PCB Piezotronics Triax ICP 260A01/FCS-10 User manual

Model 260A01/FCS-10
Triax ICP® force sensor, 1k lb (Fz), 500 lb (Fx,y), 2.5 mV/lb (z), 10 mV/lb (x,
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

Manual 21354 Rev E
ECN 50523
Repair and Maintenance
PCB guarantees Total Customer Satisfaction through its
“Lifetime Warranty Plus” on all Platinum Stock Products
sold by PCB and through its limited warranties on all other
PCB Stock, Standard and Special products. Due to the
sophisticated nature of our sensors and associated
instrumentation, field servicing and repair is not
recommended and, if attempted, will void the factory
warranty.
Beyond routine calibration and battery replacements
where applicable, our products require no user
maintenance. Clean electrical connectors, housings, and
mounting surfaces with solutions and techniques that will
not harm the material of construction. Observe caution
when using liquids near devices that are not hermetically
sealed. Such devices should only be wiped with a
dampened cloth—never saturated or submerged.
In the event that equipment becomes damaged or ceases
to operate, our Application Engineers are here to support
your troubleshooting efforts 24 hours a day, 7 days a
week. Call or email with model and serial number as well
as a brief description of the problem.
Calibration
Routine calibration of sensors and associated
instrumentation is necessary to maintain measurement
accuracy. We recommend calibrating on an annual basis,
after exposure to any extreme environmental influence,
or prior to any critical test.
PCB Piezotronics is an ISO-9001 certified company whose
calibration services are accredited by A2LA to ISO/IEC
17025, with full traceability to SI through N.I.S.T. In
addition to our standard calibration services, we also offer
specialized tests, including: sensitivity at elevated or
cryogenic temperatures, phase response, extended high
or low frequency response, extended range, leak testing,
hydrostatic pressure testing, and others. For more
information, contact your local PCB Piezotronics
distributor, sales representative, or factory customer
service representative.
Returning Equipment
If factory repair is required, our representatives will
provide you with a Return Material Authorization (RMA)
number, which we use to reference any information you
have already provided and expedite the repair process.
This number should be clearly marked on the outside of
all returned package(s) and on any packing list(s)
accompanying the shipment.
Contact Information
PCB Piezotronics, Inc.
3425 Walden Ave.
Depew, NY14043 USA
Toll-free: [phone]
24-hour SensorLine: [phone]
General inquiries: in[email protected]
Repair inquiries: [e-mail]
For a complete list of distributors, global offices and sales
representatives, visit our website, www.pcb.com.
Safety Considerations
This product is intended for use by qualified personnel
who recognize shock hazards and are familiar with the
precautions required to avoid injury. While our equipment
is designed with user safety in mind, the protection
provided by the equipment may be impaired if equipment
is used in a manner not specified by this manual.
Discontinue use and contact our 24-Hour Sensorline if:
Assistance is needed to safely operate equipment
Damage is visible or suspected
Equipment fails or malfunctions
For complete equipment ratings, refer to the enclosed
specification sheet for your product.
Definition of Terms and Symbols
The following symbols may be used in this manual:
DANGER
Indicates an immediate hazardous
situation, which, if not avoided, may
result in death or serious injury.

Manual 21354 Rev E
ECN 50523
CAUTION
Refers to hazards that could damage
the instrument.
NOTE
Indicates tips, recommendations and
important information. The notes
simplify processes and contain
additional information on particular
operating steps.
The following symbols may be found on the equipment
described in this manual:
This symbol on the unit indicates that
high voltage may be present. Use
standard safety precautions to avoid
personal contact with this voltage.
This symbol on the unit indicates that
the user should refer to the operating
instructions located in the manual.
This symbol indicates safety, earth
ground.

Manual 21354 Rev E
ECN 50523
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

Manual 21354 Rev E
ECN 50523
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.

