PCB Piezotronics 108A04 User manual

Model 108A04
Hydraulic pump ICP® pressure sensor, 30k psi, 0.15 mV/psi (long life integral diaphragm)
Installation and Operating Manual
For assistance with the operation of this product,
contact the PCB Piezotronics, Inc.
Toll-free: 716-684-0001
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.

Drawing Number: 21113
Revision: B
OPERATION MANUAL FOR
ICP® HIGH PRESSURE SENSORS
Series 108 & 109
1
1.0 INTRODUCTION
The 108 & 109 Series are acceleration-compensated,
high pressure, ICP® (Integrated Circuit Piezoelectric)
sensors primarily developed to measure ballistics
chamber pressures for R & D and production testing
of ammunition. They may also be used for explosive
air blast and other high pressure measurements in
extreme shock environments where ultra-fast, micro-
second response is required. These types of tests are
usually accompanied by large acceleration pulses,
which can add considerable error to output signals of
un-compensated sensors.
The shoulder seal design features a one-piece
diaphragm machined integral with the housing for
ruggedness.
For applications where strain sensitivity from stress
within the mounting port is a concern, the 108A1X,
108B1X, 109B1X and 109C1X utilize a floating
clamp-nut design to reduce the effects, where “X”
denotes pressure range.
2.0 DESCRIPTION
The 108 & 109 Series contain an acceleration-
compensated piezo element, which is coupled to a
microelectronic amplifier. The quartz element
contains an integral seismic mass that counteracts the
acceleration effects of the end piece and diaphragm.
This compensation acts to extend the frequency
characteristics and enhance the transient response of
the sensor.
The machined diaphragm is made from maraging
steel, selected because of its high strength and
durability. The combination of the short, rigid
element and stiff diaphragm give these sensors a high
natural frequency and linearity.
The microelectronic amplifier converts the high-
impedance voltage from the quartz package into a
low-impedance, high-level output signal. See the
Technical Information section of our website for
more complete coverage of ICP® instruments.
3.0 INSTALLATION
With a 3/8-24 (M10x1.0 for metric mount) mounting
thread and flush diaphragm design, the 108 & 109
Series transducers mount directly in existing ports
machined for PCB Series 118 & 119.
Unlike conventional diaphragm type sensors, the 108
& 109 Series are pressure sensitive over the entire
frontal area. Extra care should be exercised to avoid
bottoming in the mounting hole when recess mounted
or when mounting into existing ports.
Install the sensor, using only one of the seals
provided, with the aid of a torque wrench to monitor
the mounting torque value. The recommended torque
range can be found on the installation drawing. Seals
should be replaced each time the sensor is re-
installed.
3.1 MOUNTING IN EXISTING
RECESSED PORTS
Before installing the sensor in previously used
mounting ports, clean out the residue from previous
tests. The port can be cleaned by hand reaming the ¼
inch diameter hole using a PCB Model 040A end
cutting reamer (040A07 for metric mount) guided by
PCB Model 041A pilot bushing (M041A for metric
mount).
Pay particular attention to the sealing surface,
keeping it free from tool chatter marks, nicks and
other imperfections that could adversely affect the
seal. If the sealing surface requires re-machining
after prolonged use, refer to the installation drawing
to ensure that the ¼ inch hole is deepened to avoid
bottoming of the sensor when re-installed.
10-32 COAXIAL
CONNECTOR
5/16 HEX
3/8-24 THREAD
QUARTZ ELEMENT
CERAMIC COATING
ICP® AMPLIFIER

Drawing Number: 21113
Revision: B
OPERATION MANUAL FOR
ICP® HIGH PRESSURE SENSORS
Series 108 & 109
2
Existing Recessed Ports
If waveform distortion occurs during prolonged
testing, remove the sensor and clean the residue as
illustrated above.
3.2 PREPARING NEW MOUNTING
PORTS
Refer to the installation drawing provided in this
manual for instructions on mounting hole
preparation. For best results, do not deviate from the
steps outlined in this drawing.
To assist new mounting port preparation, PCB offers
the 040B20 Tooling Kit (040B21 for metric mount).
These installation kits provide all of the necessary
tooling required to drill, ream, and tap the mounting
ports for proper installation of the 108, 109, 118 and
119 Series transducers.
Use good machining practice in preparation of the
mounting port, paying particular attention to the seal
surface. It is important that this surface be perfectly
smooth and free from tool chatter marks, nicks and
other imperfections which might cause leaks at high
pressures.
3.3 RECESSED MOUNT
The recessed installation is shown in the Recessed
Mount figure. This type of mounting protects the
sensor diaphragm from the effects of high-flash
temperatures and particle impingement due to blast
effects, thereby prolonging sensor life.
The recommended range of passage diameters is
0.090 to 0.125 inch (2.29 to 3.18 mm) diameter.
The limitation in this type of installation lies in the
frequency-limiting effects of the passage due to its
length.
The passage behaves like an underdamped second
order system; the resonant frequency being
determined by the passage length. The length may
have a limiting effect on pressure pulse rise time and
cause passage ringing in cases where the passage is
too long.
Recessed Mount
The following relationship approximates this
resonant frequency (f r):
(Hz)
L4
V
fr=
(EQ. 1)
Where: f r = Resonant frequency of passage (Hz)
V = Velocity of sound in air (ft/sec)
L = Length of column (ft)
For air at room temperature, (EQ. 1) becomes:
L
0033
fr=
(EQ. 2)
Where: L = Passage length (in)
The natural frequency and approximate fastest
pressure step rise time for various length passages is
shown in the following chart. (Medium, air at 25C).
MODEL 040A
REAMER
MODEL 041A
PILOT BUSHING
0.010
MIN

