Solartron OD5 Manual

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Issue 10
July, 2005
OD5
USER LEAFLET
©Copyright 1995

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SAFETY SUMMARY
1. Safety Characteristics
This apparatus has been tested in accordance with IEC publication 348, Safety Requirements for
Electronics Measuring Apparatus, and supplied in a safe condition. This manual contains some
information and warnings which must be followed by the user to ensure safe operation and to retain
the apparatus in a safe condition.
1.1 Terms in This Manual
CAUTION statements identify conditions or practices that could result in damage to the
equipment or other property.
WARNING statements identify conditions or practices that could result in personal injury or loss
of life.
1.2 Terms As Marked on Equipment
CAUTION indicates a personal injury hazard not immediately accessible as one reads the
marking, or a hazard to property including the equipment itself.
1.3 Symbols in This Manual
!
This symbol indicates where applicable cautionary or other information is to be found.
1.4 Symbols as Marked on Equipment
Protective ground (EARTH) terminal.
!
ATTENTION - refer to manual.
2. SAFETY INSTRUCTIONS
Upon delivery from the factory the instrument complies with the required safety regulations, see para.
1. To maintain this condition and to ensure safe operation, the instructions below must be carefully
followed.
2.1 Power Source
This product is intended to operate from a power source that will not apply more than 250 volts
rms between the supply conductors or between either supply conductor and ground.
2.2 Do Not Operate in Explosive Atmospheres
To avoid explosion, do not operate this product in an explosive atmosphere unless it has been
specifically certified for such operation.
2.3 Grounding the Product
This product is grounded through the grounding conductor of the power cord. To avoid electrical
shock, plug the power cord into a properly wired receptacle before connecting to the product
input or output terminals. A protective ground connection by way of the grounding conductor in
the power cord is essential for safe operation.
2.4 Do Not Remove Covers or Panels
To avoid personal injury, do not remove the product covers. Do not operate the product without
the covers properly installed.
2.5 Use the Proper Fuse
To avoid fire hazard, use only the fuse of correct type, voltage rating and current rating, as
specified for your product. Refer fuse replacement to qualified service personnel.
WARNING Danger Arising From Loss of Ground
During a fault condition and upon loss of the protective-ground connection all accessible
conductive parts (including controls that may appear to be insulating) may render an electric
shock.

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SERVICE SAFETY SUMMARY
FOR QUALIFIED SERVICE PERSONNEL ONLY
Refer also to the preceding Safety Summary
This product contains no user serviceable parts
Adjustments may be made to the internal gain settings by qualified personnel, Chapter 3 paragraph
3.6 refers.
Do Not Service Alone
Do not perform internal adjustment of this product unless another person capable of rendering first aid
and resuscitation is present.
Disconnect power before removing protective panels, soldering or replacing components.

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LIST OF CONTENTS
PAGE
SECTION
Safety Summary ................................................... 2
Service Safety Summary ................................................... 3
List of Contents ................................................... 4
List of Drawings ................................................... 6
List of Tables ................................................... 6
1. GENERAL
1.1 Introduction ................................................... 7
1.2 Specifications ................................................... 7
1.3 Safety Considerations ................................................... 7
1.4 Instruments Covered by Manual ................................................... 7
1.5 Maintenance and Repair ................................................... 7
1.6 Dismantling the Instrument ................................................... 7
2. INSTALLATION
2.1 Introduction ................................................... 8
2.2 Initial Inspection ................................................... 8
2.3 Preparation for Use ................................................... 8
2.4 Power Requirements ................................................... 8
2.5
!
Voltage Selection ................................................... 8
2.6 Mounting ................................................... 10
2.6.1 Fitting Mounting Brackets ................................................... 10
3. OPTIONS
3.1 Introduction ................................................... 11
3.2 5kHz Operation ................................................... 11
3.3 Selecting 5kHz Operation ................................................... 11
3.4 2.5kHz Operation ................................................... 11
3.5 Selecting 2.5kHz Operation ................................................... 11
3.6 Gain Selection ................................................... 12
4. ELECTRICAL CONNECTIONS
4.1 Pin Designation ................................................... 13
4.2 Transducer Connections ................................................... 13
4.3 Non-Standard Connections ................................................... 14
4.4 Connecting Instrumentation ................................................... 14
4.5 Output Connections ................................................... 14
4.6 Power Connections ................................................... 15