ICPFORCE SENSOR OPERATION MANUAL
1
1.0 INTRODUCTION
ICPforce sensors incorporate a built-in MOSFET
microelectronic amplifier. This serves to convert the high
impedance charge output into a low impedance voltage signal
for analysis or recording. ICPsensors, are powered from a
separate constant current source, operate over long ordinary
coaxial or ribbon cable without signal degradation. The low
impedance voltage signal is not affected by triboelectric cable
noise or environmental contaminants.
Figure 1 - ICPSensor System Schematic
Power to operate ICPsensors is generally in the form of a low
cost, 24-27 VDC, 2-20 mA constant current supply. Figure 1
schematically illustrates a typical ICPsensor system. PCB
offers a number of AC or battery-powered, single or multi-
channel power/signal conditioners, with or without gain
capabilities for use with force sensors. In addition, many data
acquisition systems now incorporate constant current power for
directly powering ICPsensors. Because static calibration or
quasi-static short-term response lasting up to a few seconds is
often required, PCB manufactures signal conditioners that
provide DC coupling. Figure 2 summarizes a complete 2-wire
ICPsystem configuration.
Figure 2 Typical ICPSensor System
In addition to ease of operation, ICPforce sensors offer
significant advantages over charge mode types. Because of the
low impedance output and solid-state, hermetic construction,
ICPforce sensors are well suited for continuous, unattended
force monitoring in harsh factory environments. Also, ICP
sensor cost-per-channel is substantially lower, since they
operate through standard, low-cost coaxial cable, and do not
require expensive charge amplifiers.
Refer to the installation/outline drawing and specification sheet
at the back of this manual for details and dimensions of the
particular sensor model number(s) purchased. The following
pages give a brief description of the various sensor series
available, recommended mounting procedures, operation and
recommended calibration.
In addition to PCB’s line of ICP® sensors, each ICP® sensor
series outlined has corresponding charge output versions.
Charge mode versions with high output impedance are suited
for higher temperature, metal-to-metal and very high shock
applications. These models can also be used for applications
where it is desirable to manually set the output range.
In addition to standard products, PCB has the ability to design
and manufacture custom sensors/systems for specific
applications.
If questions arise regarding the operation or characteristics of
the force sensor products as outlined in this manual, feel free to
contact an experienced PCB applications engineer toll-free at
1-800-828-8840.
2.0 DESCRIPTION
IMPACT
Series 200 Impact Sensors are designed to measure
compression and impact forces from a fraction of a lb(N) to
50,000 lbs (to 22.4 kN). The flat sensing surface located on the
top of the sensor is designed to measure a dynamic force
quickly applied axially to the sensor.
As highlighted in Figure 3 compression forces directed against
the sensing surface produce a positive-going output. A tensile
output could be obtained if a static, steady-state load were
applied to the sensor. The maximum tensile output to be
measured would be that of the applied static, steady state load
as that load is quickly removed.
This force-directed input and corresponding output will
provide a positive going output signal in ICPmodels and a
negative going output in charge mode sensors. If desired,
adding the prefix “N” to a model number upon order, sometimes
desired for charge mode models, will indicate polarity reversal.

ICPFORCE SENSOR OPERATION MANUAL
2
Figure 3 - Series 200 ICPImpact Sensor
Polyimide film tape covers the cap surface to reduce high
frequency ringing associated with metal-to-metal impacts.
Internal mounting holes with uniform 10-32 threads are
prepared on each end of the sensor in the smaller models.Two
Model 081B05-mounting studs (M081B05 for metric
installation) are supplied. Larger ICP® Models 200C20 and
200C50, as well as charge mode model 210B50, have ¼-28
mounting provisions and are supplied with ¼-28 stud both ends
as well as a 1/4-28 to M6x1.0 for metric mounting.
Versions offering full-scale measurement ranges of 10 lb to
5000 lb compression (45 to 22kN) tension are available. For
higher ranges, consider the dedicated ring, link, or impact style
sensor configurations.
Applications include drop testing, machinery studies, punching
and forming operations, tensile testing, fatigue testing, fracture
analysis, and materials testing.
RINGS
Series 201B to 207C Ring Sensors are designed to measure
compression forces from a fraction of a lb(N) to 100,000 lbs
(to 444.8k N).
Each sensor is provided with a calibration certificate reflecting
the sensitivity of the sensor when calibrated with a PCB
supplied Beryllium Copper (BeCU)mounting stud. In the event
a customer is going to install the sensor in a fixture without a
mounting stud or with a stud of a stiffer material than the
supplied BeCu stud, the sensor sensitivity will be slightly
different.
Refer to Section 3 for recommended force ring mounting and
preload requirements.
Figure 4 outlines some possible mounting configurations to
which the ring series may be installed
Figure 4 - Series 201 to 207 ICP® Ring Force Sensor
Possible Installation Methods
GENERAL PURPOSE - RADIAL
Model 208C01-C05 General Purpose Sensors are designed to
measure compression and impact forces from a fraction of a
lb(N) to 5,000 lbs (to 22.24 kN). Tension forces can be
measured to 500 lbs (2.224 kN). Model 084A03, a supplied
convex, stainless steel cap with integral 10-32 mounting stud,
converts this tension/compression model to a sensor capable of
impact measurements. Polyimide film tape covers the cap
surface to reduce high frequency ringing associated with metal-
to-metal impacts.
GENERAL PURPOSE - AXIAL
Models 208A11-A15 Axial Sensors provide performance and
specifications similar to the Model 208C Sensors. These
sensors are designed primarily to measure compression and
impact forces from a few pounds(N) to 5,000 lbs (to 22.24 kN).
Tensile forces can be measured to 500 lbs (2.224 kN). The 10-
32 axial electrical connector orientation associated with these
sensors makes them ideal for installations where radial space is
restricted or where physical connector damage may occur due
to the nature of the specific application. The M7 x 0.75-6g
mounting threads (all models) may be installed directly into a
test structure so that the 10-32 electrical connector exits from
the opposite side of the mounting fixture. This helps prevent
potential damage during drop test applications. This version
also uses the Model 084A03 cap for impact measurements.
Figure 5 outlines some possible mounting configurations to
which the ring series may be installed

