ICA H & S Manual
Contents
1. 4 Core Shielded Cable Strain Gauge TX EMC Gland Terminating Shield Note The PSU terminal and Output terminal can be taken directly to a common ground if desired Take note of the grounding arrangement particularly the bolt hole which capacitively couples the common of the ICA electronics to the strain elements in the load cell which improves the EMC performance The ICA4H can be used with three wire cabling in both sink and source mode The only difference between the two modes is whether the common end of the load is connected to the positive of the PSU sink mode or the negative of the PSU source mode Mantracourt Electronics Limited DRAFT ICAH amp S User Manual 6 ICA5S ICA5A Connections The power supply for the ICA5S should be between 7 5 and 28 V The minimum supply for the ICA5A version is 9 V Please note that by design the excitation voltage provided by a 2 wire load cell amplifier decreases as the load cell s impedance decreases resulting in a reduction in the load cell s output The lower signal level requires more gain from the ICA5 to compensate leading to a degradation in performance with regard to temperature stability and noise performance Impedances greater than 1000 Ohms and sensitivities of 1mV V and higher are recommended Figure 2 10 Connection Details ICA5S amp ICA5A PSU 9 28V Strain Gauge Out N B For optimum EMC performance bolt2. Gain 160 63 200 1 Rx required mV V e g for 2 0mV V Gain 80 R 4000 Ohms use preferred value 3 k9 or 4k02 E96 Formula 3 2 To set the mV V figure HIGHER than 2 5 decrease the gain If the gain of the ICA4H needs to be reduced i e to match a HIGHER mV V setting then the two surface mount gain resistors shown above must be removed and the following formulae used to calculate the new value for the gain resistor Pe 160 f 63 200 Ohms required mV V Gain 5 e g for 5 0mV V Gain 32 R 2039 Ohms use preferred value 2 k or 2k05 E96 The new gain resistor should be fitted in position R as shown in Figure 2 2 11 Mantracourt Electronics Limited DRAFT ICAH S User Manual ICA5S ICA5A The ICA5S ICA5A 2 wire 4 20 mA In Cell strain gauge amplifiers are supplied un calibrated but optimized for a sensitivity of 2 5 mV V To accommodate other sensitivities the gain resistor R2 as shown in Figure 2 10 can be changed according to the following formulae Load cells with less than 1mV V sensitivity are not recommended N B a high quality lt 50 ppm C 1 metal film resistor should be used for optimum performance It may be necessary to use an E96 value to optimise the trim range Table 3 6 ICA5S amp ICA5A 10 Volts Gain Resistor Formula A 613 6 Z 20000 i E 20000 10 k Ohms Where mV Vis the sensitivity of the load cell in mV V Vexc is the excitation voltage in Vol
3. ICA H amp S Strain Gauge or Load Cell Embedded Analogue Amplifiers antracourt co mE mantracourt ICA H amp S Manual Contents Chapter 1 The ICA H amp SRaQNgl ccoococoncononconancanancanancanannanancnrancanancnra rasca rara rara rasca rara rara rara rara ranannas 2 Figure 1 1 Block DATAN A A ta Aa 2 Chapter 2 Installing the ICA H amp S Range ococoocococcononcancncanannanannanancnnancanannnnanancn rara ran cn rara rana rra ra ranannas 3 Pre InstallatiON v oomiaror ire da a da dnde 3 Figure 2 1 DIMENSIONS da da 3 ICA1H S ICA2H CONNECTION Sann esii eeraa A vos tien gh eeu Madde Belated ae ital all 4 Figure 2 2 Connection Details for the ICALH amp ICA2H ccceceece erect eect cece teat eee eae EE EEEE REEERE EEEE EEEE 4 Figure 2 3 Connection Details for Best EMC IMMUN Ity c cece ccc ece eee eee ttrt trr EE narrar nr rn anar nr rr rr rr rra 4 CASH SI CAB CONNECTIONS A A A AE A Ain 5 Figure 2 4 Connection Details for the ICABH oococcccccccncnncnncnncnncnncn nn on ttti rn nor teas sates eee eee eee EEEE EEEE EEEE EEE 5 Figure 2 5 Connection Details for the ICABH oooocccocccccncnncnncnncnnconcnn ttrt rro nro rn eee ee tees essen EEEE EREEREER 5 Figure 2 6 Connection Details for Best EMC IMMUN Ity c cece ccc ece cece eect eee ee corno rra rn eet eeeeeeeeeeeeeateaenaees 5 ICAAH CONNECTIONS cita tgs A yet ate EE a bad ec AE A Ea a a EA dads yrede ape d 6 Figure 2 7 Connection Details for the ICA4H So
4. ICA input is designed to accept Torque Sensor Pressure amp temperature transducers Noise Null A condition such as balance which results in a minimum absolute value of output Offset Offset is otherwise identified as ZERO Calibration of the ICA is determined by setting the Offset Zero and Gain Span Potentiometer Two potentiometers variable resistors are used in the ICA1 2 for fine calibration Pressure The Pressure Transducer is one of a series of Strain Gauge sensors that the ICA Transducer input is designed to accept Torque Sensor Load Cell and Temperature Transducers Proportional The Voltage or Current outputs are calibrated to be directly proportional to the Outputs input from the sensor The output is within the sensor limits taken as linear and no linearity compensation is required within the ICA Resolution The input corresponding to a one unit change in the least significant digit of the data acquisition display equipment Good resolution is not necessarily equal to good accuracy Mantracourt Electronics Limited DRAFT ICAH amp S User Manual 16 Sensing Element That part of the Transducer which reacts directly in response to the input Sensitivity This is the relationship between the change in Strain Gauge input to the level or magnitude of the output Signal Conditioner A circuit module that offsets attenuates amplifies linearizes and or filters the signal The ICA is essentially a Signal C