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5. SETTING UP
5.1 Gain ................................................... 16
6. CALIBRATION
6.1 Calibration with Standard Solartron Transducers............................. 17
6.2 Calibration using Phase Adjustment ................................................... 17
10. APPENDIX
A General Transducer Connections (LVDT) ................................................ 18
B General Transducer Connections (MACH 1) .............................................. 19
C Specifications ................................................ 20
Return of Goods

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LIST OF DRAWINGS
FIGURE TITLE PAGE
1.1 Instrument Identification 7
2.1 Protective Cover 9
2.2 Voltage Selection Switch 9
2.3 Mounting Bars 10
3.1 Internal Option Links 12
4.1 Connector 3 13
4.2 Connector 1 and 2 14
4.3 Voltage Output 15
4.4 Current Output 15
LIST OF TABLES
TABLE TITLE PAGE
3.1 Link Position 12
3.2 Gain Selection 12
4.1 Connector 3 13
4.2 LVDT Connections 13
4.3 Connector 2 Designation 14
5.1 Gain Selection 16
C1.1 Common Specifications C-1
C1.2 Instruments Referred to by this Manual C-1

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GENERAL
1.1 INTRODUCTION
The OD5 provides high performance single channel conditioning for most types of LVDT transducers.
The self-contained unit offers excellent characteristics, together with full flexibility and ease of use. For
the industrial user, the OD5 will provide facilities for diverse applications such as automatic processing,
testing, etc., both on the shop floor or in the laboratory. In more scientific fields, the unit will find favour
due to its versatility and adaptability to a wide range of transducers.
1.2 SPECIFICATIONS
Instrument specifications are listed in Table C1.1. These specifications are the performance standards or
limits against which the instrument is tested.
1.3 SAFETY CONSIDERATIONS
Before operation, the instrument and manual, including the safety page, should be reviewed for safety
markings and instructions. These must then be followed to ensure safe operation and to maintain the
instrument in a safe condition.
1.4 INSTRUMENTS COVERED BY MANUAL
Attached to the top of this instrument is a name plate (Fig. 1.1 ), this manual only refers to instruments
listed in table C1.2.
1.5 MAINTENANCE AND REPAIR
If the instrument is suspected of being unsafe, take it out of operation permanently. This is the case when
the instrument:
- shows physical damage;
- does not function anymore;
- is stressed beyond the tolerable limits (eg. during storage and transportation).
1.6 DISMANTLING THE INSTRUMENT
When removing covers or other parts by means of tools, live parts or terminals could be exposed. Before
opening the instrument, disconnect it from all power sources. Refer to the Service Safety Summary.
Calibration, maintenance or repair must be performed only by trained personnel being aware of the risks.
After disconnection from all power sources, the capacitors in the instrument may remain charged for
some seconds.
Solartron Metrology,
Bognor Regis,
W
est Sussex.
PO22 9ST
Telephone [phone]
Fax: [phone]
Fig. 1.1 - Instrument Identification

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INSTALLATION
2.1 INTRODUCTION
This section provides installation instructions for the instrument. It also includes information about initial
inspection and damage claims, preparation for use and packaging, storage and shipment.
2.2 INITIAL INSPECTION
Inspect the shipping container for damage. If the container or cushioning material is damaged, it should
be kept until the contents of the shipment have been checked for completeness and the instrument has
been checked mechanically and electrically. If the contents are incomplete, or if there is a mechanical
damage or defect, or if the instrument does not pass the operator’s checks, notify the nearest Solartron
Metrology office. Keep the shipping materials for carrier’s inspection.
2.3 PREPARATION FOR USE
WARNING:
To avoid hazardous electrical shock, do not perform electrical tests when there are signs of
shipping damage to any portion of the outer enclosure.
It is recommended that all installation instructions are read fully prior to installation of the instrument.
2.4 POWER REQUIREMENTS
The instrument requires an AC power source of 115 or 250V AC, at a frequency of 50-60 Hz single
phase.
2.5
!
VOLTAGE SELECTION
BEFORE SWITCHING ON THIS INSTRUMENT make sure that the instrument is suited to your local
power source. DO NOT attempt to operate the instrument with a power source that it has not been set
for.
2.5.1 Refer to Safety Summary page i and Service Safety summary page ii.
2.5.2 Ensure that the unit has been isolated from the power supply.
2.5.3 Remove the four (4) screws securing the lid of the OD5.
2.5.4 Remove the lid.
2.5.5 Locate and remove the two (2) screws securing the protective cover (ref. fig. 2.1).
2.5.6 Remove the protective cover.
2.5.7 Locate voltage selection switch SW1 (ref. fig. 2.2).
2.5.8 Move the switch to the required voltage setting (ref. fig. 2.2).
2.5.9 Re-assembly is the reverse procedure (2.5.5 - 2.5.3).