Drawing Number: 21113
Revision: B
OPERATION MANUAL FOR
ICP® HIGH PRESSURE SENSORS
Series 108 & 109
3
PASSAGE
LENGTH (in)
PASSAGE
RESONANCE
(kHz)
APPROX.
FASTEST PULSE
RISE TIME (sec)
.050
66
5
.100
33
10
.200
16.5
20
.50
6.6
50
1.0
3.3
100
Passage Resonance vs. Passage Length
Actual resonant frequencies measured in practice
may differ slightly from the chart values. These
differences are due to variations in the velocity of
propagation of sound in air caused by changes in
temperature and pressure of the air in the passage.
For best matching of passage to diaphragm, maintain
the 0.010 inch (0.254 mm) clearance ahead of the
diaphragm as shown in the Recessed Mount figure on
the previous page.
3.4 FLUSH MOUNT
In the flush mount installation, there is no reduced
area passage from the sensor diaphragm to the test
chamber; rather the sensor diaphragm is mounted
flush with (or slightly recessed from) the inside
surface of the test chamber.
Use this type of installation only if space or rise time
considerations preclude the use of recessed
installation.
In severe pyrotechnic environments, sensor life may
be severely limited with flush installation.
3.5 FLASH TEMPERATURE
EFFECTS
If more protection from flash thermal effects is
required with the recessed mount, the passage can be
filled with silicone grease (DC-4 or equivalent).
Several layers of black vinyl electrical tape directly
on the diaphragm have proven effective in many
cases as well.
Flash temperature effects are usually longer term and
will show up as a baseline shift long after the event to
be measured has passed.
For flush mount installations, a silicone rubber
coating approximately 0.010 inch thick can be
effective; RTV 106 is recommended, and is available
from PCB as Model 065A67. Follow manufacturer’s
instructions to apply. It is best to recess the
diaphragm 0.010 inch for this type of protection.
3.6 INSTALLING CABLES
It is convenient, though not necessary, to use coaxial
cable, such as PCB 002 Series, to connect the
transducer to the power unit. Cable need not be low-
noise treated.
If the use of lighter, more flexible cable is desired,
PCB Model 070B09 solder connector adaptors may
be used to employ twisted pair or other types of two-
wire cable.

Drawing Number: 21113
Revision: B
OPERATION MANUAL FOR
ICP® HIGH PRESSURE SENSORS
Series 108 & 109
4
3.7 CIRCUIT CONNECTIONS
The figures below show two typical circuit
connections normally used to connect the 108 & 109
Series to power units.
The first figure is the connection scheme used for
most applications. In this set up, the signal is AC-
coupled from the bias voltage meaning the voltage at
the "scope" terminal will be at a zero volt bias level.
Normal Connection AC-Coupled Output
In this case, the system discharge time constant will
be determined by the input resistance and capacitance
of the power unit. Most PCB power units have
approximately a 10 second discharge time constant.
Alternate Connection to take Advantage of Sensor
Discharge TC
The second figure illustrates an optional connection
scheme which can be used during calibration to take
full advantage of the sensor’s discharge time
constant.
With this arrangement, the readout is direct-coupled
to the sensor and the output signal will be added to
the DC bias voltage (11 VDC nominal).
The discharge time constant will then be determined
only by the sensor and should be in the order of 2000
seconds; this is sufficient for most types of static
calibration methods. (See Calibration Section 4.0)
Typical Connection
The figure above shows the 108 & 109 Series
connected to a PCB Model 484B06 power unit. The
484B06 is a power unit that can be AC or DC-
coupled.
In the DC-couple mode, a level-shifting circuit
removes the bias level and provides a zero adjust
feature at the front panel. The system’s discharge
time constant is determined by the sensor in this
mode.
An AC-coupled mode is provided for normal AC-
coupled operation.
4.0 CALIBRATION
PCB 108 & 109 Series sensors are supplied with a
calibration certification from the factory.
Recalibration services are provided at the factory for
a nominal fee.
Static calibration methods may be employed using
the set-up shown in the Alternate Connection figure
or by use of the Model 484B06 Power Unit as shown
in the figure above – use the 484B06 in DC mode.
Following thermal stabilization of the sensor, use a
high pressure pump with dial reference sensor or a
dead weight tester to apply pressure in desired
increments to full scale. Release pressure after taking
the reading and before proceeding to the next higher
pressure level.
With a 2000 second discharge time constant, 1% of
the signal will be lost in 20 seconds, so it is
imperative that the pressure setting and recording of
output be accomplished quickly.
A calibration graph can be plotted using output
voltage vs. input pressure to determine sensitivity and
linearity.
108 & 109
SERIES
002 SERIES
ICP®
POWER SUPPLY
READOUT
108 & 109
SERIES
ICP®
POWER SUPPLY
002 SERIES
READOUT
ICP®
POWER SUPPLY
SERIES 002
READOUT
108 & 109
SERIES