5. the ICA5 to the load cell chassis via this hole The strain gauge cable should be attached to the solder pads as illustrated N B The voltage between either of the power supply connections and the load cell chassis should not exceed 50 V Any leakage will be greater than 10 M Ohms Figure 2 11 Connection Details for Best EMC Immunity PSU 9 28V The securing bolt should be used to provide a good electrical ground and mechanical support This is important for optimum EMC performance 7 Mantracourt Electronics Limited DRAFT ICAH S User Manual Output Connections The ICA5 analogue output is 4 to 20 mA The power and signal are combined in a single pair cable simplifying installation N B Neither connection to the output load is electrically common to the load cell The following formula gives the suitable range of shunt resistance for low supply voltage operation Output Shunt Resistance Formula ICA5S the shunt resistance must be less than Vsupply 7 5 20 mA Rwiring e g assuming 10 Ohms wiring resistance and 9 V supply Max shunt resistance 9 7 5 0 02 10 65 Ohms ICA5A the shunt resistance must be less than Vsupply 9 20 mA Rwiring Table 2 1 The ICA H amp S Cable Data This typical cable data is provided for information only The cable should have 2 x twin twisted cables Ideally each pair should be individually shielded and with an overall shield Coun
6. _O SS A Strain A Com N Supply Load Cell Chassis 1 Apply the known low calibration conditions weight force or mV V This may be zero if required and using the Z potentiometer set the output to the relevant low level depending on the model e g 0 1 V for the ICA1H 4mA for the ICA4H etc 2 Apply the known high calibration conditions ideally between 75 and full scale and adjust the S potentiometer to set the output to the relevant high level depending on the model e g 5 1 V for the ICA2H at full scale 20 mA for the ICA4H etc 3 Apply the known low calibration conditions and re adjust the Zero if required 13 Mantracourt Electronics Limited DRAFT ICAH S User Manual Chapter 5 Trouble Shooting 1 No Output a Check power supply is present and the correct polarity b Check the output connections are correct with no open circuit connections c Check terminations ensure there are no dry joints d Check the sensor is connected typically reading 350 Ohm across output amp with the power off e Check the Excitation voltage is correct f Check the load is connected and is not open or short circuited g Check Span and Gain calibration 2 Low Output This is when an output is present but not of sufficient magnitude to meet the required value Remember to allow for Tare Weight and ensure it is measured and allowed for in the output from the ICA a Check power supply is within specified limits i e is no
7. cal Maximum Units Notes Bridge Excitation 1 05 1 11 1 16 Volts Note 1 Bridge Impedance 350 1000 5000 Ohms Bridge Sensitivity 0 5 2 5 55 mV V Note 2 Output load 700 Ohms Note 3 Bandwidth DC 1000 Hz Zero adjustment 2 YFR Note 4 Span adjustment 8 YFR Linearity 0 02 R Temperature stability Zero Temperature Stability 0 001 0 005 YFR Deg C At 2 5 mV V Span Temperature Stability 0 007 0 014 YFR Deg C At 2 5 mV V FR Full Range 16 mA Note 1 1000 Ohm load cell Typically 0 53 V for 350 Ohm cell Note 2 Set by calibration resistor Note 3 24 V supply minimum Note 4 1000 Ohms load cell change R1 to suit other load cell impedances see Chapter 3 Note Recommended bridge impedance is 1 000 Ohms Note The voltage between either of the power supply connections and the load cell shield should not exceed 50 V Any leakage will be greater than 10 M Ohms 23 Mantracourt Electronics Limited DRAFT ICAH S User Manual Table 8 7 ICA6H 10 V Electrical and Environmental Parameter Minimum Typical Maximum Units Notes Supply voltage Range 14 15 27 Volts Note 1 Operating Current 8 mA Note 2 Operating Temperature 40 _ 85 Deg C Range Storage Temperature Range 40 85 Deg C Reverse polarity Protection 30 Volts Note 1 Ideally this should be limited to 15 V to 18 V for 350 Ohm load cells to minimise the on board tem
