Cleveland Motion Controls MWI-13262 User Manual

I

7550 Hub Parkway Cleveland, Ohio 44125 Phone: [phone] Fax: [phone] www.cmccontrols.com

MWI-13262 U

NSTRUCTION

(MAN-13262)

F

OR

DIN

R

AIL

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ON

Industrial Products Division

-I

A

SOLATED

M

ANUAL

MPLIFIER

LTRA

S

ERIES

REVISION

BA

DIN RAIL AMPLIFIER, MWI-13262 ULTRA SERIES MAN-13262 ULTRA REV BA

REVISION HISTORY

Rev ECO Author Date Description of Change

AA XXX DJM 01/19/04 As Released

BA CLE2912 DJM 08/12/04

Updated Block diagram, 4-20 mA section, Replaced
Transducer Wiring Diagram, Added Damped mA with
Scaling Board diagram.

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ABLE OF CONTENTS

1 P

RODUCT OVERVIEW

1.1 G

1.2 G

1.3 P

1.4 E

1.5 O

1.6 EMC T

1.7 E

2 S

2.1 L

2.2 P

2.3 O

2.4 R

2.5 C

2.6 P

2.7 E

2.8 C

2.9 G

2.10 M

2.11 M

2.12 W

2.13 T

ENERAL DESCRIPTION

1.1.1 CE EMC Responsibility .............................................................................................5

ENERAL SPECIFICATIONS
HYSICAL SPECIFICATIONS
NVIRONMENTAL REQUIREMENTS

PERATING CONDITIONS

ECHNICAL RATINGS

MISSION SPECIFICATIONS

ETUP AND CONFIGURATION

OAD CELL (TRANSDUCER) TERMINALS

OWER SUPPLY TERMINALS

UTPUT TERMINALS
ECOGNITION DIAGRAMS
ONFIGURING THE SWITCH SETTINGS
OTENTIOMETERS
XCITATION VOLTAGE SELECT
HANNEL SELECT

AIN SELECT SWITCHES

ETER VOLTAGE/CURRENT CONFIGURATION
ETER OUTPUT DAMPING SELECT

IRING

........................................................................................................................14

2.12.1 Wiring termination ...................................................................................................14

2.12.2 Transducer Wiring ...................................................................................................14

HE POWER SUPPLY

2.13.1 Power Wiring diagram .............................................................................................15

2.13.2 Output wiring ...........................................................................................................15

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LTRA

3 P

OWER-UP AND TESTING

3.1.1 Before Applying Power............................................................................................19

3.1.2 Power Application....................................................................................................20

3.2 T

3.3 A W

3.4 A

3.5 A

3.6 A

3.7 A

3.8 G

3.9 EMC C

A

PPENDIX

A

PPENDIX

RANSDUCER POLARITY CHECK

ORD ABOUT CALIBRATION
PPLYING FORCE TO TRANSDUCERS
DJUSTMENT TOOLS
DJUSTING AMPLIFIER COURSE ZERO
DJUSTING THE

AIN AND FINE ZERO CALIBRATION

ONNECTIONS AND INSTALLATION

A. M

B. C

LCH-RCH B

ANUFACTURERS DECLARATION OF CONFORMITY

ABLE GLANDS

.........................................................................19

.......................................................................................20

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..............................................................................22

ALANCE

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ARRANTY

Cleveland Motion Controls warrants the goods against defects in design, materials and workmanship for the period
of 12 months from the date of delivery on the terms detailed in the Cleveland Motion Controls, Inc. Terms and
Conditions of Sale, document number AO-90131

Cleveland Motion Controls, Inc. reserves the right to change the content and product specification without notice.

© 2003 in this document is reserved to:
Cleveland Motion Controls, Inc.
7550 Hub Parkway
Cleveland, OH 44125
216-524-8800 Phone
216-642-2199 Fax

I

NTENDED USERS

This Instruction Manual is to be made available to all persons who are required to configure, install or service the
amplifier equipment described in this manual or any other related activity.

F

URTHER INFORMATION

For the latest product information, technical literature etc., visit our website at www.cmccontrols.com

ATTENTION: The following information is provided merely as a guide for proper installation. Cleveland Motion
Controls cannot assume responsibility for the compliance (or failure to comply) to any code (national, local or other)
that prescribes the proper installation of this electronic device or associated equipment. A hazard of personal injury
and/or property damage can exist if applicable codes are not adhered to.

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RODUCT OVERVIEW

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1.1 G

The Ultra Series DIN Rail amplifier (non-isolated) provides a complete signal conditioning solution for amplifying
and reporting signals from a pair of strain-gage-based load cells. Either semiconductor or foil-based load cells can
be used. Note that the non-isolated version of the Ultra Series DIN Rail amplifier shares the same ground reference
(common) between the 24VDC supply, output signals, and strain-gage bridge.