Drawing Number: 21113
Revision: B
OPERATION MANUAL FOR
ICP® HIGH PRESSURE SENSORS
Series 108 & 109
5
5.0 OPERATION
Select desired mode of circuit connection and turn
power unit on.
Observe fault monitor meter at the front panel of the
power unit.
Normal operation is indicated by an approximate
midscale reading. Shorted cable or connections are
indicated by a zero reading (red area).
Open cable or connections are indicated by a full-
scale (yellow area) reading.
Allow instrument several minutes to warm up and
thermally stabilize.
When output from the power unit is connected to
readout equipment, a drift in the voltage signal will
be noticed; this is normal. This voltage signal drift is
caused by the charging of the coupling capacitor in
the power unit and will cease within several minutes.
6.0 POLARITY
The 108 & 109 Series are designed to produce a
positive output voltage for increasing pressure at the
diaphragm.
7.0 MAINTENANCE
The small size and sealed construction of the 108 &
109 Series precludes field maintenance and repair.
Contact the factory for further assistance.
ICP® is a registered trademark of PCB Piezotronics

FLUSH INSTALLATION RECESSED INSTALLATION
1
1
2
2
3
3
4
4
A A
B B
CODE
IDENT. NO.
52681
DWG. NO.
SCALE: SHEET
DRAWN CHECKED ENGINEER
TITLE
UNLESS OTHERWISE SPECIFIED TOLERANCES ARE:
DIMENSIONS IN MILLIMETERS
[ IN BRACKETS ]
XX ±0.13
ANGLES 2 DEGREES
3425 WALDEN AVE. DEPEW, NY 14043
[phone] E-MAIL: [e-mail]
DIMENSIONS IN INCHES
DECIMALS XX ±.01
ANGLES 2 DEGREES
FILLETS AND RADII
.003 - .005
DECIMALS X ± 0.3
FILLETS AND RADII
0.07 - 0.13
INSTALLATION DRAWING
108-1020-90
1 OF 13X
MODEL 108A02, 108A04
HERMETICALLY SEALED PRESSURE
XXX ±.005
JJF 5/21/21 JJF 5/21/21 NJL 5/21/21
SENSOR
108-1020-90
PCB Piezotronics Inc. claims proprietary rights in
the information disclosed hereon. Neither it nor any
reproduction thereof will be disclosed to others
without the written consent of PCB Piezotronics Inc.
1.84 [46.7]
.248 - .250 [6.30 - 6.35]
.96 [24.4]
.41 [10.4]
.360 [9.14]
.035 - .040 [.89 - 1.02]
.248 - .249 [6.30 - 6.32]
.245 - .246 [6.22 - 6.25]
.319 - .320 [8.10 - 8.13]
1
1
1
1
1
2
3
4
5
6
7
8
ELECTRICAL CONNECTOR
CO-AXIAL 10-32 UNF-2A
HEAT SHRINKABLE
TUBING GROOVE
3/8-24 UNF - 2A
MODEL 065A06 SEAL
.318 [8.08] O.D.
X .010 [.25] THICK
MATERIAL: 316 ST STL
.312 [7.93] HEX 2
REVISIONS
REV DESCRIPTION DIN
H CORRECTED MOUNTING HOLES 51799
.800 [20.32] 3
.260 [6.60]
.800 [20.32] 3
"A"
.260 [6.60]
67
"B" 7
MOUNTING HOLE DIMENSIONS
.252 ±.001 [6.40 ±.03]
THRU
.332 ±.001 [8.43 ±.03]
(.540 [13.72])
3/8-24 UNF-2B
.460 [11.68]
35
45
8
MOUNTING HOLE DIMENSIONS
.252 ±.001 [6.40 ±.03]
(.800 [20.32])
.332 ±.001 [8.43 ±.03]
(.540 [13.72])
3/8-24 UNF-2B
.460 [11.68]
3
4
8
5
5
CAUTION: DO NOT TOUCH SEAL SURFACE WITH TAP WHEN TAPPING HOLE
DIMENSION "A" & "B" TO SUIT USER REQUIREMENTS
KEEP "A" AS SHORT AS POSSIBLE, SEE OPERATING GUIDE FOR OPTIMUM PASSAGE LENGTH
THESE DIAMETERS TO BE CONCETRIC WITHIN .001 [.03] TIR
SEAL SURFACE SHOULD BE FLAT AND FREE OF TOOL MARKS WITH A MINIMUM FINISH OF 63 [1.6] FOR BEST RESULTS
DIMENSIONS SHOWN ARE FOR .800 [20.32] WALL THICKNESS. C'BORE FOR THICKER WALL
RECOMMENDED MOUNTING TORQUE ON .312 [7.93] HEX: 20-25 FT-LBS [27-34 Nm]
MATERIAL: C-300 MARAGING STEEL