LORD AP5103 Series User manual

SERIES AP5103
DIN-Rail DC Strain Gage Conditioner
TECHNICAL MANUAL
Copyright © 2016 LORD Corporation • All Rights Reserved
Part No. 234200B DCN 10087
237 Commerce Drive • Amherst, NY 14228 • USA
Tel: 716.250.1900 • ax: 716.250.1909
Web: stellartech.com • Email: [email protected]
Due to the nature of technology, changes are inevitable. or latest technical specifications, see our website.
ISO 9001/AS9100
1 of 9

GENERAL DESCRIPTION AND SPECIFICATIONS
The Series AP5103 is a single-channel DIN Mount instrument which is easily
configured, rugged, analog based signal conditioner made to operate with traditional
Wheatstone mv/V stain gage bridge sensors used to measure force, pressure, torque
and other DC strain gage related measurements. The Series AP5103 has an
extremely wide DC power input range with user selectable gain, zero and anaolg
output making it adaptable to any users sensor application that requires stable,
repeatable and noise free analog signals for control or data acquisition.
The Series AP5103 is best calibrated by means of a “two-point (dead-weight)” or
shunt-calibration technique, which is outlined in section three. The supplied
calibration resistor is 59 kilohms, 1% which is located internally to the AP5103 case.
Series AP5103
DC Strain Gage Module
Access switch settings via the front
panel of the AP5103 by gently pulling
the
clear plastic cover (from the bottom
side) so the cover rotates open from
or without power to the unit. Once
completed, return the cover to the
the top. Use a small tool or finger to
place the switches to the left or right
position as you face the front of the
module. This process can be done with
original position.
DC Strain Gage Symmetry Operation
or applications requiring precision in
both tension and compression (CW &
CCW for torque cells), the AP5103
contains a symmetry adjustment which
corrects for negative span or slope of
the transducer.
Vi w of Sid Lab l of th S ri s AP5103 Strain Gag Modul
2 of 9

AP5103 SPECIFICATIONS
Measurement Range: Adjustable 0.5 mV/V to 10.0 mV/V; nominal full-scale
Transducer Types: Conventional 4-arm strain gage bridges, 120 to 10 k ohm
Excitation: 2.5 or 5.0, selectable - up to 70mA
Power Supply : 11 - 28 Vdc regulated; 2 watts max.
Analog Ouput : selectable; ± 0 to 5, ± 0 to 10 Vdc, 4-12-20 or 4-20mA
(20% over-range, voltage only)
Operating Temperature : -10 to +70 Degrees C, 5 to 95% relative humidity, non-condensing
Amplifier
Common - Mode Range : ± 3 V operating; ± 30 V without instrument damage
Common - Mode Rejection Ratio : - 60 dB @ 1/2 excitation
Input Impedance : Differential and Common-Mode > 10,000 MΩ
Offset : user adjustable; vs. Temperature: ±30 ppm /°C; vs. Time: ±10 ppm/month
Gain Accuracy : Limited only by calibration accuracy
Gain Stability : vs. Temperature: ±30 ppm/°C; vs. Time: ±10 ppm/month
Linearity : better than ± 0.03% of full scale
Filter: 3-pole modified Butterworth; 3 dB down at 10 Hz, 200 Hz or 5kHz; selectable
Step-Response Settling Time (Full-Scale Output @ 10 Hz):
To 1% of final value: 0.068 sec; (0.0034 sec @ 200 Hz) (0.00015 sec @ 5 kHz)
To 0.1% of final value: 0.090 sec; (0.0046 sec @ 200 Hz) (0.00018 sec @ 5 kHz)
To 0.02% of final value: 0.100 sec; (0.0054 sec @ 200 Hz) (0.0002 sec @ 5 kHz)
Dimensions
3 of 9

TRANSDUCER CONNECTIONS
The Series AP5103 I/O CONNECTIONS are via non-removable screw terminals which will
accept wire sizes from AWG 12 to 26. NOTE: The recommended transducer
cabling would be eight wire, individually shielded, twisted pair - wired as indicated ( ig. 1)
Sense lines must be connected at the transducer (as recommended) or at the AP5103
screw terminals - as a minimum. Table 2 denotes screw terminal assignments.
Table 2 Series AP5103 Pin Assignments
Fig. 1 Series AP5103 Transducer Cabling
4 of 9