The Ultra Series DIN Rail amplifier uses a dedicated Instrumentation Amplifier (IA) for each transducer channel.
The IA stage amplifies the millivolt level signals generated by the load cells, while effectively rejecting common­mode noise. A wide range of switch selectable gains can be used to provide the most appropriate level of initial
amplification. Low drift Surface Mount Technology (SMT) components, Multi-layer Printed Circuit Boards (PCB)
and optimum circuit topologies are incorporated to promote load cell signal integrity.

A summing amplifier stage combines the left and right IA channels. The gain of this stage is adjustable over a 10:1
range to allow span calibration of the analog outputs. To improve rejection of “out of band” signals, the summing
stage is followed by a DC accurate 2-pole active filter.

A precision voltage source is provided for exciting the strain gage elements in the inter-connected load cells (tension
transducers). The circuit includes a short circuit current limit feature to protect the amplifier in the event of mis­wiring. Output voltage is selectable to either of the following:

The final analog tension signal is available in a variety of forms. The un-damped output signal can be provided
from a +/-10V analog buffer stage, as well as a standard 4-20 mA current loop stage. The voltage supply for the
current loop bias is internally provided. The current loop scaling has been specially designed so that minor negative
excursions of the tension signal can continue to be reported as currents below 4 mA.

A damped (low pass filtered) version of the tension signal is available for driving displays or recording devices. The
damping is switch selectable for a cutoff frequency of either 0.3 Hz or 3.7 Hz. Damping is useful for improving the
readability, effectively masking higher frequency fluctuations superimposed on the tension signal. This damped
output stage can be configured to be either:

ENERAL DESCRIPTION

• 5.0 VDC

• 10.0 VDC

• +/- 2V analog output - intended primarily for driving Digital Panel Meters (DPM).

• +/-1 mA current source - When configured as the current source, the 1 mA output is

typically used to drive D’Arsonval style analog meters.

1.1.1 CE EMC R

Cleveland Motion Controls DIN Rail Amplifier MWI-13262 Ultra Series module can be considered a component
performing a direct function and therefore is subject to the provisions of the EMC Directive.

The Cleveland Motion Controls DIN Rail Amplifier MWI-13262 module may be used by a manufacturer as a
component of a larger system, along with other components, which may or may not bear the CE mark. The system
assembler is responsible for the compliance of the system as a whole with the EMC Directive.

To assist manufacturers, suppliers, and installers of relevant apparatus, the Cleveland Motion Controls DIN Rail
Amplifier MWI-13262 module is compliant to EN61326:1997 when installed according to these instructions.
Manufacturers, suppliers, and installers of relevant apparatus may use this compliance as a contributing basis for
their own justification of overall compliance with the EMC Directive.

Before installing the Ultra Series DIN Rail Amplifier you must clearly understand who is legally responsible for
conformance with the EMC Directive. Misappropriation of the CE mark is a criminal offense.

ESPONSIBILITY

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1.2 G

Item Specification Comments

Input Supply

Power Supply Requirements 24 VDC @ 160 milliAmps Basic Non-Isolated Amplifier

Power Supply Limits 20 to 28 VDC Basic Non-Isolated Amplifier

Load Cell (Transducer)

Transducer Excitation (Vexc) 5.0 or 10.0 VDC Shipped with V EXC. Set at 5.0 VDC.

Transducer Resistance Range 100 to 1000 Ohms Do not exceed maximum excitation

Transducer Gage Types Semi-Conductor (20-100 mV/V) or

Amplifier

Input Impedance 10K (Line-Line) Nominal Inputs may be used single ended or

Selectable Gains, IA stage 8, 30, 120, 500 Gains switched by referring to section

Calibration Range, summing
stage

Zero Range +/- Full Scale Output Coarse adjustments for each channel

Nominal Input Signal Levels 0-500 milliVolts

Pulse Response 10-90% Stop,

Amplifier Output Signal +/-10 VDC @ 2 mA

ENERAL SPECIFICATIONS

Foil (2-3 mV/V)

Min. 0.9 - Max. 9 Multi-turn Gain adjustment provided.

0-20 milliVolts

0-10V and 4-20 mA

4-20 mA current loop
0-2 VDC @ 2 mA
+/- 1milliAmp

100milliAmp maximum.
Switchable to 10 VDC with internal
switch.

current.

Gain switches configure each input
gain from 5 to 620 as needed, to
amplify transducer voltage.

together as a differential pair

2.5 in this document.

provided. Fine adjustment affects
sum.

Each semi-conductor load cell
Each foil-gage load cell

300 milliseconds for undamped
signals

+/-10 is undamped signal
Current loop undamp
+/- 2VDC signal (or 1mA) has switch
selectable damping (0.3 or 3.7 Hz)

1.3 P

Item Specification Comments

Enclosure Type

Enclosure Size

Weight – Basic Amplifier 170 Grams 6 ounces

Terminals

HYSICAL SPECIFICATIONS

DIN Rail mountable with main user
adjustments accessible from front
surface. Snap-on cover to access
configuration switches and setup
potentiometers.

