PCB Piezotronics 1204-12A User manual

Model 1204-12A/084A101
PCB L&T load cell, low profile, 25,000 lbf rated capacity, 50% overload
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: [phone]
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.
Total Customer Satisfaction –PCB
Piezotronics guarantees Total Customer
Satisfaction. If, at any time, for any
reason, you are not completely satisfied
with any PCB product, PCB will repair,
replace, or exchange it at no charge.
You may also choose to have your
purchase price refunded in lieu of the
repair, replacement, or exchange of the
product.
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 insure 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 insure that your
returned materials are handled in the
most expedient manner. Before
Warranty, Service, Repair, and
Return Policies and Instructions

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
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.
Warranty –All equipment and repair
services provided by PCB Piezotronics,
Inc. are covered by a limited warranty
against defective material and
workmanship for a period of one year
from date of original purchase. Contact
PCB for a complete statement of our
warranty. Expendable items, such as
batteries and mounting hardware, are
not covered by warranty. Mechanical
damage to equipment due to improper
use is not covered by warranty.
Electronic circuitry failure caused by the
introduction of unregulated or improper
excitation power or electrostatic
discharge is not covered by warranty.
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: [phone]
24-hour SensorLineSM: [phone]
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
O
O
O
O
O
O
PCB板
X
O
O
O
O
O
电气连接器
O
O
O
O
O
O
压电晶体
X
O
O
O
O
O
环氧
O
O
O
O
O
O
铁氟龙
O
O
O
O
O
O
电子
O
O
O
O
O
O
厚膜基板
O
O
X
O
O
O
电线
O
O
O
O
O
O
电缆
X
O
O
O
O
O
塑料
O
O
O
O
O
O
焊接
X
O
O
O
O
O
铜合金/黄铜
X
O
O
O
O
O
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: C
ECN: 45605
Component Name
Hazardous Substances
Lead
(Pb)
Mercury
(Hg)
Cadmium
(Cd)
Chromium VI
Compounds
(Cr(VI))
Polybrominated
Biphenyls
(PBB)
Polybrominated
Diphenyl
Ethers (PBDE)
Housing
O
O
O
O
O
O
PCB Board
X
O
O
O
O
O
Electrical
Connectors
O
O
O
O
O
O
Piezoelectric
Crystals
X
O
O
O
O
O
Epoxy
O
O
O
O
O
O
Teflon
O
O
O
O
O
O
Electronics
O
O
O
O
O
O
Thick Film
Substrate
O
O
X
O
O
O
Wires
O
O
O
O
O
O
Cables
X
O
O
O
O
O
Plastic
O
O
O
O
O
O
Solder
X
O
O
O
O
O
Copper Alloy/Brass
X
O
O
O
O
O
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.

