SENSY COND-SGA-A Manuale utente

 
MA-COND SGA-A & SGA-D_EN.docx 
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COND-SGA-A & COND-SGA-D 
 
STRAIN GAUGE TRANSDUCER AMPLIFIER 
 
 
 
INTRODUCTION .................................................................................................................................................................................2
1. The Strain Gauge Amplifier COND-SGA.....................................................................................................................................2
INSTALLATION ...................................................................................................................................................................................3
1. Pre-installation.............................................................................................................................................................................3
2. Wiring ..........................................................................................................................................................................................3
2.1. Power connection................................................................................................................................................................3
2.2. Input connection..................................................................................................................................................................4
2.3. Output connections .............................................................................................................................................................4
SWITCH SETTINGS............................................................................................................................................................................5
1. Switch positions...........................................................................................................................................................................5
2. Analogue output and excitation voltage - SW4 ...........................................................................................................................5
3. Output filter settings - SW3 .........................................................................................................................................................7
3.1. Output current mode and input filter - JP1, JP2 & JP3 .......................................................................................................7
4. Span (gain) setting switch - SW1 ................................................................................................................................................8
4.1. Shunt calibration switch - SW1/8 ........................................................................................................................................9
5. Zero (offset) setting switch - SW2 ...............................................................................................................................................9
CALIBRATION.....................................................................................................................................................................................9
1. Output........................................................................................................................................................................................10 
2. Zero offset .................................................................................................................................................................................10 
3. Sensitivity ..................................................................................................................................................................................10 
3.1. Using a millivolt source .....................................................................................................................................................10 
TROUBLESHOOTING.......................................................................................................................................................................12 
PRODUCT CARE..............................................................................................................................................................................13 
SPECIFICATIONS.............................................................................................................................................................................13 
1.1. Output options...................................................................................................................................................................14 
1.2. Connections ......................................................................................................................................................................14 
1.3. Enclosure ..........................................................................................................................................................................14 
1.4. Controls.............................................................................................................................................................................14 
2. CE Approvals ............................................................................................................................................................................14 
3. SGA/A & SGA/D Connection details .........................................................................................................................................15 
 

MA-COND SGA-A & SGA-D_EN.docx

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Rev: 09/04/2019

Rev.

Date

Reason

09/04/2019

Text corrections

1. INTRODUCTION

1.1. The Strain Gauge Amplifier COND-SGA

The COND-SGA is a Strain Gauge Amplifier, converting a strain gauge input to a voltage or current output –otherwise known as a

Signal Conditioner.

The COND-SGA provides a wide range of signal conditioning for Strain Gauges, Load Cells, Pressure and Torque transducers.

Offered in two versions, the COND-SGA-A for 110/230 V AC or 18-24 V DC operation and the COND-SGA-D which is DC powered

only.

A further powering option is available; the IS1224 module comprises a DC-DC converter enabling the COND-SGA to be powered

from 9-36 V DC. The ISS1224 can only be fitted to the COND-SGA-D as it occupies the same space as the mains transformer in the

COND-SGA-A. The COND-SGA-A however, is isolated when AC powered by virtue of its mains transformer.

Transducer sensitivity of between 0.1 mV/V and 30 mV/V are possible. This is achieved by a combination of gain (span) DIP

switches and associated fine adjustment by a potentiometer.

Similarly, transducer zero offset and scale dead band of up to 79% can be compensated for in the module. This is achieved again by

a combination of zero DIP switches and associated fine adjustment by a potentiometer.

The module has built-in filters to cancel the field effects of vibration, agitation and electrically noisy environment. The on-board low

pass filter can be switched in and adjusted (from 1Hz to 5kHz) using a series of DIP switches.

A wide range of proportional output options for currents and voltages can be configured by DIP switch settings.

Both the AC and DC versions are based on a common board and are mounted in an IP65 (NEMA 4X) ABS case.

The COND-SGA is a single channel signal conditioner but can supply sufficient excitation current to supply four 350 Ωload cells

connected in parallel. The resulting output is the average of the individual cells.

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2. INSTALLATION

2.1. Pre-installation

See Specification details in Chapter 8 for details of Environmental Approvals.

Carefully remove the COND-SGA-A unit from its packing. Check that the unit is complete and undamaged.