Base: 45 mm wide by 75 mm high
Depth: 105 mm

Two removable plugs of eight
terminals each, keyed to avoid mis­plugging

Phoenix EG type ABS enclosure. Color green.

1.8 inches (width) by 3.0 inches (height)

4.2 inches (depth)

Screw type terminals, will accept up to one 12
AWG or equivalent.
Phoenix “Combicon” type.

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Requirement Description

Enclosure

Operating temperature

Humidity

Altitude

Atmosphere Non-flammable, non-corrosive and dust free

Storage temperature range

Transport temperature range

1.5 O

Condition Ultra Series DIN Rail amplifier

Installation category Category III

Pollution Pollution Degree 2

Input supply Earth (Ground) referenced

Protection Enclosure mounted

NVIRONMENTAL REQUIREMENTS

IP20
NEMA 1

0 to 55 degrees C
32 to 132 degrees F

Non-condensing
85% at 55 degrees C
85% at 132 degrees F

1000 meters
3300 feet

-25 to 80 degrees C

-13 to 176 degrees F

-25 to 80 degrees C

-13 to 176 degrees F

PERATING CONDITIONS

1.6 EMC T

Port Phenomenon Test Standard Level Test Standard

Enclosure ESD EN 61000-4-2: 8KV AD, 1KV CD EN 61326:1997

Enclosure RF Field EN 61000-4-3 10V/m,1 Khz AM EN 61326:1997

Transducer Leads

Output Leads

Transducer Leads

Output Leads

AC Power Line Surge EN 61000-4-5

AC Power Line Voltage Dips EN 61000-4-11

1.7 E

Port Phenomenon Test Standard Level Generic Standard

Enclosure Radiated EN 61326:

ECHNICAL RATINGS

Fast Transient
Burst

Fast Transient
Burst

Conducted
Immunity

Conducted
Immunity

EN 61000-4-4 1kV EN 61326:1997

EN 61000-4-4 1kV EN 61326:1997

EN 61000-4-6 3V/m EN 61326:1997

EN 61000-4-6 3V/m EN 61326:1997

MISSION SPECIFICATIONS

1997

The levels of performance indicated are achieved when the Ultra Series DIN Rail Amplifier is
installed by using the instructions and specifications outlined in this document.

+/-2KV L to PE
+/-1KV L to L

+/-0.5 Cycle
100%

EN 61326:1997

EN 61326:1997

Class A EN 61326:1997

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Figure 1 - Block Diagram of Ultra Series DIN RAIL MWI -13262

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ETUP AND CONFIGURATION

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2.1 L

Terminal Function Description Notes

EXC RET

+V EXC

-IN LCH

+IN LCH

-IN RCH

+IN RCH

OPEN (N.C.) NO CONNECTION Make no connection

SHLD DRN

OAD CELL (TRANSDUCER) TERMINALS

Supply return for bridge
excitation

Bridge excitation source for
LCH and RCH transducers

Load cell signal from LCH
transducer

Load cell signal from LCH
transducer

Load cell signal from RCH
transducer

Load cell signal from RCH
transducer

Cable shield
drain terminal

Zero voltage terminal for
LCH and RCH transducers

5.0 Volt or 10.0 Volt supply terminal, max. load 100 mA

Low going output from LCH
transducer

High going output from LCH
transducer

LOW going output from RCH
transducer

High going output from RCH
transducer

Cable Shield for LCH and RCH
transducer cables

COMMON

10K ohm line-to-line

10K ohm line-to-line

Connect only at amplifier

Transducers (load cells) use strain gages which have limited insulation levels to ground (earth).
This requires that the COM terminals be connected to ground (earth) to prevent damage to the

2.2 P

Output Terminal Function Description Notes

J2-1 24V RET Power Supply Power supply return

J2-2 +24 VDC Power Supply Positive supply source

transducers (load cells).

OWER SUPPLY TERMINALS

Must not exceed 50 volts
from P.E.
+20 to +28 VDC
@ 160 mA max

A fuse with a rating of 0.38A must be used in the 24 VDC supply lead to limit potential
damage to the amplifier in the event of circuit malfunction.

2.3 O

Output Terminal Function Description Notes

J2-3 COMMON Output signal return

J2-4 +/- 10V OUT Voltage Output signal

J2-5 mA MTR RET mA meter signal

J2-6 METER OUT Output signal

J2-7 4-20mA OUT

J2-8 4-20mA RET Output current signal

UTPUT TERMINALS

Current loop Output
signal

Undamped bi-polar
tension signal
Used for current format meter
return
Damped bi-polar tension
signal
Undamped tension signal,
current loop source
Current return for
4-20 mA loop

Common for +/- 10V and
+/-2V output

max. load 2 mA

Current through 1 mA
meter returns here
Switchable 2.0 V F.S.
or 1 mA F.S.