Model Number
1204-12A LOW PROFILE LOAD CELL Revision: B
ECN #: 43809
Performance ENGLISH SI
Measurement Range 25 lbf 111 N [6][7]
Sensitivity(± 10 %)(RO) 4.0 mV/V 4.0 mV/V [3][1]
Non-Linearity ≤ 0.05 % FS ≤ 0.05 % FS [6][8]
Hysteresis ≤ 0.06 % FS ≤ 0.06 % FS [6][8]
Non-Repeatability ≤ 0.01 %RO ≤ 0.01 %RO [3][8]
Eccentric Load Sensitivity 0.25 %/in 0.25 %/25.4mm [8]
Resonant Frequency 12 Hz 12 Hz
Side Load Sensitivity 0.25 %/in 0.25 %/25.4mm [8]
Creep(in 20 minutes) 0.025 % 0.025 % [8]
Static Error Band ≤ 0.05 % FS ≤ 0.05 % FS [6][8]
Environmental
Overload Limit 37.5 lbf 167 N
Load Limit(Side Force, FX or FY) 10 lbf 44 N [4]
Load Limit(Bending Moment, MX or MY) 10 lbf-in 1130 Nm [4]
Load Limit(Axial Torque, MZ) 10 lbf-in 1130 Nm [4]
Temperature Range(Operating) -65 to +200 °F -54 to +93 °C
Temperature Range(Compensated) +15 to +115 °F -9 to +46 °C
Temperature Effect on Output(Maximum) ± 0.0008 %Reading/°F ± 0.0018 %Reading/°C [5]
Temperature Effect on Zero Balance(Maximum) ± 0.0008 %FS/°F ± 0.0018 %FS/°C [5]
Electrical
Bridge Resistance 350 Ohm 350 Ohm [1]
Excitation Voltage(Recommended) 10 VDC 10 VDC [2]
Insulation Resistance >5K GOhm >5K GOhm
Zero Balance ± 1 %RO ± 1 % FS [3]
Output Polarity +Tension +Tension
Physical
Size (Diameter x Height) 6.06 in x 3.50 in 153.9 mm x 88.9 mm [9]
Weight 21 lb 9.53 g
Mounting Thread 1 1/4 - 12 UNF-3B No Metric Equivalent
Housing Material Painted Steel Painted Steel
Sensing Element Strain Gage Strain Gage
Mounting Torque 1400 lbf-in 158 Nm
Deflection at Full Scale Capacity 0.002 in 0.05 mm
Electrical Connector PT02E-10-6P PT02E-10-6P
All specifications are at room temperature unless otherwise specified.
In the interest of constant product improvement, we reserve the right to change specifications without notice.
1204-12B - PC04E-10-6P Connector
1204-12C - PT02E-12-8P Connector
1204-12D - PC01E-12-8P Connector
NO ES:
[1]Nominal.
[2]Calibrated at 10 VDC, usable 5 to 20 VDC or VAC RMS.
[3]RO - Rated Output.
[4]Singularly applied, i.e. no other extraneous loads.
[5]Over compensated operating temperature range.
[6]FS - Full Scale.
[7]Calibrated in tension and compression.
[8]Performance specifications guaranteed with factory installed optional Tension Base 084A101
[9]See Outline Drawing 49932 for Complete Dimensions
OP IONAL ACCESSORIES:
Model 084A101 TENSION LOAD BASE W/ 1.25-12 THD.
Model 084A56 Pre-Tension Stud
Model 084A90 Connector Shroud
Model 181-012A PT06A-10-6S(SR)
Model 8311-01-10A CABLE
PCB Load & Torque, Inc.
24350 Indoplex C rcle
Farm ngton H lls, MI 48335
UNITED STATES
Phone: [phone]
Fax: [phone]
E-Ma l: lt [e-mail]
Web s te:
http://www.pcbloadtorque.com
OPTIONAL VERSIONS
Optional versions have identical specifications and accessories as listed for the standard model
except where noted below. More than one option may be used.
Entered: AP Engineer: PE Sales: JC Approved: JSD Spec Number:
Date: 2/16/2015 Date: 2/16/2015 Date: 2/16/2015 Date: 2/16/2015 56134

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
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
2
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)
1
2.50 63.5 3.50 88.9 4.50 114.3 6.50 165.1
2
1.37 34.8 1.75 44.5 2.50 63.5 3.50 88.9
3
1.13 28.7 1.75 44.5 2.00 50.8 3.00 76.2
4
1.25 31.8 1.63 41.4 2.25 57.2 3.25 82.6
∅
∅∅
∅ 5
4.12 104.6 6.06 153.9 8.00 203.2 11.00 279.4
R 6 2.54 64.6 3.53 89.7 4.85* 123.2* 6.10* 154.9*
∅
∅∅
∅ 7
3.50 88.9 5.13 130.2 6.50 165.1 9.00 228.6
∅
∅∅
∅ 8
1.25 31.8 2.42 61.4 3.50 88.9 5.38 136.5
∅
∅∅
∅ 9
1.25 31.8 2.25 57.2 3.50 88.9 4.50 114.3
10
45º 30º 22.5º 22.5º
11
0.25 6.4 0.37 9.4 0.48 12.2 0.75 19.1
12
0.03 0.76 0.03 0.76 0.03 0.76 0.03 0.76
13
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
14
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
15
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
1
Total Height
2
Load Cell Height
3
Tension Base Height
4
Load Cell Body
Height
∅
∅∅
∅ 5
Load Cell Diameter
R 6
Max. Clearance
Radius
∅
∅∅
∅ 7
Bolt Circle Diameter
∅
∅∅
∅ 8
Top Loading Surface
Diameter
∅
∅∅
∅ 9
Bottom Loading
Surface Diameter
10
Angle Between
Screws
11
Screw Head Height
12
Bottom Loading
Surface Height
13
Screw for Tension
Base
14
Load Cell Mounting
Thread
15
Tension Base
Mounting Thread
Table 1 – Dimension
Descriptions
∅
∅∅
∅ 9
15
1
2
3
4
11
∅
∅∅
∅
5
12
1
0
R
6
1
3
1
4
∅
∅∅
∅
7
∅
∅∅
∅
8