8. cted such that when the four resistance s are matched the galvanometer will show a zero deflection or null reading Zero Zero is otherwise identified as OFFSET It relates to the proportional output to ed the sensor input Calibration of the ICA is determined by setting the Span Gain and Zero Offset the display corresponds to a non zero signal instrument See Zero Suppression Zero Suppression The Span is Offset from Zero Zero Suppressed such that neither limit of the Span will be Zero For example an instrument which measures a load of a 100kg Span from 400kg to 500kg is said to have 400kg Zero Suppression Alternating Current mv 17 Mantracourt Electronics Limited DRAFT ICAH S User Manual Chapter 8 Specifications for the ICAH Range Table 8 1 ICA1H 0 1 to 10 1 V Electrical and Environmental Parameter Minimum Typical Maximum Units Notes Supply voltage Range 13 24 30 Volts Operating Current 8 mA Note 1 Operating Temperature Range 40 85 Deg C Storage Temperature Range 40 85 Deg C Reverse polarity Protection 30 Volts Note 1 Not including excitation current e g when connected to a 350 Ohm load cell excitation current 5 350 14 mA Total current 22mA Measurement Parameter Minimum Typical Maximum Units Notes Bridge Excitation 4 90 5 5 10 Volts Bridge Impedance 350 1000 5000 Ohms Bridge Sensitivity 0 5 2 5 150 mV V Note 1 O
9. dge Excitation 1 05 1 11 1 16 Volts Note 1 Bridge Impedance 350 1000 5000 Ohms Bridge Sensitivity 0 5 2 5 55 mV V Note 2 Output load 800 Ohms Note 3 Bandwidth DC 1000 Hz Zero adjustment 2 YFR Note 4 Span adjustment 8 YFR Linearity 0 02 R Temperature stability Zero Temperature Stability 0 001 0 005 H YFR Deg C At 2 5 mV V Span Temperature Stability 0 007 0 014 H YFR Deg C At 2 5 mV V FR Full Range 16 mA Note 1 1000 Ohm load cell Typically 0 53 V for 350 Ohm cell Note 2 Set by calibration resistor Load cells with less than 1mV V sensitivity are not recommended drift and noise performance will suffer Note 3 24 V supply minimum Note 4 1000 Ohms load cell change R1 to suit other load cell impedances Note Recommended bridge impedance is 1 000 Ohms Note The voltage between either of the power supply connections and the load cell shield should not exceed 50 V Any leakage will be greater than 10 M Ohms Mantracourt Electronics Limited DRAFT ICAH amp S User Manual 22 Table 8 6 ICA5A 2 wire 4 20 mA Electrical and Environmental Parameter Minimum Typical Maximum Units Notes Supply voltage Range 9 0 24 30 Volts Operating Temperature Range 40 85 Deg C Storage Temperature Range 40 85 Deg Reverse polarity Protection 30 Volts Measurement Parameter Minimum Typi
10. e unit The mounting hole will accept an M2 screw or American equivalent 0 80 Important Note DO NOT USE 2 screw size Take care when soldering cables to the pads Use a temperature controlled soldering iron set to a maximum 330 C for no longer than 2 seconds per pad Excessive heat or increased soldering time may result in damage to the PCB If changing the gain resistor R do so at a workbench and not on site The ICAH solder pads are as shown in the wiring diagrams 4 pads for the strain gauge Power supply and output pads 2 pads for sink or source option ICA4H only The fixing screw hole provides a ground connection to improve EMC performance 3 Mantracourt Electronics Limited DRAFT ICAH S User Manual ICA1H amp ICA2H Connections The power supply for the ICA1H is nominally 24 V dc between 13 and 28 V and ICA2H is nominally 12 V dc between 8 5 and 28 V The power supply is commoned with the output at the com connection Figure 2 2 Connection Details for the ICA1H amp ICA2H A rain Gauge Load Cell Chassis TNS The strain gauge cable should be attached to the solder pads as illustrated For most applications 3 wire un shielded field wiring is quite adequate For best EMC performance use the connections shown in Figure 2 3 Figure 2 3 Connection Details for Best EMC Immunity Terminating Screen N B The PSU Com or Load common connection can be taken to ground T
11. eadings can be correlated to the actual value being measured CMR The ability of an instrument to eliminate the effect of AC or DC noise between Common Mode signal and ground Normally expressed in dB at DC to 60 Hz One type of CMR is Rej ection specified between SIG LO and PWR GND In differential meters a second type of CMR is specified between SIG LO and ANA GND METER GND The ability of an instrument to reject interference from a common voltage at Rejection Ratio its input terminals with relation to ground Usually expressed in db decibels Drift Change of a reading set point value over periods due to several factors Excitation The external application of electrical voltage current applied to a transducer calibration These are potentiometers P1 and P2 for Span and Zero respectively Gauges Gain Gain is otherwise identified as SPAN It relates to the proportional output to the sensor input Calibration of the ICA is determined by setting the Gain Span and Offset Zero The amount of amplification used in an electrical circuit Linearity The closeness of a calibration curve to a specified straight line Linearity is expressed as the maximum deviation of any calibration point on a specified straight line during any one calibration cycle Load The electrical demand of a process expressed as power watts current amps or resistance ohms associated external circuitry The load cell is one of a series of STRAIN GAUGE sensors that the
