of the low profile load cell.

4.0 MECHANICAL INSTALLATION

The following mechanical installation instructions should be

observed if optional components are to be used.

4.1 Mounting Bases

All low-profile load cells are calibrated with a factory

installed standard mounting base. An optional custom

(customer supplied) mounting base can, with special

arrangements, be installed and used for calibration.

However, there will be an extra charge for the installation of

the load cell on the customer’s base / fixture.

NOTE: To insure catalog performance specifications are met

the customer’s supplied fixture or base must be flat to

within 0.0002 inch and provide similar stiffness and

hardness to a factory base.

Unless otherwise specified/requested, the load cell is

calibrated with a factory installed mounting base. It is

important to note that the performance of the load cell may

be affected if the mounting base is not used or modified.

4.2 Mounting Load Cell to a Standard Base or

Custom Fixture

If the load cell is to be mounted to a custom base or fixture, it

is necessary to consider the following:

1. The thickness of the new base or fixture must not be

any thinner than the original base supplied with the

load cell. Materials used must have the same

temperature coefficient of expansion (for example,

4140 Steel).

2. The mounting surface must be flat (within 0.0002

inches), and steel fixtures must have a hardness of

Rockwell C 38 to 42.

3. The threaded holes and under-head of the fasteners

must be lightly lubricated with 30 weight oil or

equivalent prior to tightening the mounting bolts.

4. Refer to Table 4 for the final tightening torque

required for each bolt size.

5. Tighten the bolts in an incremental cross pattern with

the following sequence: start with all bolts finger

tight followed by 25%, 50% and finally 100% of the

required torque being applied.

Tension

Base

Connector

Protector

Pre

Tension

Stud

Pre

Tension

Stud

Jam Nut

Load Cell

Connector

Figure 2 – Standard Components

Figure 3 – Optional Components

Item Number Item Description

084A40 Lifting Rings (side), 1211/1411 Series

084A41 Lifting Plug (top), 1211/1411 Series

084A55 Pre-Tension Stud (5/8”-18 Thread), 1203/1403 Series

084A56 Pre-Tension Stud (1 ¼”-12 Thread), 1204/1404 Series

084A57 Pre-Tension Stud (1 ¾”-12 Thread), 1208/1408 Series

084A58 Pre-Tension Stud (2 ¾”-8 Thread), 1211/1411 Series

084A59 Pre-Tension Stud (2 ¾”-8 to 1 ¾”-12 Thread) 1211/1411 Series

084A90 Connector Protector, 1403 and 1404 Series

084A100 Tension Base (5/8”-18 Thread) 1203/1403 Series

084A101 Tension Base (1 ¼”-12 Thread) 1204/1404 Series

084A103 Tension Base (1 ¾” -12 Thread) 1208/1408 Series

084A104 Tension Base (2 ¾” -8 Thread) 1211/1411 Series

Table 3 – Optional Components

PCB Load & Torque, Inc. Toll-Free in USA 866-684-7107 716-684-0001 www.pcbloadtorque.com

GENERAL PURPOSE LOW PROFILE LOAD CELL OPERATION MANUAL

4.3 Threaded Tension Rods

NOTE: Threaded tension rods are an optional feature on the

low profile load cell.

Installation of the load cell

starts with tension pre-loading

the load cell to 120-150% of

full scale capacity and lightly

tightening a jam nut to lock in

the preload on both the load cell

and base tension rods. Once the

preload tension is released, the

threads will be securely

engaged.

Failure to pre-load the

attachment rods/ fixtures can

result in damage to the threads

on the load cell and base during

cyclic load tests.

Threaded rods engaging the load cell should have Class 3

threads to ensure thread-to-thread close contact forces.

NOTE: It is important that the tension rods installed in the

load cell and base use full thread engagement, but are

not jammed, or torqued. They should be ½-1 turn

from the bottom of the threads in both the base and

load cell.

4.4 Mounting Optional Connector Protectors

Models 1203, 1403, 1204, and 1404 general purpose low

profile load cells do not come standard with connector

protectors. If optional connector protectors are to be mounted,

it is necessary to consider the following:

4.4.1 Included Components in Kit (084A90)

4.4.2 Required Tools

4.4.3 Installation of Connector Protector

1. Remove the #4-40 x 1/4” button head cap screws

from the connector using a 1/16” hex wrench as

shown in Figure 7.

2. Carefully pull the connector from the load cell. Take

care to not break or loosen any wire connections.

3. Slide the connector protector (54823-02) behind the

connector as shown in Figure 8.

4. Apply a drop Loctite® Threadlocker Blue 242® to

the threads of the #4-40 x 3/8” socket head cap

screws.