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GENERAL PURPOSE LOW PROFILE LOAD CELL OPERATION MANUAL
3
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
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

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GENERAL PURPOSE LOW PROFILE LOAD CELL OPERATION MANUAL
4
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
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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
C
A
D
B
- 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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6.1.1 Measured Output
The applied load starting at zero is measured in five
increments to full scale. Output (mV/V) is measured at each
increment. The straight-line from zero to the full scale
measurement is compared to the measured readings at each
increment to calculate the error at each load increment. The
deviations (% Full Scale) corresponding to non-linearity at
each measurement increment are then calculated.
6.1.2 Hysteresis
The difference between the ascending and descending
measured readings at 40% of full scale is used to calculate the
hysteresis value.
6.1.3 Best Fit Output
The best fit calibration second-order equation has been
calculated from the calibration data by the method of least
squares. Deviation between measured output and best-fit
output is calculated and displayed in the column next to the
best-fit output for each measurement increment. The
deviations (% Full Scale) of measured outputs from the
calculated best fit are tabulated for each measured reading.
6.1.4 Strain Gage Measurements
6.1.5 Shunt Calibration Standard Resistor
All low profile load cell calibrations use a 120kΩ(±0.1%) (for
1200 series) or a 60kΩ(±0.01%) (for 1400 series) precision
resistor shunt calibration value that is supplied into the
calibration report.
6.1.6 Static Error Band (SEB)
The static error band (SEB) is determined by the maximum
deviations of the ascending and descending calibration points
from the best fit straight line through zero output. The SEB
includes the effects of nonlinearity, hysteresis, and non-return
to minimum load.
7.0 MOMENT COMPENSATION
When an eccentric axial load is
applied to a load cell that is not
coincident exactly with the
centerline of the load cell, it
introduces bending moments
into the load cell structure. The
strain gage bridges on general
purpose low profile load cells
are adjusted such that the error
due to eccentric loading is less
than ±0.25% per inch of offset
for 1200 series load cells and
±0.1% per inch of offset for
fatigue-rated 1400 series load
cells.
Side loads, moments and torque must be limited to avoid
electrical or mechanical damage to the load cell. The
allowable extraneous loads are directly related to the rated
capacity of the load cell.
•Maximum side force allowed is 100% of the rated
capacity for the load cell.
•Maximum moment allowed is 100% of the rated
capacity times 1 inch.
•Maximum torque allowed about the measurement
axis is rated capacity times 1 inch.
8.0 FATIGUE & OVERLOAD
Fatigue-rated low profile load cells (1400 series) are designed
and manufactured to perform accurately and reliably for 100
million fully reversed full scale load cycles. They have been
specifically designed for applications involving high cycle
fatigue loading on products and structures. The designs are
based on nearly three decades (since 1986) of experience in
the design and manufacture of precision low-height load cells.
The load cell structure is machined from aircraft quality alloy
steel, heat treated, and finished with attention to details critical
for maximum fatigue life. For maximum stiffness and low
stresses throughout the load cell structure, the maximum
stresses are concentrated precisely under the strain gages.
The load cell structural safety factor against fatigue failure is
in excess of 2.5 for alloy steel and 2 for aluminum. See Figure
14. The maximum shear stress measured by the bonded strain
gages is less than 40% of the endurance limit shear stress for
alloy steel and 48% for aluminum.
Bridge Resistance: 350 Ohm Nominal
Excitation: +P(A) to –P(D) Ohms
Signals: +S(B) to –S(C) Ohms
Leakage to Ground: > 5k GOhm
Bridge Unbalance: ±1.0% Full Scale
Output: 4.0 mV/V Nominal (1200 Series)
2.0 mV/V Nominal (1400 Series)
Maximum Voltage: 20 VDC
Table 7 – Strain Gage Measurements
T
M
X
M
Y
S
Primary
Axis
Figure 13 - Extraneous Loads