CALIBRATION
Calibration of the AP5103 is accomplished by the conventional shunt technique, using an internally
installed calibration resistor, or via the "dead-weight" method.
Calibration Resistor. If a fixed resistor is shunted across one arm of a strain gage bridge, it
produces an unbalance equivalent to that of a particular value of mechanical input. If this Equivalent
Input value is accurately known, it can be used as a reference point for shunt calibration of the
system. Upon completion of installation of the transducer and its associated cabling, the user can:
1. Perform an overall dead weight calibration using a precisely known
value of mechanical input. The calibration can then be transferred to the
installed calibration resistor for convenience in subsequent checking.
2. Replace the installed calibration resistor with one (or an equivalent
resistance value) supplied by the transducer manufacturer to achieve a
precisely known Equivalent Input allowing the instrument sensitivity to
be adjusted correctly.
3. Determine the Equivalent Input value for the installed calibration resis-
tor, knowing the transducer sensitivity, and adjust the instrument sen-
sitivity accordingly.
A one percent, 59-kilohm calibration resistor is installed in the AP5103 at the factory. The installed
resistor can usually be used even though the transducer calibration data mentions some other
resistance value. In Section 4 of this manual, the techniques described above are demonstrated. If,
however, the installed value of calibration resistor is not appropriate for the transducer and
measurement range to be used, the 59-kilohm resistor should be replaced at this time. The
calibration resistor is mounted on terminals located internally to the AP5103 conditioner's printed-
circuit board. It can be accessed by removing the instrument case ( ig. 5).
Not : A vari ty of DC Load C lls and Slip Ring Torqu Transduc rs ar suppli d
with th appropriat calibration r sistor int gral to th transduc r. Wh n this typ
of transduc r is us d it will b n c ssary to plac a short across th 59-kilohm
r sistor int rnal to th instrum nt. Th transduc r calibration r sistor can b appropri-
at ly conn ct d to th AP5103 calibration circuit via th transduc r cabling. R f r to
cabling diragam s ction of this manual in th ar a of CAL SENSE.
This section contains the instructions for calibrating the AP5103. Included is a functional description
of the instrument front-panel (see igure 2). To perform calibration, proceed as follows with the
sensor or calibration standard connected.
A. Turn power ON to the AP5103 DC Power input terminal (11 to 28 Vdc input)
The front-panel indicator should light green to indicate the application of
dc power. Allow 10 minutes of warmup for stabilization of transducer
characteristics. Set the Coarse Zero and Span controls label marked position.
5 of 9

CALIBRATION (cont.)
B. Set the Coarse Zero and Span controls to the marked label position (<, Min>).
C. Position the front panel switches to the desired settings for the application. Refer
to ig. 2 for details. Connect readout device (i.e. voltmeter) to ANO & A Common.
D. With the transducer unloaded, adjust the Coarse Zero and the ine Zero control until
the desired analog output is achieved. If greater zero authority is desired, place the
front panel Switch 7 - "Zero Adj" to the extended range. This will allow the user to obtain
100% zero offset control. The Normal postion of switch 7 allows for approx.
25% Zero authority.
E. Apply a known dead weight value which is greater than one half of full scale
in the positive direction or activate the "SHP" terminal (shunt positive) by connecting
"SHP" to "Power Common" as described in ig. 3. Adjust Coarse Span to obtain your
nominal full scale analog output. Use ine Span control to adjust the signal to the
precise value required (or for an analog value that correspondes with the
appropriate Shunt Calibration value). Unload the transducer and check "Zero"
and adjust as necessary. Repeat Span load and verify values. If the transducer is to be
also used in the negative realm, load the transducer in the negative direction with the
the same dead weight value or activate the "SHN" (shunt negative) and adjust the
Symmetry control until you obtain the proper negative output reading.
. Repeat step (e) as needed to obtain analog output precision. Note that
any Span (gain) adjustments will effect the Zero (balance) value.
Not : Wh n appling th SHUNT r sistor valu for calibration, th s nsor should b in an
"unload d" condition.
Wh n compl t d, r plac th plastic front cov r to its original position and nsur conn ctions and
prop r shi lding to th modul , and to th DIN rail to which th AP5103 is attach d, ar corr ct.
Fig. 3 Shunt Connections
6 of 9

