PCB Piezotronics 1203-15A User manual

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: [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.
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: [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: 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
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.

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

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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
5
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