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RV2
Securing Screws
Protective Cover
Gain
Link 2
Frequency RV3
Zero
Link 4
Filter
RV1
Phase
Link 1
Gain
CON1
LVDT Connector CON2
Output Connector
Link 3
Filter
R B W G
1 2 3 4 1 2 3
Fig. 2.1 - Protective Cover
250V 120V
T1
SW1
Note: Switch
SW1 shown
in 250V operation
position.
Fig. 2.2 - Voltage Selection Switch

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2.6 MOUNTING
The instrument is supplied with two (2) mounting bars that may be fitted to the base of the OD5 box.
These bars in turn provide accessible fixing holes for mounting the instrument into a jig or fixture.
2.6.1 Fitting Mounting Bars
To fit the optional mounting bars perform the following steps.
a) Locate the two fixing bars and four fixing screws.
b) Turn OD5 onto its lid.
c) Position the mounting bars onto the base of the OD5.
d) Fit the mounting bars onto the OD5 with the four fixing screws.
101.5
120
110
4 Fixing Holes
5
120
Fig 2.3 - Mounting Bars

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OPTIONS
3.1 INTRODUCTION
The OD5 has optional excitation frequencies of 2.5kHz and 5kHz which allow the device to operate with
all standard Solartron Displacement and Gauging LVDT’s. Selection of the excitation frequency is by
internal link settings.
3.2 5kHz OPERATION
The 5kHz excitation frequency is required for operation with standard Solartron Gauging and
Displacement LVDT’s calibrated at 5kHz. The optimum output filter selection at 5kHz is 250Hz. The gain
setting ”Hi or Lo” will be determined by the user.
3.3 SELECTING 5kHz OPERATION
To select 5kHz operation perform the following steps:
3.3.1 Refer to Safety Summary page i and Service Summary page ii.
3.3.2 Ensure that the OD5 has been isolated from the power supply.
3.3.3 Remove the four (4) screws securing the lid of the OD5.
3.3.4 Remove the lid.
3.3.5 Referring to the internal label or fig. 3.1, locate the frequency link ”link 2”. Move the link to the
5kHz position (ref. table 3.1).
3.3.6 Referring to the internal label or fig.3.1, locate the output filter selection links ”link 3” and ”link 4”.
Move link 3 and link 4 to the 250Hz position (ref. table 3.2).
3.3.7 Proceed with calibration section (Section 6) or re-assemble the OD5 replacing the lid and
securing screws.
3.4 2.5kHz OPERATION
The 2.5kHz excitation frequency is required for operation with standard Solartron Gauging and
Displacement LVDT’s calibrated at 2.5kHz. The optimum output filter selection at 2.5kHz is 110Hz. The
gain setting ”Hi or Lo” will be determined by the user.
3.5 SELECTING 2.5kHz OPERATION
To select 2.5kHz operation perform the following steps:
3.5.1 Refer to Safety Summary page i and Service Summary page ii.
3.5.2 Ensure that the OD5 has been isolated from the power supply.
3.5.3 Remove the four (4) screws securing the lid of the OD5.
3.5.4 Remove the lid.
3.5.5 Referring to the internal label or fig. 3.1, locate the frequency link ”link 2”. Move the link to the
2.5kHz position (ref. table 3.1).
3.5.6 Referring to the internal label or fig.3.1, locate the output filter selection links ”link 3” and ”link 4”.
Move link 3 and link 4 to the 110Hz position (ref. table 3.2).
3.5.7 Proceed with calibration section or re-assemble the OD5 replacing the lid and securing screws.

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Link 2
Link 4
Link 1
CON1 CON2
Link 3
1 2 3 4 1 2 3
Fig. 3.1 - Internal Option Links
Frequency Frequency Selection Filter Selection
Link 2 Link 3 Link 4
5.0kHz
2.5kHz
= Position of Shorting Link
Table 3.1 - Link Position
3.6 GAIN SELECTION
Link 1 allows selection of Hi and Lo gain. In the Hi position (normal for gauging transducers) the gain pot
RV2 will allow a gain adjustment between 10-290 for a ±5V output. In the Lo position (normal for
displacement transducers) the gain pot RV2 will allow a gain adjustment between 5 and 140 for a ±5V
output (ref. table 3.2).
Gain Selection
Link 1
Hi
Lo
= Position of Shorting Link
Table 3.2 - Gain Selection

