PCB Piezotronics W200B03/002C05 User manual

Model W200B03/002C05
Impact ICP® quartz force sensor, 500 lb comp., 10 mV/lb
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.

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
ICP®version Charge mode version

ICPFORCE SENSOR OPERATION MANUAL
5
on both ends of 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
12 for 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