CALIBRATION (cont.)
If the transducer calibration is unknown, the following calculation is useful to calculate an
Equivalent Input value for the factory installed, 59K Ohm shunt resistor. This will approximate
the value assuming that the mv/V sensititivity and bridge resistance of the sensor are known.
Remote Calibration Check.
The instrument can be placed in the calibration mode
(positive or negative) by shorting pin Power Common and SHP for positive or SHN for
negative on the lower I/O connector. igure 4 indicates two methods of remotely
entering the calibration mode (external switch, or push button control). The
Remote Cal function provides a convenient method of periodically monitoring
calibration of the instrument in the positive or negative realm.
Fig. 2 Front Panel Settings and Indicators
7 of 9

VERIFICATION OF NORMAL OPERATION
It is the purpose of this section to aid the user in determining, in the event of a malfunction of which
the Series AP5103 is suspected of contributing, whether the instrument is functioning normally or
whether it is the source of the observed trouble. In the event the unit requires repair, the user may
also contact the factory Service Department or the local Daytronic Representative for assistance.
Daytronic service information is located on the last page of this document.
If the instrument is suspected of faulty operation, perform the following steps.
A. If the unit is totally inoperational (front-panel power indicator does not
light), check the primary power input terminals for proper connection.
Input power can be from 11 to 28 Vdc and will draw less than 2 watts.
If properly connected, the front panel Green LED will be illuminated. Before
reapplying power, visually inspect the power supply and the input power
connections for any discrepancy which could have caused the overload.
B. If the transducer has some preloading, the BALANCE controls may not
allow successful zeroing of the instrument output. This condition can be
remedied by connecting a resistor (50 k- 200 k range, metal-film type)
from the +Signal terminal of the transducer to the + or –Excitation Sense
terminals. The Excitation terminal to which the connection is made is
determined by the direction of the loading or off-zero reading.
C. The inability to balance correctly, where the instrument output reads
totally off scale and the BALANCE controls have no authority, can very
likely be the result of a damaged or defective transducer or cable. This
possibility can be confirmed (or eliminated) by substituting a transducer
and cable known to be in good condition or by simulating a balanced
transducer, using either a commercially available transducer simulator
or the simple star bridge arrangement shown in igure 7. The star bridge
simulates a conventional four-arm bridge in an exact condition of bal-
ance. To construct a star bridge, connect four 10% carbon resistors as
shown in igure 5. Use 180-ohm resistors to simulate a 350-ohm bridge
and use 56-ohm resistors to simulate a 120-ohm bridge. Neither the
resistor values nor temperature characteristics are critical since the
balance condition of a star bridge is not determined by the resistance
values. Solder two resistors together, then solder the remaining two
resistors together. Next, connect the two junctions together using a
separate wire as shown. There is a good reason for this method of
construction, and it should be followed. Connect the substitute or simu-
l ated transducer to the instrument I/O connector using a short 4-wire
cable configuration as shown in igure 4. Attempt to balance the substitute
simulated transducer. If conditions now appear to be normal, the transducer
or cable is at fault. If the previous difficulties persist, the AP5103 may be faulty.
8 of 9

Fig. 4 Star Bridge
Fig. 5 Internal Shunt Location
ARRANTY: Stellar Technology warrants that its product shall be free from defective workmanship
and/or material for a twelve month period from the date of shipment, provided that Stellar Technology’s
obligation hereunder shall be limited to correcting any defective material OB our factory. No
allowance will be made for any expenses incurred for correcting any defective workmanship and/or
material without written consent by Stellar Technology. This warranty is in lieu of all other warranties
expressed or implied.
Copyright © 2016 LORD Corporation • All Rights Reserved
Part No. 234200B DCN 10087
237 Commerce Drive • Amherst, NY 14228 • USA
Tel: 716.250.1900 • ax: 716.250.1909
Web: stellartech.com • Email: [email protected]
Due to the nature of technology, changes are inevitable. or latest technical specifications, see our website.
ISO 9001/AS9100
9 of 9
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