The COND-SGA-A & COND-SGA-D units can operate in any industrial environment providing the following limits are not exceeded

Operating Temperature

-10 ºC to +50 ºC

Humidity

95% non-condensing

Storage temperature

-20 ºC to +70 ºC

While the unit is sealed to IP65 (NEMA 4X) it is advisable to follow the following installation practice where possible

•Minimise vibration.

•Do not mount next to strong electrical fields (transformers, power cables)

•Ensure easy access to interior of the module

•Install electrical protection device, as the unit is not internally fused.

•Always ensure the lid is properly fitted and all 4 screws tightened.

•Always ensure the cable gland is sealing against the cable to maintain the IP (NEMA) rating.

The 4 screws for the lid are captive and must be tightened to maintain the seal. The 4.5 mm (0.18”) holes for the mounting screws in

the base are directly behind the screws for the lid. The box must not be drilled as this would invalidate the IP rating. Allow sufficient

space at both sides for the cable entry. The Nylon 66 M16 cable glands are designed for ROUND cables. The waterproof entry and

strain relief will seal to a higher rating than the enclosure. Cable diameter should be between 4 mm (0.16”) and 7 mm (0.27”).

2.2. Wiring

2.2.1. Power connection

Two power supply options are available

COND-SGA-A

220/230 VAC, 50/60 Hz

110/120 VAC, 50/60 Hz

5 W Max.

COND-SGA-A & COND-SGA-D

18-24 V DC

5 W (approx. 150 mA fully loaded)

NOTE: The COND-SGA-A can be powered from AC or DC sources whichever is available. It is also possible to connect

BOTH AC and DC simultaneously for security of power supply.

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Standard mains 2 or 3 core cable PVC sheathed (unshielded) cable will suffice for the power.

NOTE: Connect the appropriate power to the COND-SGA. For AC powering observe the correct transformer jumper

connections as shown above.

To accommodate automotive installations, the COND-SGA can be fitted with an IS1224 module enabling it to be powered from 9 to

36 V DC. This module also has the advantage of electrically isolating the DC power supply from the measurement electronics which

minimises errors and instability due to earth loops in the system.

The power supply should be capable of supplying at least 1 A

for 12 V installations and 0.5 V for 24 V.

Connections to the COND-SGA-A & COND-SGA-D input/output

signal and the power supply are made via 2.5 mm² field terminal

connectors. Cable entry in the cased versions is via glands in

the ends of the case.

2.2.2. Input connection

NOTE: The Ref 5 V / 2.5 V is generated internally and used for calibration.

The cable connecting the sensor to the COND-SGA should be shielded. The cable should have 2 x twin twisted cables, ideally with

each pair individually shielded and with an overall shield.

If possible, segregate the signal cable from Power Cables; allow a 1 meter (3 feet) distance from such cables.

Do not run signal cables parallel to power cables. Cross such cables at right angles.

The ground connection conductor should have enough cross-sectional area to ensure a low impedance path to attenuate RF

interference.

2.2.3. Output connections

Two analogue outputs are available from the COND-SGA, proportional DC current and DC voltage. The ranges available are as

follows:

OUTPUT

RANGE

The DC current support both ‘sink’ and ‘source’ modes of

operation. Two jumpers JP1 & JP2 provide the means of

selecting the desired mode.

DC voltage

±10 V

NB: Maximum Load on

voltage ranges is 2mA

±5 V

0 –10 V

0 - 5V

DC current

4 - 20 mA

NB: Maximum impedance

500R

0 - 20 mA

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In ‘Sink’ mode the positive end of the load is connected to the internal +15 V supply on the COND-SGA and the negative end is

connected to the COND-SGA output. The current through the load is ‘sunk’ by the COND-SGA towards ground (0 V). In this mode

neither connection to the output load is electrically common to the load cell. Select this option by fitting the two jumpers, JP1 and JP2

to the ‘outside’ positions (See next chapter)

In ‘Source’ mode the positive end of the load is connected to the COND-SGA output and the current is ‘sourced’ by the COND-SGA

output through the load towards ground (0 V). This mode has the advantage that the negative output connection is common to the

load cell ‘- Excitation’ terminal. Select this option by fitting the two jumpers, JP1 and JP2 to the ‘inside’ positions (See next chapter)

See Chapter 3 for switch settings and details of SINK & SOURCE jumpers.