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ELECTRICAL CONNECTIONS
4.1 PIN DESIGNATION
Connections should be made to the appropriate pins detailed in table 4.1 and 4.2. Refer to Section 2 prior
to making any connections. Transducer Connections
Pin Number Designation
1Excitation (+)
2Excitation (-)
3 N/C
4Input (+)
5Input (-)
Case Screen/Shield
Table 4.1 - Connector 3
2
15
34
Fig. 4.1 - Connector 3
4.2 TRANSDUCER CONNECTIONS
LVDT Connections - The following connections for standard Solartron transducers should be made:
AX/AC/MACH 1 (5kHz)
Series MACH 1 (2.5kHz) Series Pin Number Function
Red Yellow/Red 1Excitation (+)
Blue Yellow/Black 2Excitation (-)
White Black 4Demodulator Input (+)
Green Red 5Demodulator Input (-)
Blue
Green
Yellow to White or Green via resistor provided
Table 4.2 - LVDT Connections
}Join together and insulate

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4.3 NON-STANDARD CONNECTIONS
For non-standard transducer connections please contact your nearest Solartron Metrology office.
Note: To reverse the transducer output, ie. change for + for inward movement from null to - for inwards
movement from null, reverse connections for the green and white wires (AX/AC series) or the
black and red wires (MACH 1 series).
4.4 CONNECTING INSTRUMENTATION
Connections should be made with no power applied to the OD5. Once connections have been made
pass the wire through the grommet in the case. If required provide some cable retention to prevent
unwanted disconnection from the terminal block. Do not operate the OD5 unit without the top cover
securely fastened.
Output Connector CON2
Pin Number Designation
1±20mA
2Ground
3±5V
Table 4.3 - Connector 2 Designation
CON1 CON2
±
5V
Ground
20mA
1 2 3
1 2 3 4
R B W G
Fig. 4.2 - Connector 1 and 2
4.5 OUTPUT CONNECTIONS
The output of the OD5 is simultaneously available as a ±5V DC or ±20mA current source/sink (with
reference to CON2 Pin 2 ground). From the connector block CON2 situated on the PCB wires connecting
to CON2 should be passed through the adjacent hole in the case. Connections to CON2 are as follows.

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4.5.1 Voltage Output - Connect between the ground terminal and ±5 volt terminal of the internal
connection block. Ref. Fig. 4.3.
±20mA
Ground
±5V
2
1
CON2
To (-) or ground of indicating device
To (-) or signal of indicating device
3
Fig. 4.3 - Voltage Output
4.5.2 Current Output - Connect between the ground terminal and ±20mA terminal of the internal
connection block.
±20mA
Ground
±5V
2
1
CON2
From indicating device
To indicating device
3
Fig. 4.4 - Current Output
Note: The current output is derived from the voltage output and their zero and full scale values will
correspond to within ±0.5%, no adjustment is provided. The voltage output is short circuit
protected. The current output will drive resistances not greater than 100Ω.
4.6 POWER CONNECTIONS
The power supply should be connected as follows:
Green/Yellow to E Earth (Ground)
Blue to N Neutral
Brown to L Live (Hot)
The power supply line must contain a switch or other adequate means for isolation of the power supply
from the OD5.

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SETTING UP
5.1 GAIN SELECTION
The OD5 is designed to operate with a transducer having a full scale output in the range 17-1,000mV/V.
An internal link allows selection of Hi and Lo gain ranges (ref. section 3.6). Multi turn potentiometers
allow fine adjustment of phase, zero and span settings. With reference to table 5.1 set the internal gain
link to the range most suited to the transducer in use.
Link 1 Setting for Standard Solartron Transducers
AX/AT(P)(V) Series AC/ACR Series SM Series SAF/SACR Series MACH 1 Series
(2.5kHz)
AX/1.0 Hi AC/15 Lo SM/1 Hi SAF/15 Lo B/1.5 Hi
AX/1.5 Hi AC/25 Lo SM/3 Lo SACR/15 Lo B/2.5 Lo
AX/2.5 Hi AC/50 Lo SAF/25 Lo B/5 Lo
AX/5.0 Lo AC/100 Lo MD Series SAF/50 Lo B/7.5 Lo
A6G/1.0 Hi AC/150 Lo MD/1.0 Hi B/10 Lo
AX/0.5 Hi AC/250 Lo MD/2.5 Hi B/15 Lo
AX/0.25 Hi AC/300 Lo M6D/1.0 Hi B/25 Lo
AX/51 Hi B/50 Lo
OP Series B/75 Lo
OP/1.5 Hi B/100 Lo
OP/6.0 Lo B/125 Lo
OP/12.5 Lo B/250 Lo
Table 5.1 - Link 1 Gain Selection