12. he ICA should be mounted by means of the bolt hole This capacitively couples the common of the ICA1H amp ICA2H electronics to the strain elements in the load cell which improves the EMC susceptibility performance Take note of the grounding arrangement particularly the bolt hole which capacitively couples the common of the ICAH electronics to the strain elements in the load cell which improves the EMC performance Mantracourt Electronics Limited DRAFT ICAH amp S User Manual 4 ICA3H amp ICA6H Connections The ICA3H requires a 14V bipolar dc power supply within the limits of 13 V to 15 V The ICA6H requires a 15 to 24 V uni polar dc power supply Ideally this should be limited to 15 V to 18 V for 350 Ohm load cells to minimise the on board temperature rise thereby reducing any warm up time In both cases the power supply is commoned with the output at the Com connection Figure 2 4 Connection Details for the ICA3H A Strain Gauge The strain gauge cable should be attached to the solder pads as illustrated For most applications 3 wire un shielded connections for field wiring is quite adequate Load Cell Chassis For best EMC performance use the connections shown in Figure 2 4 Figure 2 5 Connection Details for the ICA6H A Strain Gauge Bottom PCB Load Cell Chassis The power supply connections for the ICA6H are located on the bottom PCB In the following connection diagrams the Supply c
13. her than 10 V is required e g 5V then reduce the gain calculation in proportion i e for 5 Volt Gain 372 xX 5 R 40 000 Ohms required mV V 10 Gain 1 e g 1 For 2 5 mV V Gain 74 4x R 545 Ohms Use preferred value 549R E96 Factory setting ICA4H The ICA4H In Cell strain gauge amplifier is supplied un calibrated but optimised for a sensitivity of 2 5 mV V To accommodate other sensitivities the gain resistor R must be fitted see Figure 2 2 The value of R is calculated using the formulae below N B a high quality component e g 1 25 ppm metal film resistor should be used for optimum performance use 10 15 ppm metal film devices to maintain their temperature drift performance It may be necessary to use an E96 value to optimise the trim range Use the appropriate formula below depending on whether the ICA4H needs to be adjusted for a higher or lower mV V sensitivity Mantracourt Electronics Limited DRAFT ICAH amp S User Manual 10 N B The ICA4H gain resistor comprises two surface mount gain resistors instead of the leaded type see diagram To configure the amplifier to suit a load cell higher than 2 5mV V these must be removed and formula 3 2 used to calculate the value of R Use formula 3 1 to suit load cells less than 2 5mV V Gain resistors Table 3 5 ICA4H Formula 3 1 To set the mV V figure LOWER than 2 5 increase the gain To match a LOWER mV V setting use the following formulae
14. hich combines an ICA3H with a DC DC power module The power module generates both positive and negative supply rails for the ICA3H thereby enabling it to produce its normal 10 V output from a single 15 24 V supply The ICA6H also has pads on its underside which can be used to mount and provide connections for a range of Transducer Electronic Data Sheet ICs TEDS Mantracourt Electronics Limited DRAFT ICAH amp S User Manual 2 Chapter 2 Installing the ICA H amp S Range Pre Installation See Specification details in Chapter 8 for details of Environmental Approvals Carefully remove the ICA unit from its shipment box Check that the unit is complete and undamaged The ICA units can be operated in any industrial environment providing the following limits are not exceeded Operating Temperature 402C to 85 C Humidity 95 non condensing Storage temperature 402C to 85 C The following installation practices are advised Minimise vibration Do not mount next to strong electrical fields transformers power cables Ensure easy access to the module Install electrical protection device as the unit is not internally fused a short across the excitation terminals could cause permanent damage e Always ensure the package is secure and protected Figure 2 1 Dimensions ICA1 5 ICA6 20 0mm 19 5mm 0 79 0 77 E 10 8mm es 0 425 The module is designed to fit in the strain gauge pocket Use the 2 1mm hole to secure th
15. ld be used for optimum performance It may be necessary to use a value from the less common E96 series to optimise the trim range Table 3 1 ICA1H 0 1 V to 10 1 V Gain Resistor Formula Gain 372 Rgain 40 000 Ohms required mV V Gain 1 e g 1 For 2 5 mV V Gain 149x R 270 Ohms Use preferred value 270R Factory setting e g 2 For 0 5 mV V Gain 744 x R 53 8 Ohms Use preferred value 53 6R E96 series Table 3 2 ICA2H 0 1V to 5 1V Gain Resistor Formula Gain 186 Rgain 40 000 Ohms required mV V Gain 1 e g 1 For 2 5 mV V Gain 744x R 545 Ohms Use preferred value 549R E96 series Factory setting e g 3 For 5 0 mV V Gain 37 2x R 1105 Ohms Use preferred value 1K1 Table 3 3 ICA1H ICA2H Offset Resistor Formula The ICA1H and 2H can be used in a pseudo bipolar mode by fitting a resistor Roffs as shown in Figure 2 2 This will shift the output voltage to a known level Voffs when the input is zero 0mV V allowing both tension and compression of the load cell to be measured Use the following formula for the ICA1H ICA2H to calculate the value of Roffs in k Ohms Roffs 148 k Voffs 0 1 e g for 2 5V offset bipolar ICA2 Roffs 148 k 148k 61 7kOhms Use preferred value 61 9 k E96 series 2 5 0 1 2 4 e g for 5 0V offset bipolar ICA1 Roffs 148 k 148k 30 2 k Ohms Use preferred value 30 k 5 0 0 1 4 9 The gain of the ICAH will need to be reduced t