3. SWITCH SETTINGS

3.1. Switch positions

e.g. the first switch on the left of this figure is ’ON’, the second ‘OFF’

3.2. Analogue output and excitation voltage - SW4

Use switch 4 to select the required output and, if

required, the low pass filter and 5V Excitation.

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INPUT

RANGE

OUTPUT OPTION

4-20 mA

0 –20 mA

4-20 mA

0 –20 mA

0 - 10 V

0 - 5 V

±10 V

±5 V

+ Full Scale

20 mA

10 V

5 V

10 V

5 V

↑

4 mA

0 mA

12 mA

10 mA

5 V

2.5 V

0 V

↓

- Full Scale

n/a

4 mA Note 1

0 mA Note 1

0 V

-10 V

-5 V

N.B.: Full scale output on the voltage ranges is achieved with a bi-polar (±) input.

Note 1: Negative inputs can be accommodated on the current (mA) output ranges by setting the ‘Zero’ switch SW2 to +50% and

setting SW1 to twice the required mV/V setting.

SW4

±10 V

0↓

1↑=Filter in

1↑Filter out

1↑=10 V Exc

0↓=5 V Exc

±5 V

0↓

1↑

0↓

1↑=Filter in

1↑Filter out

1↑=10 V Exc

0↓=5 V Exc

0-10 V

0↓

1↑

1↑=Filter in

1↑Filter out

1↑=10 V Exc

0↓=5 V Exc

0-5 V

1↑

1↑=Filter in

1↑Filter out

1↑=10 V Exc

0↓=5 V Exc

0-20 mA

0↓

1↑=Filter in

1↑Filter out

1↑=10 V Exc

0↓=5 V Exc

4-20 mA

1↑

1↑=Filter in

1↑Filter out

1↑=10 V Exc

0↓=5 V Exc

Filter out

0↓

1↑

1↑=10 V Exc

0↓=5 V Exc

Filter in

1↑

0↓

1↑=10 V Exc

0↓=5 V Exc

10 V Exc

1↑=Filter in

1↑=Filter out

1↑

5 V Exc

1↑=Filter in

1↑=Filter out

0↓

Switch settings (0 = Off 1 = On X = Don’t Care)

Important: Low pass filtering is switched into operation by setting SW4/6 ‘ON’↑ and SW4/7 ‘OFF’↓.

Reverse these settings to bypass the filter.

It should be noted that either one of these switches MUST be on but NOT BOTH

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Example: - 0-10 Volt output with no filter

required

SW4

0-10 V

0↓

1↑

0↓

1↑

3.3. Output filter settings - SW3

The COND-SGA incorporates a second order (-12 dB/oct) low pass filter which can be switched in to improve the performance and

output signal quality in electrically noisy environments. It can also be used to reduce the effects of high frequency fluctuations in the

load or applied force to the load cell.

The cut off frequency of the filter is set by the DIP switch SW3 as illustrated in the table below.

SW3

1 Hz

0↓

1↑

5 Hz

1↑

0↓

1↑

10 Hz

1↑

0↓

1↑

50 Hz

1↑

100 Hz

0↓

500 Hz

1↑

0↓

1↑

0↓

800 Hz

See note**

1 kHz

1↑

0↓

1↑

0↓

5 kHz

1↑

0↓

** Note: A SECONDARY low pass filter, with a cut off frequency of 800 Hz, can be switched into the COND-SGA input by fitting a link

to JP3

Important: Low pass filtering is switched into operation by setting SW4/6 ‘ON’↑ and SW4/7 ‘OFF’↓. Reverse these settings

to bypass the filter. It should be noted that either one of these switches MUST be on but not BOTH

Example: The Switch Settings for a cut-off

frequency of 50 Hz.

Note: SW4/6 must be ‘ON’ and SW4/7 must

be ‘OFF’.