ICPFORCE SENSOR OPERATION MANUAL
3
Figure 5 - Series 208 General Purpose and Axial
Connector ICP® Force Sensor Installation Methods
LINKS
Series 221B to 227C ICPLink Sensors are designed for
measuring compression from a few pounds(N) to 50,000 lbs (to
222.4 kN), and tension forces from a few pounds (N) to 30,000
lbs (to 133.4 kN). A link consists of a standard PCB ring sensor
preloaded between two hex end nuts. All hex nuts are internally
threaded for mounting ease to a customer test structure. Unlike
ring design sensors, additional external preloading is not
required as the factory installed external mounting hardware
places the sensor in a preloaded state.
The hex nuts do not loosen naturally. DO NOT ADJUST THE
NUTS WITH A WRENCH. Loosening or tightening of the
hex nuts will change the preload applied to the sensor. The
result is that the sensor output will no longer match the factory
supplied calibration certificate. In the unlikely event the
mounting hardware becomes loose, contact PCB’s service and
repair document for proper instructions for returning the sensor
to PCB for recalibration..
Figure 6 outlines some possible mounting configurations of the
link series of sensors.
Figure 6 – Series 221 to 227 ICP®Force Link Sensor
Mounting Method
3- COMPONENT TRIAX SENSORS
PCB’s line of 3-Component force sensors is capable of
simultaneously measuring force in three (3) orthogonal
directions (X, Y, and Z). Internally, three sets of quartz crystals
are cut, oriented and preloaded so the maximum output from
the crystal cut for the specific plane is obtained when a force is
applied axially to the specific x, y or z plane. Sensor output
from loads applied in the alternate, transverse
planes(considered channel cross-talk) is negligible as the
crystal sets are cut for maximum output in a specific plane.
Optimum performance and linear operation of 3-component
force sensors is obtained when a preload is applied to the sensor.
Versions are available with ranges up to 10K lb (45kN) in the
Z-axis (perpendicular to the top surface), and up to 4,000 lbs
(18kN) in the X and Y (shear) axes.
There are two modes of triaxial force sensors. ICPtriaxial
designs utilize built-in microelectronic circuitry that provides a
low-impedance voltage, the electrical output of which is passed
to external signal conditioning via one multi-pin connector
mounted on the sensor housing This design mechanically has
one 4-pin electrical connector that may be coupled to a single
multi-conductor sensor cable.
High impedance charge mode models contain three (3)
separate electrical output connectors on the sensor housing,
each corresponding to the respective x, y, or z axis. Low noise
cables should be used in low impedance system arrangements.
These models are ideal for use in harsh industrial or high
temperature environments.
Figure 7 outlines installation possibilities of triax force sensors.