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CALIBRATION
6.1 CALIBRATION WITH STANDARD SOLARTRON TRANSDUCERS
With reference to Section 5 select the appropriate link 1 position. Unplug transducer and insert a link
between pins 4 and 5 of connector 3.
Adjust the zero control for zero output of the conditioner. Remove the link and replace the transducer.
Adjust the transducer mechanically to give minimum output. Trim with fine zero potentiometer to give
zero.
Set the transducer to its mechanical full scale. Adjust the span control to give the full scale.
Reset transducer to mechanical zero and recheck for zero output.
6.2 CALIBRATION USING PHASE ADJUSTMENT
Method 1
Using an oscilloscope to monitor IC4 (18 pin device between RV1,RV2,LK2) pin 5 set up the LVDT as in
6.1.
Move the LVDT to its maximum outwards position.
Note the waveform at pin 5.
Using the phase control (RV1) and moving between the transducer maximum out and maximum inwards
positions adjust RV1 so that the waveforms obtained at both positions are a mirror image of each other.
Re-check zero and span as in 6.1 above.
Method 2
Monitoring the output V or I set up the LVDT as in 6.1.
Move the LVDT to its fully outward position.
Adjust the phase control (RV1) for peak output.
Re-check zero and span as in 6.1 above.

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APPENDIX A
GENERAL TRANSDUCER CONNECTIONS: AX, AC, MD, SA & SM SERIES
Connections to the DIN plug connector 3 should be made as indicated:
Yellow wire on LVDT’s:
a) Normally left unconnected and insulated.
b) On some transducers a resistor must be connected from yellow to green or white as instructed on
transducer calibration sheet.
c) Do not extend beyond standard cable length fitted to transducer.
Plug connections apply to DIN standard 5-way 240°type.
Where screen is used, connect to case of plug. Ensure that elsewhere the screen is isolated electrically.
Cable colours are as fitted to Solartron transducers.
Increase of element impedance marked P gives a positive going voltage output.
P
LVDT Blue Pin
Red
Screen
2 Energising
1 Voltage
White
Green
5
To Conditioner
4
Black Ground
Note:The black lead should only be connected if the transducer case is to be grounded.

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APPENDIX B
GENERAL TRANSDUCER CONNECTIONS: MACH 1 SERIES
Connections to the DIN plug connector 3 should be made as indicated:
Do not extend beyond standard cable length fitted to transducer.
Plug connections apply to DIN standard 5-way 240°type.
Cable colours are as fitted to Solartron transducers.
Increase of element impedance marked P gives a positive going voltage output.
P
LVDT Pin
5To Conditioner
4
2 Energising
1Voltage
Yellow/Black
Black
Green
Blue
Red
Yellow/Red

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APPENDIX C
Common Specification
Power Supply Oscillator/Demodulator
Power Supply 250V AC 50-60Hz
or 120V AC 50-60Hz Oscillator frequency Oscillator output voltage
Oscillator max. current
2.5 or 5kHz Sinusoid
3V rms
20mA
Loading 4W (Max.) Input sensitivity for rated output Lo 35 to 1000mV/V
Hi 17 to 500mV/V
Fuse Rating @ 250V 63mA Slow Blo
@ 120V 63mA Slow Blo For Rated Output Lo 5 to 140mV/V Hi 110 to 290mV/V
Output ±5V into 10KΩ
±20mA into 100Ωmaximum
Mechanical Output Zero Offset 0 to ±100% adjustable
Case Size 130mm x 96mm x 35mm Output protection Output open/short circuit
protected
Weight 400g Output ripple @ 5kHz 250Hz
Filter <10mV pk/pk at 10kHz
Mounting Two (2) Fixing Bards Output filter 2nd order low pass fc at
250Hz or 110Hz
Termination 5-Pin DIN Connector Non-Linearity Less than 0.05% of rated output
Temperature range 0 - 60°C
Temperature Coefficient Max. Typical
Overrange 0 - 60°CZero
Gain <0.02% fro/°C
<0.02% fro/°C<0.01% fro/°C <0.01% fro/°C
Oscillator protection Will withstand open CCT or
short CCT of oscillator
Table C1.1
Instruments Referred to by this Manual
Part Number Description
911134 OD5 LVDT Conditioning Unit
Table C1.2