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The strain gages used are made with Modulus Compensated
Modified Karma Alloy. The alloy steel gages have a safety
factor against fatigue of approximately 2, and the aluminum
gages’ is approximately 4 as shown in Figure 15.
Fatigue-rated low profile load cells are capable of surviving
exceptionally high overloads. Occasional loads up to 300% of
the rated capacity (due to accidental overload) have a safety
factor against yield of the strain gage sections of
approximately 1.5 for both alloy steel and aluminum as shown
in Figure 16. Non-fatigue-rated low profile load cells can
handle loads up to 150% of the rated capacity.
9.0 SHUNT CALIBRATION DESCRIPTION
Shunt calibration is used to simulate a known tension or
compression load on a load cell. The calibration certificate
will indicate which leg of the bridge to apply the shunt resistor
to for both tension and compression load simulation. Typically
tension is simulated by inserting the shunt resistor between the
+P and +S connector leads. Compression loading is simulated
by inserting the shunt resistor between the +S and –P
connector leads.
9.1 Resistor Value
General purpose low profile load cells have a nominal 4.0
mV/V full scale output for non-fatigue rated and a nominal 2.0
mV/V full scale output for fatigue-rated. For a 350Ωstrain
gage bridge the precision shunt resistor, 120kΩ±0.1% for
non-fatigue-rated (1200 series), and 60kΩ±0.01% for
fatigue-rated (1400 series), simulates an output of
approximately 73% of the full scale output for the load cell.
The calibration values for each bridge are found on the
calibration certificates supplied with each load cell.
9.2 Shunt Calibration Process
To perform the shunt calibration, use the following procedure:
1. Stabilize all forces on the load cell. If possible,
remove all loads.
2. Power up the host signal conditioner and connect it to
the load cell via appropriate cable, and allow for a 30
minute warm up.
3. Set the load indicator display to read exactly 00.000.
4. Connect the shunt resistor to the terminals specified
in the calibration certificate, and adjust the span or
gain until the display reads the force value stated on
the certificate.
5. Repeat steps 1-3 to verify that a valid calibration
setting has been obtained.
6. If possible, apply a known load to the measurement
system to further verify that the calibration has been
accurately set up.
9.3 Estimating Shunt Resistor for a Given Load
The following formula can be used to estimate the
approximate value of shunt resistor required to simulate a
mechanical load.
R
cal
= (25 * R
b
) / (Output
FS
* L
cal
)
Where: R
cal
= Shunt Resistor (K ohms)
R
b
= Bridge Resistance (ohms)
Output
FS
= Full Scale output of the load cell (mV/V)
L
cal
= Load to be simulated, % of Load Cell Capacity
10.0 MAINTENANCE
Routine maintenance of the low profile load cell should
include cleaning the electrical connectors, housings, and
mounting surfaces with solutions and techniques that will not
harm the physical material of construction. Make sure liquids
Steel Safety Factor > 2.5
Aluminum Safety Factor ≈2
Note:
Aluminum alloy does
not have an endurance limit.
Figure 14 - S-N Curve (Load Cell)
Figure 15 - Strain-N Curve (Strain Gages)
Figure 16 - Shear Stress/Strain Curves (Fatigue-Rated Load Cell)
10
2
10
3
10
4
10
5
10
6
10
7
10
8
10
9
Endurance Limit
Number of Load Cycles (Fully Reversed)
Shear
Stress
(ksi)
120
100
80
60
40
20
S.F. Steel
S.F. Alum.
Aircraft Quality Steel Alloy
Aluminum Alloy
10
2
10
3
10
4
10
5
10
6
10
7
10
8
10
9
5000
4000
3000
2000
1000
Number of Load Cycles (Fully Reversed)
Steel (2 mV/V)
Microstrain
Aluminum (4 mV/V)
Modulus Compensated
Modified Karma Alloy
Strain Gages Strain Gage Safety Factors
Steel S.F. ≈2
Aluminum S.F. ≈4
Design Stress
Steel = 25 psi
Aluminum = 8 psi
25
125
100
75
50
150
Strain
Shear
Stress
(psi)
Yield Alloy Aluminum
Yield Alloy Steel
Safety Factor
≈
1.5 @ 300% Overload
300% Overload Steel