16. libration This section assumes that the unit is providing an output that is not stuck at top or bottom of the scale See paragraphs 1 3 if this is the case Ensure you are connected to the correct sensor and not to another adjacent unit Ensure you have the correct calibration data from the sensor manufacturer This must include a certified table with offset zero and linearity Ensure you have the calibration set up correctly installed i e mV source and output as required Ensure the temperature and other environmental parameters are within specification and where necessary taken into account when calibrating should such parameters have an effect on the calibration 6 Fine Span Gain and Zero Offset Adjustment Problems If the adjustment cannot reach the maximum output desired then check the tare is not too high If the potentiometer does not alter the output the unit must be repaired remove from service It is always wise to check a known good ICA against the problem installation before rejecting the suspect ICA Mantracourt Electronics Limited DRAFT ICAH amp S User Manual 14 Chapter 6 Product Care A worn out component excessive use in harsh environments an overly zealous operator regrettably some circumstances necessitate repair At Mantracourt Electronics Ltd we cant guarantee that a product will never require repairing We can however promise a repair service of exceptional quality one which is governed by a rigorous p
17. nn nr rra rr rra 10 CA at rd dd dde aida 10 Table 3S ACA4H ina A E Eaa E A aaa tea 11 CAS CASA ito AS AUNAR Y AAE AAAA A A Ad A 12 ICA5S amp 5A Offset Resistor RD AAA AAA AA AA AAA AA 12 Chapter 4 Calibration ooomococcoconconancnnancanancnnancanancnnancarananan ranas ranas ra nanra nan ra ran rn ran aaa rarananannas 13 Figure 4 1 Connection Details for Calibrati0N coccocccccccnnconcnncnnconconconcnnno nro nn r nro nr nn rn nr rra rra nr rra rr rr EEEE 13 Chapter 5 Trouble Sho0ting mcoococoococonconanconancanancnnancarancarancararancanancanancnranenrancaranennanennanenraneananenoa 14 Chapter 6 Product Care oocococcononconanconancanancarancanancarancanancnnaranan ranas ranas raras raras ra nan raranrn rasca ranraranannanas 15 Chapter 7 GloSSArY ocoococonconanconancanancnnancanancanancn ronca narra rara nrnrarrn raras ranas raras raras ranas rnnanrn ran NSAN 16 Chapter 8 Specifications for the ICAH Range cocoococoncononconancanancanancanancanancanancanarancananennanearanennaneananensa 18 Table 8 L 1GATH 0 1 t VOL A A A A AE ever 18 Table 8 2 ICA2H 0 AO Vi A A A 19 Table 8 3NCASHO 10 Vi ii AAA AAA AAA AAA A AAA AAA AAA dc 20 E CAH ES 00 OP MAN a nn A asad peated ayad asada ead eee 21 Table EAS 2 Wwire 4 20 MA ciora e coed a os 22 Table 8 6 CASA 2 wit 4 20 MA wsscasavn rrea ataca Melee 23 Table S271 CAGH AO Vii ars in td da detained edad 24 1 Mantracourt Electronics Limited DRAFT ICAH S User Manual Chap
18. o account for the lower output swing required for a given input change For the ICA1H re calculate Rgain by scaling the load cell s mV V by the ratio 10 V bipolar output change and 5 V bipolar output change for the ICA2H and use the above formulae For example an ICA2H is required to operate at 2 5 V 2 4 V for a 2 5 mV V input Fit Roffs 61 7 k as above and re calculate Rgain from Table 3 2 using 5 V 2 4 V x 2 5m V V 5 208m V V 9O Mantracourt Electronics Limited DRAFT ICAH S User Manual i e Gain 35 71 therefore Rgain 1152 Ohms The nearest preferred value is 1k15 E96 series ICA3H amp ICA6H The ICA3H ICA6H are 10 V Strain Gauge Amplifiers They are supplied un calibrated but optimized for a sensitivity of 2 5 mV V To accommodate other sensitivities the gain resistor R as shown in Figure 2 2 can be changed according to the following formula N B a high quality component e g 1 15 25 ppm C metal film resistor should be used for optimum performance It may be necessary to use an E96 value to optimise the trim range Table 3 4 ICA3H ICA6H 10 Volts Gain Resistor Formula Gain 372 R 40 000 Ohms required mV V Gain 1 e g 1 For 2 5 mV V Gain 149x R 270 Ohms Use preferred value 270 R Factory setting e g 2 For 0 5 mV V Gain 744 x R 53 8 Ohms Use preferred value 53 6 R E96 e g 3 For 5 0 mV V Gain 74 4x R 5450hms Use preferred value 549 R E96 N B If an output ot