NOTE: Please refer to the Loctite® Threadlocker Blue 242®

technical data sheet for directions of use.

5. Attach the connector protector (54823-02) to the load

cell with the #4-40 x 3/8” socket head cap screws

using a 3/32” hex wrench as shown in Figures 9 and

10.

Bolt Size Part Number Installation Torque

1/4-28x1 3/4

100-8011-10 15-17 LbFt (180-204 LbIn)

3/8-24x2 1/4

100-8082-20 75-80 LbFt (900-960 LbIn)

1/2-20x3 1/2

100-8011-30 120-130 LbFt (1440-1560 LbIn)

3/4-16x4 1/2

100-10026-40 370-400 LbFt (4440-4800 LbIn)

Table 4 – Tension Base Installation Torque Values

Jam Nut

Preload (120

150% FS)

Pre

Tension

Stud w/3B

Threads

Jam Nut

Pre

Tension

Stud w/3B

Threads

Preload (120

150% FS)

Figure 4 – Installation of Pre-

Tension Studs

Table 5 - Kit Components

Component Quantity

Connector Protector (54823-02) 2

#4-40 x 3/8” Socket Head Cap Screw 8

Figure 5 - Connector

Protector (54823-02) Figure 6 - #4-40 x 3/8”

Socket Head Cap Screw

Table 6—Required Tools (Not Included)

1/16” Hex Wrench

3/32” Hex Wrench

Loctite® Threadlocker Blue 242®

Figure 7 - Remove the #4-40 x 1/4”

Button Head Cap Screws Figure 8 - Slide the Connector

Protector (54823-02) Behind the

Connector

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GENERAL PURPOSE LOW PROFILE LOAD CELL OPERATION MANUAL

5.0 ELECTRICAL INSTALLATION

5.1 Electrical Drawing / Western Regional Std.

All load cells are wired following the Western Region

Standard. All models utilize strain gages configured into a

Wheatstone Bridge Circuit to produce the primary sensing

element. The four-arm Wheatstone bridge configuration is

shown below in Figure 11.

The gages are bonded to the load cell's structure.

Typically, a regulated DC or AC excitation is applied

between A and D of the bridge. When a force is applied to

the load cell, the Wheatstone bridge becomes unbalanced,

causing an output voltage between B and C, which is

proportional to the applied load. This configuration allows

for temperature and pressure compensation, as well as

cancellation of signals caused by forces not directly

applied to the axis of the applied load. Output is typically

expressed in units of mV/V of excitation.

5.2 Cable & Grounding Considerations

Proper grounding and shielding is required to prevent

electrical noise in strain gage load cell measuring systems.

The cable must be shielded twisted pairs with a drain wire.

Cable shields must be grounded only at one end, for example,

on the instrument or control system ground. The load cell

case is grounded by mechanical attachment to the structure to

which it is mounted.

The instrument or control system is grounded through its

power cord. Ground loops and measuring system wiring may

result in unstable or noisy signals.

A simple test with a voltmeter connected between the power

cord ground and the structure on which the load cell is

mounted can confirm that the structure has been properly

grounded. If the power cord ground and structure ground are

not at the same potential, it may be necessary to provide a

secure structure ground, perhaps by driving a copper rod and

attaching a ground strap.

6.0 CALIBRATION

Every general purpose low profile load cell purchased from

PCB Load & Torque, Inc. has been fully calibrated in tension

and compression per ISO/IEC 17025 procedures, and meets all

published specifications. Each load cell will come with a

calibration certificate designated with matching model and

serial numbers. PCB Load & Torque also offers calibration

services on an on-going basis.

6.1 Calibration Certificate Description

Calibration reports supplied with PCB Load & Torque general

purpose low profile load cells contain valuable information to

assist the customer in use of the equipment. A separate

calibration report is provided for tension and compression

calibrations on each bridge. Calibration procedures,

equipment, and reports comply with ISO/IEC 17025.

Load Cell Receptacle “A”: PT02E-10-6P

Mating Connector: PT06A-10-6S PCB Item No: 181-012A

Load Cell Receptacle “B”: PC04E-10-6P

Mating Connector: PC06A-10-6S PCB Item No: 182-025A

Load Cell Receptacle “C”: PT02E-12-8P

Load Cell Receptacle “D”: PC01E-12-8P

Table 6 – Electrical Connection Options

Figure 12 - Grounding

Test Rig Ground

Power Supply

Instrument Ground

Cable Shielding

Load Cell

- Signal White

- Excitation Black

+ Excitation Red

+ Signal Green

Figure 11 - Western Regional Strain Gage Committee Wiring Code

Figure 9 - Attach the Connector

Protector (54823-02) using #4-40 x

3/8” Socket Head Cap Screws

Figure 10 - Fully Assembled

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