SW3

50 Hz

1↑

3.3.1. Output current mode and input filter - JP1, JP2 & JP3

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3.4. Span (gain) setting switch - SW1

Ranges 1 to 60: from 0.06 mV/V to 30.30 mV/V

↑= ON (1) ↓= OFF (0) SW1/8 switches on the shunt cal. function

0.06 mV/V

↓

↑

↓

↑

0.11 mV/V

↑

↓

↑

↓

↑

0.17 mV/V

↓

↑

↓

↑

0.23 mV/V

↑

↓

↑

↓

↑

0.28 mV/V

↓

↑

↓

↑

↓

↑

0.31 mV/V

↓

↑

↓

0.34 mV/V

↑

↓

↑

↓

↑

0.39 mV/V

↓

↑

↓

↑

0.44 mV/V

↑

↓

↑

0.50 mV/V

↓

↑

↓

↑

0.55 mV/V

↑

↓

↑

↓

↑

0.60 mV/V

↓

↑

↓

↑

0.61 mV/V

↑

↓

↑

↓

0.65 mV/V

↑

↓

↑

0.70 mV/V

↓

↑

↓

↑

0.75 mV/V

↑

↓

↑

0.75 mV/V

↓

↑

0.80 mV/V

↓

↑

0.91 mV/V

↓

↑

↓

1.20 mV/V

↑

↓

↑

↓

1.41 mV/V

↑

↓

↑

1.49 mV/V

↓

↑

↓

↑

↓

1.78 mV/V

↑

↓

↑

↓

1.99 mV/V

↓

↑

2.07 mV/V

↓

↑

↓

2.35 mV/V

↑

↓

2.49 mV/V

↑

↓

↑

2.63 mV/V

↓

↑

↓

2.91 mV/V

↑

↓

↑

↓

2.95 mV/V

↓

↑

↓

↑

3.19 mV/V

↓

↑

↓

3.35 mV/V

↑

↓

↑

3.46 mV/V

↑

↓

3.72 mV/V

↓

↑

3.73 mV/V

↓

↑

↓

4.00 mV/V

↑

↓

4.00 mV/V

↓

↑

↓

4.05 mV/V

↑

↓

↑

4.26 mV/V

↓

4.36 mV/V

↓

↑

↓

↑

4.63 mV/V

↑

↓

↑

↓

↑

4.89 mV/V

↓

↑

↓

↑

5.12 mV/V

↑

↓

↑

5.34 mV/V

↓

↑

↓

↑

5.54 mV/V

↑

↓

↑

5.72 mV/V

↓

↑

7.50 mV/V

↑

↓

↑

↓

10.50 mV/V

↓

↑

↓

13.20 mV/V

↑

↓

↑

↓

15.60 mV/V

↓

↑

↓

↑

↓

17.80 mV/V

↑

↓

↑

↓

19.70 mV/V

↓

↑

↓

21.50 mV/V

↑

↓

↑

↓

23.10 mV/V

↓

↑

↓

↑

↓

24.60 mV/V

↑

↓

↑

↓

↑

↓

25.60 mV/V

↓

↑

↓

↑

↓

27.10 mV/V

↑

↓

↑

↓

28.30 mV/V

↓

↑

↓

↑

↓

29.30 mV/V

↑

↓

↑

↓

30.30 mV/V

↓

↑

↓

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Please Note: When using 5 V Excitation (SW4 switch 8 = OFF), divide the transducer's mV/V output by two and set SW1 to the

nearest setting shown in the table above.

e.g. for 2.5 mV/V with 5 V excitation choose the 1.2 mV/V setting

Example: A strain gauge has a sensitivity of

2.809 mV /V - Select Switch Setting

number 28 from the table above and fine

tune with potentiometer PI

SW1

2.63 mV/V

0↓

1↑

0↓

Refer to Chapter 4 for calibration details.

3.4.1. Shunt calibration switch - SW1/8

SW1/8 connects a 120k 50 ppm surface mount resistor across the ‘+Excitation’ and ‘+ Input’ terminals of the COND-SGA. This

shunts one arm of the connected load cell to produce a known change in output which can be used for calibration or checking the

integrity of the load cell and associated wiring.

SW1

Shunt Cal ON

1↑

Shunt Cal OFF

0↓

The 120k resistor can be taken out of circuit and replaced by a user defined leaded component

by carefully cutting the fine link as shown in the figure. Use the right hand pad and either of the

left hand pads to fit the new component.

The surface mount resistor can be reinstated by re-connecting the two pads either side of the

cut link.

3.5. Zero (offset) setting switch - SW2

This offset can be used to compensate for the transducer zero error, to tare the scale dead load or to shift the output. These settings

allow the user to calibrate a zero offset. The range allows for up to 78% of the span. Potentiometer P2 provides fine adjustment

(±1.25%, and ±79% for both).