Internal Loop supply

At -15 VDC with respect to
common

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2.4 R

ECOGNITION DIAGRAMS

9
9
9
.
1

M
A

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R

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G

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r

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m

s

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T

RIGHT SIDE VIEWLEFT SIDE VIEW

C

W

M

I

C

T
H

P
A

N

L

R

I

O

N

T

N

E

N

-

L

I

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S

O

M

O

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L

B

D

A

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C

T

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E

E

:

D

L

M

L

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U

M

I

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-

1

P

U

3

L

T

2

I

S

F

6

I

2

E
R

FRONT VIEW

Figure 2– Front and Side Views of Ultra Series DIN Rail Amplifier MWI 13262

Figure 3 - Ultra Series DIN Rail Amplifier Mounting Diagram

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J8
Channel
Select

2.5 C

J1

J1

J2

J4

J5

RCH Gain

P4
Balance

P5
LCH Course
Zero

J10

LCH Gain

J9

J2

J3

J7

J6

Figure 4 - Internal Jumper-switches and Potentiometer Location

ONFIGURING THE SWITCH SETTINGS

Output
Board

P3
RCH Course
Zero

Input
Board

A number of operational characteristics can be configured prior to mounting or wiring the amplifier. We
recommended that you first familiarize yourself with the internal switch locations, settings, and potentiometers by
opening the snap-on access cover. Figure 4 illustrates the location of configurable items on each of the printed
circuit boards.

Use an approved anti-static wrist strap when adjusting any switch settings/potentiometers on the amplifier.

Switch PCB Location Function

J3

J8

J1

J2

J10
J9
J7

J6
J5
J4

J1

J2

Input

Input

Input

Input

Input

Input

Output

Output

Configures Excitation voltage for 5.0 or 10.0 VDC. The amplifier is factory set at (setting 1-2 ) for

5.0V

Selects left channel only (setting 2-3) or LCH + RCH (setting 1-2) as input to summing amplifier
stage. Slide the jumper switch to (1-2) for normal operation with two transducers. Refer to
setup/calibration section for more information.

Connects completion resistances of RCH transducer input to ½ of excitation voltage
(setting 1-2). Slide the jumper switch to setting (2-3) for normal operation with Ultra Full-Bridge
transducers. Slide jumper switch to setting (1-2) if the channel is unused.

Connects Completion resistances of LCH transducer input to ½ of excitation voltage
(setting 1-2). Slide the jumper switch to setting (2-3) for normal operation with Ultra Full-Bridge. Slide
the jumper switch to setting (1-2 ) if the channel is unused.

Sets voltage gain of LCH Instrumentation amplifier to 5, 25, 125 or 620. The jumper switches are
factory set to (1-2) for minimum gain (Av = 5). Refer to section 2.9 for more information on setting
Gain select switches.

Sets the fixed gain of RCH Instrumentation amplifier. The jumper switches are factory set to
(1-2) for minimum gain (Av=8).

Configures meter output stage for +/- 2V F.S. or +/- 1 mA F.S. The jumper switch is factory set to (1­2 ) for voltage output. Voltage and current modes use different terminals.

Selects meter damping 0.3 Hz or 3.7 Hz. The jumper switch is set to (2-3) for minimum damping. (3.7
Hz)

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2.6 P

OTENTIOMETERS

In addition to the Gain and Zero adjustable Potentiometers visible on the front of the unit, there are adjusts you can
make by removing the snap-off cover on the side of the amplifier. The adjustments are on the output and input
printed circuit boards as shown in Figure 4. The following table provides you with a list of Potentiometers, where
they are located on the Ultra Series DIN Rail input printed circuit board, and a description of their functions.

Potentiometer

GAIN P2 Unit Front

ZERO P1 Unit Front

LCH Coarse
Zero

RCH Coarse
Zero

LCH-RCH
Balance

Reference

Designator

P5

P3

P4

Location Function

Provides 10:1 “vernier” adjustment of the summing amplifier. It is a multi­turn potentiometer, with clockwise rotation causing an increase in amplifier
gain. When turned fully counter clockwise, the potentiometer will cause the
summing amplifier stage to provide the minimum gain of 0.9.

Provides a fine zero (offset) adjustment. It simultaneously and equally
affects both of the instrumentation amplifiers. It is a multi-turn
potentiometer, with clockwise rotation causing a positive shift in the analog
outputs. It should be set mid-way prior to setting the COARSE ZERO
adjustment.