19. onditioner more specifically known as a Strain Gauge Amplifier in that it CONDITIONS alters the input signal from a load cell to an electrical output Single Card The ICA has only the one Printed Circuit Board assembly on which all the Assembly components are mounted The assembly is then mounted inside an environmentally rugged enclosure Span Span is otherwise identified as GAIN It relates to the proportional output to the sensor input Calibration of the ICA is determined by setting the Span Gain and Zero Offset The ability to adjust the gain of a process or strain meter so that a specified display span in engineering units corresponds to a specified signal span Stability The quality of an instrument or sensor to maintain a consistent output when a constant input is applied Strain Gauge The Strain Gauge is a resistance bridge device where the bridge value alters linearly and proportionally to the force exerted on it be it pressure torque or load The ICA is designed to convert this change in the of the Strain Gauge to a proportional electrical signal Strain Gauge The ICA is essentially a type of Signal Conditioner that it conditions alters the Amplifier input signal from a strain gauge to an electrical output Torque Transducer The Torque Transducer is one of a series of Strain Gauge sensors that the ICA input is designed to accept Wheatstone Bridge A network of four resistance s an emf source and a galvanometer conne
20. onnection can be ignored for the ICA6H Figure 2 6 Connection Details for Best EMC Immunity See Figure 2 3 for ICA6H power connections EMC Gland A Terminating Screen N B The PSU Com or Load common connection can be taken to ground The ICA should be mounted by means of the bolt hole This capacitively couples the common of the ICA3H electronics to the strain elements in the load cell which improves the EMC susceptibility performance Take note of the grounding arrangement particularly the bolt hole which capacitively couples the common of the ICA electronics to the strain elements in the load cell which improves the EMC performance 5 Mantracourt Electronics Limited DRAFT ICAH S User Manual ICA4H Connections The power supply for the ICA4H is 24 V dc within the limits of 13 V to 28 V Figure 2 7 Connection Details for the ICA4H Source mode Current flow Supply y gt Wa ICA4 Output Stage Strain Gauge ICA4H A XA Load Cell Chassis Supply or Common Note Output is connected internally to the supply Com terminal Current flow Supply EN 5 Output Output ICA4H A ICA4H Output Stage Strain Gauge E Sad or Common Load Cell Chassis end of load can be connected Mots Output ls connected to separate 5 30 V supply if required internally to the Supply terminal Figure 2 9 Connection Details for Best EMC Immunity Load Load Cell R Z
21. perature rise thereby reducing any warm up time Note 2 Not including excitation current e g when connected to a 350 Ohm load cell excitation current 5 350 14 mA Total current 22 mA Measurement Parameter Minimum Typical Maximum Units Notes Bridge Excitation 4 90 5 5 10 Volts Bridge Impedance 350 1000 5000 Ohms Bridge Sensitivity 0 5 2 5 150 mV V Note 1 Output load 5000 Ohms Bandwidth DC 1000 Hz Zero adjustment 2 YFR Span adjustment 8 YFR Linearity 0 02 R Temperature stability Zero Temperature Stability 0 0004 0 0015 t F R Deg C At 2 5 mV V Span Temperature Stability 0 002 0 0051 F R Deg C At 2 5 mV V FR Full Range 10 V Note 1 Set by calibration resistor CE Approvals European EMC Directive 2004 108 EC BS EN 61326 1 2006 BS EN 61326 2 3 2006 j CESR E Designed manufactured and supported in the UK In the interests of continued product development Mantracourt Electronics Limited reserves the right to alter product specifications without prior notice Doc No 517 936 Issuel 0 Mantracourt Electronics Limited DRAFT ICAH S User Manual 22 04 14 REGISTERED FIRM 24
22. rocedure Detailed below is our pledge to you a defined set of ground rules and procedures to which we will adhere All we ask in return is that you assist us with our procedure such that we can maintain our promise to you Please note that warranty repairs may not be available on overdue accounts and that a strict interpretation of our conditions of trading invalidates warranty claims where late payment has occurred Please refer to the RMA Form Return Material Authorization contact your distributor for a copy In the unlikely event you have problems with the ICA module we would advise that you take the following precautions e The unit is installed as instructed e Recommended spares are kept in stock We can assist e Sufficient expertise available for first line maintenance e Routine maintenance checks are performed annually is recommended e The necessary documentation for the product is available to the maintenance personnel We recommend you keep on file as a minimum e This Manual e The calibration figures for the attached sensors e Arecord of the normal output if applicable e Acalibration record of the ICA e Acontact phone number from the supplier for assistance 15 Mantracourt Electronics Limited DRAFT ICAH S User Manual Chapter 7 Glossary Background Noise The total noise floor from all sources of interference in a measurement system independent of the presence of a data signal See Noise r