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GENERAL PURPOSE LOW PROFILE LOAD CELL OPERATION MANUAL
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are not allowed to migrate into devices that are not
hermetically sealed. Such devices should only be wiped with
a damp cloth, and never be submerged or have liquids poured
on them. Never use a pressure washer on the load cells.
General purpose low profile load cells, when mounted on the
factory supplied base, are barometric compensated through a
small port located in one of the spanner wrench holes on the
base.
The bolts used to install bases at the factory have been
tightened to specifications to prevent loosening under normal
usage. However, if the base has been removed for any reason,
or the load cell has been mounted on a custom fixture without
the base, it is a good idea to periodically test the mounting bolt
tightness using a calibrated torque or click wrench.
11.0 TROUBLE SHOOTING
Proper performance of a load cell requires careful attention to
both electrical and mechanical aspects of the measurement
system. A basic understanding of the electrical and
mechanical installation requirements is recommended.
11.1 Mechanical Trouble Shooting
A mechanical checklist includes:
1. Check for proper installation of load cell.
2. Check for properly tightened bolts.
11.2 Electrical Trouble Shooting
An electrical checklist should start with:
1. Check cables for proper wiring.
2. Inspect for loose or dirty electrical connections.
3. Check for improper shield grounds.
4. Check for proper grounding of the structure that the
load cell is mounted on.
5. Check the signal conditioning electronics for proper
setup.
6. Check the insulation resistance of shielded
conductors for short circuits.
7. Check isolation resistance, load cell flexure to
conductors.
8. Check load cell bridge resistances, (A-D) excitation
and (B-C) the signal leads.
9. Check bridge balance.
10. Keep a record of your observations, correct problems,
or contact PCB factory for assistance.
11.2.1 Estimating Bridge Balance using an Ohm Meter
A load cell that has been severely overloaded will exhibit a
significant zero offset in the Wheatstone bridge. It can be
useful to estimate the bridge unbalance using a digital ohm
meter with resolution of at least 0.1 ohm.
Following the Western Region wiring diagram measure the
resistances for each leg of the bridge, i.e.: R
AB
, R
AC
, R
DB
, and
R
DC
.
1. Estimate the Zero Offset (mV/V):
Zero Offset = 1.4 x (R
AC
- R
AB
+ R
DB
- R
CD
)
2. Estimate the Bridge Unbalance (% Full Scale):
Bridge Unbalance = 100 x (Zero Offset / Output
FS
)
Where: Output
FS
= Full Scale output of the load cell (mV/V)
A Zero Offset of greater than 10% indicates probable overload
or possible fatigue damage. A load cell that has been
significantly overloaded enough to create a large zero offset is
not repairable. In some instances it may be possible to
temporarily continue to use the load cell by attempting to
balance the bridge through use of external resistors. However,
the user should expect that such a load cell no longer will meet
the performance parameters related to its original
specifications. (User beware!!)
12.0 CALIBRATION / REPAIR SERVICES
PCB Load & Torque offers calibration and repair services.
The PCB Calibration Laboratory in Farmington Hills,
Michigan is A2LA Accredited per ISO/IEC 17025.
D
B
C
A
R
DB
R
CD
R
A
B
R
AC
Figure 17 – Wheatstone Bridge

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Standard calibration certificates list five force points
ascending and one point descending in both tension and
compression. Additional data points are available at extra cost
upon request.
Certificate information includes tabulated measurement
variable data zero balance, bridge input/output resistance,
computer nonlinearity and hysteresis, static error band (SEB)
calculations and entries abilities and traceability statements.
If an initial evaluation shows that a transducer requires repair,
PCB will provide the customer with an estimate prior to taking
any corrective action.
12.1 RMA / Purchase Order
Please request a return material authorization (RMA) before
sending a load cell back to the factory for any reason. For
calibration services, if possible, a copy of the purchase order
covering the requested services should be included with the
returned load cell.
13.0 WARRANTY
Standard warranty on general purpose low profile load cells
covers parts and workmanship. For full details, refer to the
Warranty Statement supplied with each load cell.
If the load cell is defective for reasons other than overloads,
return it to the factory for detailed evaluation. Factory
evaluation may show that the load cell is repairable or non-
repairable and if repair or replacement will be under warranty.
If not under warranty, the customer will be contacted with the
cost of repairs and recalibration. Once authorization to
proceed is received, a delivery date will be provided.
Manual Number: 56261
Manual Revision: NR
Revision Date: 6/12/13
ECO Number: 41636