Establishes the coarse zero of the Left Channel (LCH) instrumentation
Input, behind
access cover

Input PCB,
behind access
cover

Input PCB,
behind access
cover

amplifier. Because of the ability to cause +/- Full scale (+/- F.S.) output

shifts, it is important to correctly follow the final set-up and calibration

procedure so that premature amplifier “clipping” is avoided

Establishes the coarse zero of the Right Channel (RCH) instrumentation

amplifier. Because of the ability to cause +/- Full scale (+/- F.S.) output

shifts, it is important to correctly follow the final set-up and calibration

procedure so that premature amplifier “clipping” is avoided. This is a multi-

turn adjustment potentiometer.

Allows for matching (balancing) the gain between transducers if needed.

Don’t adjust this unnecessarily; it has been factory set for equal balance.

Turning clockwise boosts the signal for the Left Channel. This multi-turn

adjustment potentiometer has been deliberately “set back” from the

adjacent ZERO potentiometers to discourage accidental adjustment.

2.7 E

XCITATION VOLTAGE SELECT

The Excitation Voltage is determined by the position of jumper switch J3. Refer to Figure 4 for Jumper-switch
locations. The jumper default setting is J3 (1-2) for 5.00V excitation Do not use 10V setting J3 (2-3) unless
explicitly permitted by the load cell electrical specifications. Promptly verify the excitation voltage after power-up
to avoid overdriving strain gages. Note that if there is no external load resistance, the voltage may rise to 6.4V, but
will immediately regulate at 5.00V when the load cells are connected.

Keep in mind that the strain gage based load cells can readily operate at less than rated voltage (with a
corresponding reduction in output signal). This fact is helpful in the event that a “10 V “ load cell exhibits an output
signal that is excessive for even the lowest amplifier gain.

2.8 C

HANNEL SELECT

Jumper-switch J8 configures the inputs to the Variable Gain Summing Amplifier stage. For most applications
involving a pair of transducers, it is placed in the J8 (1-2) position so that the analog outputs represent the sum of the
left and right channels (LCH + RCH). During portions of the calibration procedure, or if only the left transducer
channel is utilized, it is placed in the J8 (2-3) position. In this position, the signals at the analog outputs represent
only the left channel (LCH).

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2.9 G

AIN SELECT SWITCHES

The group of jumper-switches that control the fixed gain of the Instrumentation Amplifiers (IA) are located closest
to the front left edge of the Input card. (Refer to Figure 4) Typically, you configure both channels to the same setting
if both transducers are the same force rating.

When the amplifier is held horizontally with the pluggable connectors facing toward the right (refer to Figure 4), the
leftmost cluster (J10, J9, J7) sets the gain for the LCH (Left Channel) Instrumentation Amplifier. Similarly, the
right cluster (J6, J5 and J4) sets the gain for the RCH (Right Channel) Instrumentation Amplifier. The lowest gain
(Av = 8) occurs when all of the switches are in the 1-2 position. As switches are moved “away” (into position 2-3)
from left to right, the gain progressively increases as described in following table:

Left Channel

J10 J9 J7

1-2 1-2 1-2 5 1-2 1-2 1-2

2-3 1-2 1-2 25 2-3 1-2 1-2

2-3 2-3 1-2 125 2-3 2-3 1-2

2-3 2-3 2-3 620 2-3 2-3 2-3

Voltage Gain

Right Channel

J6 J5 J4

When changing the internal Jumper-switch settings, it is always advisable to change the settings
with the 24 VDC power removed. If this is not possible, it becomes particularly important to use
a non-conductive tool to alter switch positions.

Make sure that Jumper- switch settings are fully in position to avoid accidentally leaving a switch in an “in­between” state.

The total gain range of the amplifier is the product of the IA and summing amplifier gains (variable).

Using the lowest gain switch settings, the net gain is 5 x (.9 to 9.0 ) or 4.5 to 45

With the other gain combinations available, a 10 volt output can be produced with input voltages ranging from
between 0.002 to 0.50 volts.

2.10 M

The damped output for a tension indicator can be configured as either a +/- 2V output or a +/- 1mA output by
changing the position of jumper-switch J1 located on the Output Card (Refer to Figure 4 for location). Voltage
output is selected by setting J2 (1-2). Current output is selected when J2 (2-3 ). Note that different wiring terminals
are employed for the signal return when configured for current or voltage.

2.11 M

The amount of damping for the meter output (intended to drive a tension indicator) can be configured by the position
of jumper-switch J2 on the Output card (refer to Figure 4 for location information). Setting the jumper switch to J2
(1-2) sets the break frequency at 0.3 Hz. Setting the jumper switch to J2 (2-3), the break frequency setting is raised
to 3.7 Hz

ETER VOLTAGE/CURRENT CONFIGURATION

ETER OUTPUT DAMPING SELECT

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2.12 W

IRING

Most start-up problems are the result of mis-wiring or failure to reference the detailed information in this manual.
While a convenient basic wiring diagram can be found printed on the side label of the amplifier case, the diagram is
intended only as a helpful guide when checking field wiring. Additional information details can be found in the
subsequent sections of this manual and should be referenced before actual installation begins.