23. t low b Check the sensor is connected typically reading 350 Ohm across output amp with the power off c Check the Excitation voltage is at 5 V dc for the ICA1 4H ICA6H see Table 3 6 for ICA5S ICA5A d Check the calibration e Check the Zero offset is correct for the sensor this too is a common reason for low outputs 3 High Output This is when an output is present but higher in span or zero than expected High output is not normally a problem It is most likely to be incorrect connections and as such the output would be high and fixed a Check the sensor is connected typically reading 350 Ohm across output amp with the power off b Check the Excitation voltage is at 5V dc for the ICA1 4H and 6H see Table 3 6 for ICA5S ICA5A c Check the Zero offset d Check the calibration 4 Unstable Output This is when the output is unstable or varies The cause could be a poor installation or b a noisy environment Poor Installation This is when an output is present but higher or lower in span or zero than expected a Check the installation for problems and repair where necessary b Poor termination c High resistance on cable leads d Low insulation impedance e Proximity to High Voltage Equipment Transformers Contactors Motors etc Noisy Environment a Check if the source can be found and remove noise b Check the cable shielding and ensure it is correctly installed and terminated 5 Ca
24. te 1 Set by calibration resistor 19 Mantracourt Electronics Limited DRAFT ICAH amp S User Manual Table 8 3 ICA3H 10 V Electrical and Environmental Parameter Minimum Typical Maximum Units Notes Supply voltage Range 13 14 15 Volts Operating Current 8 mA Note 1 Operating Temperature Range 40 85 Deg C Storage Temperature Range 40 85 Deg C Reverse polarity Protection 30 Volts Note 1 Not including excitation current e g when connected to a 350 Ohm load cell excitation current 5 350 14 mA Total current 22 mA Measurement Parameter Minimum Typical Maximum Units Notes Bridge Excitation 4 90 5 5 10 Volts Bridge Impedance 350 1000 5000 Ohms Bridge Sensitivity 0 5 2 5 150 mV V Note 1 Output load 5000 Ohms Bandwidth DC 1000 Hz Zero adjustment 2 YFR Span adjustment 8 YFR Linearity 0 02 IFR Temperature stability Zero Temperature Stability 0 0004 0 0015 R Deg C At 2 5 mV V Span Temperature Stability 0 002 0 0051 t FR Deg C At 2 5 mV V FR ull Range 10 V Note 1 Set by calibration resistor Mantracourt Electronics Limited DRAFT ICAH amp S User Manual 20 Table 8 4 ICA4H 4 to 20 mA Electrical and Environmental Parameter Minimum Typical Maximum Units Notes Supply voltage Range 13 24 30 Volts Operating Current 8 mA Note 1 Operating Temperat
25. ter 1 The ICA H S Range Figure 1 1 Block Diagram POWER y SUPPLY IN CELL Load Cells 0 1 to 10 1 V Strain Gauges 0 1 to 5 1 V Torque Transducers 10 V 15 V supply Pressure Transducers 4 20 mA 40 20 mA 2 wire 10 V 15 24 V supply The ICA is a Strain Gauge Amplifier converting a strain gauge input to a Volt or mA output otherwise known as a Signal Conditioner The ICA provides a wide range of signal conditioning for Strain Gauges Load Cells Pressure and Torque Transducers Offered in 5 Very High Stability versions e CA1H 3 wire 0 1 to 10 1 V e CA2H 3 wire 0 1to5 1V e CA3H 4 wire 10V 15 V supply e CA4H 3 wire 4 to 20 mA e ICA6H 3 wire 10 V 15 24 V supply Industrial Stability versions e ICA5S amp A 2wire 4to 20mA N B The ICA5 is designed for a 1000 Ohm bridge or higher however 350 Ohms can be used but with reduced performance see Chapter 3 ICA5S amp ICA5A Transducer SENSITIVITY of between 0 5 mV V and greater than 10 mV V are possible As supplied they are optimised to 2 5 mV V This range covers most but not all strain gauges Sensitivity adjustment SPAN is achieved by a combination of gain span resistor R change and associated fine adjustment by potentiometer Similarly transducer ZERO can be compensated for in the module This adjustment is to compensate for slight errors in the strain gauge and not to offset tare The ICA6H The ICA6H is a two part module w
26. try Supplier PartNo Description _ O o o O Supplier _ Farnell 118 2117 Individually shielded twisted multi pair cable 7 0 25mm 2 pair Tinned copper drain Individually shielded in polyester tape Diameter 4 1mm Capacitance m core to core 115 pF amp core to shield 203 pF UK Farnell 585 646 Individually shielded twisted multi pair cable 7 0 25mm 3 pair Tinned copper drain Individually shielded in polyester tape Capacitance m core to core 98 pF amp core to shield 180 pF UK RS 749 2591 Braided shielded twisted multi pair cable 7 0 2mm 1 pair le ied Miniature twin round Diameter 5 2 mm Capacitance m core to core 230 pF core to shield 80 pF If possible segregate the signal cable from Power Cables allow a 1metre 3 feet distance from such cables Do not run signal cables in parallel with power cables and cross such cables at right angles The ground connection conductor should have sufficient cross sectional area to ensure a low impedance path to attenuate RF interference Mantracourt Electronics Limited DRAFT ICAH amp S User Manual Chapter 3 Calculating the Gain Resistor Values ICA1H amp ICA2H The ICA1H and 2H are supplied un calibrated but optimized for a sensitivity of 2 5mV V To accommodate other sensitivities the gain resistor Rgain shown in Figure 2 2 can be changed according to the following formula N B a high quality component e g 1 10 15 ppm C metal film resistor shou