SW2

+Ve Offset

-Ve Offset

40%

20%

10%

Example: An installation has a tare of 15 kg with a 200 kg strain gauge

which gives an output of 6.37 mV/V at 10 V excitation. The tare

equates to 7.5% (15/200). Set the switches to nearest % (5 + 2) and

fine trim with Potentiometer P2. The tare must be subtracted therefore

the ‘-Ve Offset’ switch SW2/2 should be ‘ON’. The calibrated zero mV

reading would be 4.78 mV i.e. 7.5% of 63.7 mV @10 V excitation

SW2

7.5%

0↓

1↑

0↓

1↑

0↓

Note SW2 /1 & 2 should never be 'ON' together. Either one or other should be 'ON' if an offset is required; otherwise

both switches should be 'OFF'. Switch settings 3 to 8 are ADDITIVE. The offset value of each switch is added to

give a total offset of 78%. Fine adjustment is provided by potentiometer P2 (±1.25%, and ±79% for both).

4. CALIBRATION

The COND-SGA-A & COND-SGA-D provides the excitation supply and signal conditioning to cater for a wide range of strain gauges,

load cells, pressure transducers or torque transducers.

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4.1. Output

Select the analogue output range as detailed in Chapter 3.2 via SW4.

4.2. Zero offset

Select the offset as detailed in Chapter 3.5 by means of SW2. Having selected the polarity and the offset nearest to that required

with the switches, use the fine potentiometer P2 to achieve the final setting.

4.3. Sensitivity

Select the sensitivity as detailed in Chapter 3.4, by means of SW1. Switches 1-4 of SW1 provide fine setting of the COND-SGA

sensitivity while switches 5-7 give coarse control.

This arrangement allows the COND-SGA to cover a wide range of strain gauge sensitivities without sacrificing stability and ease of

set up. Locate the required sensitivity in the table and set switches 1-7 of SW1 accordingly. Potentiometer P1 provides fine trimming

and range overlap to enable the COND-SGA to be calibrated precisely to any given value within its ranges.

Note If the range is repeated in the table e.g. 4 mV/V (4.0, 4.05 and 4.0 mV/V) choose the setting which has the

greatest number of switches 1-4 set to ‘off’ i.e. SW1 = [1000][000]. This will enable finer trimming to the final

value using potentiometer PI.

The sensitivity settings shown in Chapter 3.4 assume that the load cell is fully loaded. The sensitivity settings can be used to

maximise the output when the full range of the load cell is not being used. Here are a couple of examples.

Example 1 A 2.5 mV/V load cell provides 10 V for an l00 Ib load. However, it is never loaded above 50 lb.

The sensitivity setting can be set to 1.25 mV/V.

1.20 mV/V SW1 = [1101] [000]

Example 2 When a reduced output is required from a fully loaded transducer, use a less sensitive switch setting. For an 8

volt output from a fully loaded 2.5 mV/V load cell use the 3.19 mV/V setting i.e. (10/8x2.5=3.125 mV/V)

1.20 mV/V SW1 = [0010] [000]

The COND-SGA-A & COND-SGA-D can be calibrated with the transducer connected, provided that two calibration points can be

implemented, e.g. by applying known weights or forces. If this is not possible, a stable mV source or load cell simulator can be used

provided that the precise sensitivity (mV/V) and full range output (kg) of the transducer is known. In this case the 'Ref (5V/2.5V)'

output should be connected to 'Strain Input-' and the mV source applied between ‘Strain Input+’ and ‘Strain Input-’.

Actual calibration is carried out in the following way:

1. Set the correct switch settings on SW1 as described above using the transducer's calibration sheet supplied by the

manufacturer. This is normally specified as sensitivity or full range output and should be in mV/V.

2. Apply the known low calibration conditions (weight, force or mV/V: this may be zero if required). Use the fine ‘Zero’ control,

P2 in conjunction with the coarse switches SW2/3-8 and polarity switches SW2/1-2 to set the output in volts or mA to the

required absolute values.

3. Apply the known high calibration conditions (for optimum accuracy this should be at least 75% of full load) Use the fine trim

control, P1, to obtain the required output at the high calibration point.

4. Repeat steps 2 and 3 until the required output is achieved.

4.3.1. Using a millivolt source

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