2.12.1 W

Terminal(s) Conductor Size Insulation Strip Length Torque Notes

1.5mm

All

0.75mm

0.5mm

IRING TERMINATION

2

/16 AWG

2

/18AWG

2

/20AWG

7 mm ( 0.28” )

7 mm ( 0.28” )

7 mm ( 0.28” )

0.5 Nm / 4.4 lbs.-in.

0.5 Nm / 4.4 lbs.-in.

0.5 Nm / 4.4 lbs.-in.

One wire this size per terminal

Up to two wires this size per terminal

Up to two wires this size per terminal

2.12.2 T

RANSDUCER WIRING

1

2
3
4
5
6
7
8

RIGHT XDCR

CT

8
7
6
5
4
3
2
1

BRN

BLK

WHT

BLU

BRN

BLK

WHT

BLU

1

4

2

3

1

4

2

3

TC

CT

TC

LEFT XDCR

Figure 5 - Full-bridge Transducer Wiring

The successful amplification of low level signals from strain gage transducers requires particular attention to wiring
practices to avoid signal degradation in the industrial environment. Degradation can result from AC noise pickup
and/or DC errors. Refer to the following guidelines to identify measures that may help retain signal quality:

• Use Ultra Series shielded transducer cables to reduce pickup of noise through electrostatic coupling.

• Route cables away from sources of electrical interference (motor wiring, contactors, etc).

.

• Connect the shield drain wire at one end only to discourage shield currents

• Optimum high frequency grounding requires low inductance connections that are enhanced with short

conductors or planar ground conductors (wide ground braids).

• Do not pre-tin the stranded wires inserted into the pluggable connector.

• A stable connection relies on the springy nature of stranded conductors to ensure a low contact

resistance despite thermal cycling and airborne impurities.

• Avoid temperature extremes or gradients where electrical connections are made between different

metals. Connections can cause thermocouple voltages to be generated, which then become
superimposed on transducer signals.

• In severe cases, additional shielding may be required in the form of either external flexible braided

.

shields or running the field wiring wires inside metallic conduit

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2.13 T

HE POWER SUPPLY

For best performance a regulated power supply should be used with the Ultra Series DIN Rail amplifier. It is
important that you pay particular attention to the power supply for susceptibility to the effects of conducted and
radiated energy from noise sources. Every effort should be made to provide stable voltage to the amplifier using
correct wiring practices and filters. To protect against circuit damage, include a 0.38 Amp fuse in the power supply
output lead to each amplifier in case of amplifier or power supply malfunction.

2.13.1 P

OWER WIRING DIAGRAM

The 0.38 A fuse in the +24VDC power lead is required for protection of the amplifier in the event of amplifier or
power supply malfunction.

POWER
SUPPLY
24 Vdc

FUSE

+24 V

0 V

1
2
3
4
5
6
7
8

8
7
6
5
4
3
2
1

Figure 6 - Wiring diagram for use with 24 VDC power supply

The power source for the power supply shall be fused at the proper rating to prevent over current in
the supply leads due to a power supply failure.

2.13.2 O

The load in this connection may be an indicator, recorder, data acquisition device or the analog input terminals of a
control device such as a DC drive or a programmable logic controller. The output signal at this terminal is
undamped and is the output terminal that provides that fastest response to changes in the transducer (load-cell) load.
Note that the cable’s shield drain wire should be connected at only one end, preferably at the “receiving end”.

+ / - 10V LOAD
5000 OHM MIN
RESISTANCE

SHIELD GND

UTPUT WIRING

+

1
2
3
4
5
6
7
8

Figure 7 - Output Wiring, +/- 10V Analog

8
7
6
5
4
3
2

1

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2.13.2.1 4

TO 20 MA ANALOG CURRENT LOOP

The 4-20 mA current loop output is undamped and can be used concurrently with the other outputs. The 20 mA
current level corresponds to the +10V output. The 4 mA level corresponds to 0 volts on the 10V output.

This output does not have an individual Gain and Zero Potentiometer adjustment. If multiple types of analog output
are being used, a compromise must be made during calibration, or a particular output be favored (over one that can
best accommodate individual external scaling and offsetting).

The bias supply to drive the current loop is provided internally by the Ultra amplifier. External burden resistance
(loop resistance) can range between 50 and 750 ohms.

The circuitry which drives the current loop is essentially a linear regulator stage. This means that internal power
dissipation (hence temperature rise) is lessened when higher values of external burden resistance are used.
Moderate values of burden resistance can be strategically employed to minimize internal temperature rise (and
thereby minimize amplifier drift in sensitive applications).