27. ts and Z is the load cell impedance in Ohms e g For a 2 5 mV V 1000 Ohm load cell R2 228 6 k Ohms use 220 k nearest E24 preferred value or 229 k nearest E192 preferred value The following table gives calculated values of Vexc for various standard load cell impedances Load Cell Impedance Excitation voltage V exc 350 0 53 700 0 87 1000 1 08 1400 1 29 2000 1 51 5000 1 97 Use the following formulae to calculate the excitation voltage for cell impedances not given in the table Rx l Ohms 1 Rcell 4 762 x10exp 6 Vexc 2 5x Rx Volts Rx 1300 e g for a 500 Ohm load cell Rx 498 8 Ohms Excitation Voltage Vexc 0 693 V ICA5S amp 5A Offset Resistor R1 The value of R1 can be changed to offset the zero point if it is outside the normal trimming range 2 FS Its value will also depend on the impedance of the load cell The factory fitted value 180k is optimised for a 1000 Ohm cell Mantracourt Electronics Limited DRAFT ICAH amp S User Manual 12 Chapter 4 Calibration The ICA amplifiers 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 if the precise sensitivity mV V of the transducer is known Figure 4 1 Connection Details for Calibration Voltmeter Display Output WE o
28. urce MOdE c cece ccc ece cece eee eee ee teat eee eet r rra rn r EEEE EEEE EEEE EEEE 6 Figure 2 8 Connection Details for the ICA4H SINK mode cece cee ce cece eect eee eee non non teat eet rrtt rrtt rr rr rra 6 Figure 2 9 Connection Details for Best EMC IMMUN Ity c cece eee e cece eect ttrt ttr E EEEE EEEE EREEREER EEEE EEEE 6 ICA5S amp ICASA COnnectionssis deat enia eano Aan EnA TOS AD EP AREP APEYA KOA ners ADIN A AR 7 Figure 2 10 Connection Details ICA5S ICA5A oocoocccccncnncnncnncnnconco nro n rn rr nr rr nr rr EREEREER EEEE EEEE EEEE EEEE EEEE 7 Figure 2 11 Connection Details for Best EMC IMMUNILY cceccecc eee e eect eee ee teat eee ee seat EEEE EEEE EEEE EEEE 7 Output CONNECTIONS cities 8 Output Shunt Resistance Formula 2 0 0 UU EEE nts 8 Table 2 1 The ICA H SeS Cable Data viii dad aaa needa nia ee 8 Chapter 3 Calculating the Gain Resistor Values ccccccuceecuceeeuaeeeuaeeeuaeeeuaeeeuaeeeuaeeeueuaeeeuaeeeuaeaeuaeeeuanagya 9 CALA 81 CA2F A A A eve den oy A Ihde A delay ae esate 9 Table 3 1 ICA1H 0 1 V to 10 1 V Gain Resistor Formula occcccccnncccccncnnnnnnn rn rr non anar rr rr 9 Table 3 2 ICA2H 0 1V to 5 1V Gain Resistor FOrMula ooooccccccnnncccccnnnnnnnnnn nr rro nn rn r arar nn rr rara 9 Table 3 3 ICA1H ICA2H Offset Resistor FOrMula netted 9 O A RAN 10 Table 3 4 ICA3H ICA6H 10 Volts Gain Resistor FOrMuUla oooooococccccccccnnnnnnnnr nn nr nn
29. ure Range 40 85 Deg C Storage Temperature Range 40 85 Deg C Reverse polarity Protection 30 Volts Note 1 Not including excitation current and output current e g when connected to a 350 Ohm load cell Total current Operating current 8 mA Excitation current 5 350 14 mA Output current 20 mA FS 42 mA FS typical Measurement Parameter Minimum Typical Maximum Units Notes Bridge Excitation 4 90 5 5 10 Volts Bridge Impedance 350 1000 5000 Ohms Bridge Sensitivity 0 5 2 5 150 mV V Note 1 Output load 1000 Ohms Note 2 Bandwidth DC 1000 Hz Zero adjustment 2 YFR Span adjustment 8 YFR Linearity 0 02 IFR Temperature stability Zero Temperature Stability 0 0004 0 0015 H YFR Deg C At 2 5 mV V Span Temperature Stability 0 002 0 0051 H YFR Deg C At 2 5 mV V FR Full Range 16 mA Note 1 Set by calibration resistor Note 2 24 V minimum supply sink mode 21 Mantracourt Electronics Limited DRAFT ICAH amp S User Manual Table 8 5 ICA5S 2 wire 4 20 mA Electrical and Environmental Parameter Minimum Typical Maximum Units Notes Supply voltage Range 7 5 24 30 Volts Operating Temperature Range 40 85 Deg C Storage Temperature Range 40 85 Deg C Reverse polarity Protection 30 Volts Measurement Parameter Minimum Typical Maximum Units Notes Bri
30. utput load 5000 Ohms Bandwidth DC 1000 Hz Zero adjustment 2 YFR Span adjustment 8 YFR Linearity 0 02 IFR Temperature stability Zero Temperature Stability 0 0004 0 0015 YFR Deg C At 2 5 mV V Span Temperature Stability 0 002 0 0051 YFR Deg C At 2 5 mV V FR Full Range 10 V Note 1 Set by calibration resistor Mantracourt Electronics Limited DRAFT ICAH amp S User Manual 18 Table 8 2 ICA2H 0 1 to 5 1 V Electrical and Environmental Parameter Minimum Typical Maximum Units Notes Supply voltage Range 8 5 12 28 Volts Operating Current 8 mA Note 1 Operating Temperature Range 40 85 Deg C Storage Temperature Range 40 85 Deg C Reverse polarity Protection 30 Volts Note 1 Not including excitation current e g when connected to a 350 Ohm load cell excitation current 5 350 14 mA Total current 22 mA Measurement Parameter Minimum Typical Maximum Units Notes Bridge Excitation 4 90 5 5 10 Volts Bridge Impedance 350 1000 5000 Ohms Bridge Sensitivity 0 5 2 5 150 mV V Note 1 Output load 5000 Ohms Bandwidth DC 1000 Hz Zero adjustment 2 YFR Span adjustment 8 YFR Linearity 0 02 IFR Temperature stability Zero Temperature Stability 0 0004 0 0015 YFR Deg C At 2 5 mV V Span Temperature Stability 0 002 0 0051 YFR Deg C At 2 5 mV V FR Full Range 5 V No
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