ICPFORCE SENSOR OPERATION MANUAL
4
Figure 7 - Series 260 Mounting 3-Component
Force Sensor
3-COMPONENT LINK TRIAX SENSORS
Series 261 3-component force sensors are designed for
measuring z-axis compression loads from a fraction of a
pound(N) to 10,000 lbs (to 45 kN), and x and y-axis radial
forces from a few pounds (N) to 4,000 lbs (to 18 kN).
These sensors are designed to simultaneously monitor three
measurements in the x, y, and z-planes. Similar to the
piezoelectric link series, this series consists of a triaxial force
sensor factory installed and preloaded between mounting
hardware. Additional customer applied preload during
installation is not required.
The mounting hardware does not loosen naturally. DO NOT
ADJUST THE MOUNTING HARDWARE as loosening or
tightening of the hardware will change the preload applied to
the sensor. Changes to the preload result in changes the
factory supplied calibration. In the unlikely event the
mounting hardware becomes loose, contact PCB’s service and
repair document for proper instructions for returning the
sensor to PCB for recalibration.
Figure 8 – SERIES 3-COMPONENT TRIAX FORCE
SENSORS
PENETRATION
Penetration style sensors are similar to the axial models but are
specifically designed for compression and impact force
measurements in materials testing applications. Smooth,
cylindrical housings and curved impact caps avoid cutting
through specimens. This enables measurements to be taken to
determine yield, deformation, and break point measurements of
polymers, composites, and other materials. The axial connector
configuration installs into force thruster apparatus and protects
the connector from potential damage. Versions offering full-
scale measurements to 5,000 lb (to 22.24kN) are available.
Tension measurements are possible with units having
removable caps.
Figure 9 - Series 208A20 ICPPenetration Force Sensor
MINIATURE/HIGH SENSITIVITY
Series 209 Miniature Sensitivity Sensors permit low amplitude,
dynamic compression, tension, and impact force
measurements. A full-scale measurement range to 2.2 lbs (9.79
N) compression and to 1 lb (to 4.45 N) tension is standard. Two
configurations are available, one with a tapped mounting hole
and impact cap, and the other with tapped holes on both ends of
ICP®version Charge mode version

ICPFORCE SENSOR OPERATION MANUAL
5
the sensor. Link, integrated link, and freestanding installations
are possible as outlined in Figure 9.
Caution – Bending moment concerns
In this model, axial application of forces is critical during
measurements due to the sensitivity to bending moments. This
sensor series has a very high output (2200mV/lb, 500mV/N) so
care should be taken that applied forces are axial to prevent
unwanted output (noise) due to bending moments. In addition,
the “hat” applied to certain models enabling direct tensile
measurements is very small. Axial loads or excessive masses
applied to this “hat” could cause it to break away from the main
sensor body.
Due to its highly sensitive characteristic, Series 209 sensors
may be susceptible to thermal drift caused by temperature
transients. These sensors are recommended for use in
temperature stable environments only.
Figure 10 - Series 209 Miniature/High Sensitivity
ICPForce Sensor
3.0 INSTALLATION
Refer to the Installation Drawing supplied with this manual for
specific outline dimensions and installation details for your
particular model. The specification is also included to provide
details of the sensor’s characteristic properties.
It is important that the surface to which each sensor is mounted
be perfectly flat to avoid flexing of the base, which could affect
sensor sensitivity and result in erroneous data (see Figure 11).
A good mating surface may be obtained by lapping, turning,
spot-facing, or surface grinding. Surface flatness should be
held to within 0.001 (TIR) over the entire mating surface.
When mounting sensors between two plates care should be
taken to assure mounting surfaces are flat and parallel. Non-
parallel surfaces could place unwanted stress on internal
components leading to premature sensor failure. The protective
cap should remain on the electrical connector during
installation to prevent connector contamination or damage.
Figure 11 - Force Sensor Installation
A light coating of silicon grease (DC-4 or equivalent) on the
mating surface enhances the coupling between the mounting
base and mounting surface and provides the best high-
frequency response.
Connect one end of the coaxial cable to the sensor connector
and the other end to the XDCR jack input on the signal
conditioner. Make sure to tighten the cable connector to the
sensor. DO NOT spin the sensor onto the cable, as this fatigues
the cable’s center pin, resulting in a signal with a shorted output
or intermittent signal and a damaged cable.
For installation in dirty, humid, or rugged environments, it is
suggested that the electrical connection be shielded against dust
or moisture with shrink tubing or other protective material.
Strain relieving the cable/sensor connection can also prolong
cable life. Mounting cables to a test structure with tape,
clamps, or adhesives minimizes cable whip. See Figure 12for
an example of a sensor installation with a securely fastened
cable.
CAUTION!
Please read all instructions before attempting to
operate this product.
Damage to built-in amplifier
due to incorrect power or misapplication is NOT
covered by warranty