1
2
3
4
5

4 to 20 mA

i

+

LOOP RESISTANCE

50 - 750 OHMS

SHIELD GND

+

Figure 8 - Output Wiring, 4 to 20 mA Analog Current Loop, Floating Burden

6
7
8

8
7
6
5
4
3
2
1

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2.13.2.2 A

PPLICATION INTERFACE DETAILS

The 4-20 mA output stage is designed to drive a loop current through a floating burden resistance. Examples of
driving a loop current through a floating burden resistance include: a loop powered 4-20 mA display or, the isolated
input of receiving electronics (isolated Analog to Digital input). The 4-20 mA output can also drive non-isolated (or
ground referred) burden resistances provided that the circuit that employs the burden does not connect to the isolated
common (COM, J2-3) of the amplifier.

For a better understanding as to why the burden must be floating with respect to the amplifier’s isolated common
(COM, J2-3) refer to Figure 9. This figure illustrates that the 4-20 mA OUT (J2-7) is connected to the +15V internal
supply voltage and the 4-20mA RET terminal sinks loop current toward the -15V internal supply. A truly floating
burden receives the loop current that is controlled by the amount of current sinking into the -15V supply. The
current is supplied by the +15V supply. Incorrectly connecting burden resistance between the 4 -20mA OUT and
COM (J2-3) would cause excessive current to flow. Incorrectly connecting the 4-20mA RET (J2-8) to COM (J2-3)
results in the 4-20mA current being drawn from ground and bypassing the burden resistance.

Figure 9 – 4-20 mA Output Circuit Wired for Floating Burden

While it is possible to interface the 4-20 mA current loop into circuits which do exhibit resistances between their
burden and the amplifier isolated COM, (Refer to Figure 10.), this is a less desirable configuration. If you chose to
wire the amplifier in this way, you must keep the following in mind. When the commons of both circuits are
connected, be sure that the amplifier’s 4-20 mA OUT remains unconnected and that the 4-20 mA RET (J2-8) is
connected to draw loop current from a ground referred burden resistance at the receiving circuit. The burden
resistance must not exceed 250 Ohms due to the reduced bias voltage, however a full-scale signal of -5.0 VDC is
still possible (-5V= -20 mA x 250 Ohms).

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4 to 20 mA

i

+

LOOP RESISTANCE

50 - 250 OHMS

SHIELD GND

1
2
3
4
5
6

+

7
8

8
7
6
5
4
3
2
1

Figure 10 – 4-20 mA Output Wiring for Ground Referred Burden

2.13.2.3 D

IGITAL VOLTMETER

The +/- output terminal is designed to provide +2.0 volts when the +/- 10 V output terminal is adjusted (with the
Gain and Zero pots) to be +10.0 volts (this is full scale). To achieve different scaling, adjust gains on the Digital
Panel meter (DPM).

0 TO 1.99 VOLT
DIGITAL VOLT METER

+

MINIMUM METER RESISTANCE = 2000 OHMS

1
2
3
4
5
6
7
8

8
7
6
5
4
3
2
1

Figure 11

-

Output Wiring, Damped +/- 2V Analog

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2.13.2.4 D

AMPED

+/- 1 MA A

NALOG

The meter output stage can be configured to operate as current output (sinking or sourcing current depending upon
output polarity). It can be used concurrently with the other outputs. It does not have an individual Gain and Zero
adjustment, necessitating that a compromise be made during calibration, or a particular output be favored (over one
that can accommodate external scaling and offsetting).

To facilitate individual scaling of the analog meter a panel meter (MO-13655) with scaling board, is available as
an accessory for use with Ultra Series tension transducer amplifiers. The scaling board lets the analog meter
have a different scaling factor than that of the main (un-damped) analog output.

4

3

2+

1mA

MAXIMUM METER RESISTANCE = 7K OHMS

1

Figure 12 - Output Wiring, Damped mA Analog with Scaling Board

3 P

OWER-UP AND TESTING

3.1.1 B

EFORE APPLYING POWER

Before applying power, check the wiring to the amplifier. Pay particular attention to the following:

• Double check the transducer connections to ensure that the excitation supply is not short-

circuited.

• Use an approved anti-static wrist strap when adjusting any switch settings/potentiometers on the

amplifier.

• Use the appropriate tool when making any adjustments to the potentiometers on the amplifier or

changing switch settings. Damage to the circuitry may occur if excessive force is used or a
conductive tool accidentally contacts internal voltages.

Before applying power, confirm that the zero potentiometers are mid-span and the gain is minimum. Use the
following table to adjust potentiometers:

Adjustment Potentiometer Default

Gain – P2 Full counter-clockwise

Zero – P1 Mid-way (9 turns from full counter-clockwise)

LCH – course zero Mid-way (6 turns from full counter-clockwise)

RCH – course zero Mid-way (6 turns from full counter-clockwise)

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3.1.2 P

Apply DC power to the amplifier and use a DC voltmeter to confirm that the supply polarity and voltage is within
the prescribed limits. As soon as is practical, confirm that the excitation voltage is either 5.0 VDC or 10.0 VDC as
appropriate for the type of load cells being used. Promptly identifying any over-voltage condition can help
minimize potential damage to the strain gage elements internal to the transducer. Note that the excitation voltage
may rise to approximately 6.5 VDC if the amplifier is operated without any transducers attached. This voltage will
return to the precisely regulated value when the transducer load is connected.

3.2 T

This step is important in identifying transducer or wiring problems early-on in the setup procedure. Information
learned in this check will be instrumental in setting the optimum gains for the Left and Right Instrumentation
Amplifier stages. The following steps described the polarity check only for the Left Channel (LCH), but the steps
are applicable to the Right Channel (RCH) as well.

1. Measure the -LCH load cell signal with a digital volt meter (DVM) at the input to the amplifier with respect

to the Excitation Return (EXC RET) to confirm that it is roughly 58% of the excitation voltage.

Measure the +LCH signal to confirm that it is roughly 58% of the excitation voltage.

If both measurements are less than 50% of the excitation voltage, then it is likely that the BLU and BRN
transducer cable leads have been mis-wired.

2. Measure the voltage at the +LCH input to confirm that it becomes more positive when a small trial force is

applied in the transducer’s intended force direction. The –LCH input should become less positive when the
same force is again applied. If the “sense” of this voltage change is incorrect for the way the transducer is
mounted, interchange the load cells wiring for –LCH and +LCH signals.

RANSDUCER POLARITY CHECK

OWER APPLICATION

Without a calibration force applied to the load cells, measure the “UNLOADED” DC voltage difference
between the LCH+ and –LCH signals. Use the lowest practical voltmeter scale to provide a meaningful
measurement. Remember or record this measured value for later use.

3. Apply the intended full scale force to the load cell and measure the “LOADED” voltage.

Both of these voltages, as well as the difference between these two voltages, help to indicate the best Gain
setting configuration at the first amplification stage. Select the highest possible gain for the first stage that
does not result in saturation (“clipping”) of the transducer signal. If the voltages do not exceed 180mV,
then a gain of 25 is appropriate. Similarly, a lower signal of 35mV could use a higher gain of 125.

4. Set the IA gains using the Jumper-Switches (refer to section 2.9). We recommend using the same gain

setting for both the LCH and RCH, consistent with the requirement of avoiding saturation.

3.3 A W

This section describes the calibration process for establishing particular voltages at the +/- 10V analog output. If
you intend to use the 4-20 mA output, then make that output the focus of your calibration efforts. Similarly,
calibrate to the meter output if that is your primary focus.

ORD ABOUT CALIBRATION

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3.4 A

The application of an accurate calibration force can be a challenge. Keep the following points in mind:

PPLYING FORCE TO TRANSDUCERS

• The test force should be a moderate percentage of the intended working force of the

transducer, and never over the 100% Mean Working Force (MWF) or you may risk
calibrating with an overloaded (“clipped”) transducer signal.

• Allow the transducer and amplifier to reach thermal equilibrium before conducting

calibration. Ideally, the temperature should reflect the expected operating conditions.

• Cycle the load on the transducer a number of times with the test force to pre-condition or

“set” the transducer prior to calibration. Repeat this procedure again before calibrating if the
transducer has been disturbed (i.e. bolts re-torqued ).

• Always apply and remove the test load in a continuously increasing or decreasing manner, so

that the force changes are monotonic. This helps to avoid disturbing any hysteresis
component of the transducers force signal.

• Keep in mind that passing a cord over a roll on its way to the transducer will inevitably

cause some amount of friction. The worst case scenario is in passing the working part of a
cord over a roll that doesn’t readily freewheel. A test was conducted to determine the loss on
a stationary 4” diameter anodized roll with a 90 degree wrap angle. It exhibited a 25 to 30%
loss in force due to friction!

• With very low force transducers, consider that connecting a test mass will involve some

finite cord mass.

• When calibrating for a particularly wide roll that will always have a narrower product

tracking to one side, consider applying the calibration force at the roll position that
represents the center of the product. This will automatically cancel some of the affects of
transducer gain imbalance without the need to actually re-balance the transducers gains
within the amplifier.

• It is a good practice to verify linear operation of the transducer and amplifier by applying a

final test force that falls somewhere between the zero and full-scale endpoints. The intent is
not to conduct any calibration per se, but to confirm the hardware’s ability to accurately
report a measured force.

3.5 A

Using the correct tools simplifies the setup process and necessary adjustments. Keep the following points in mind:

DJUSTMENT TOOLS

• The Ultra Series DIN Rail amplifier utilizes two different potentiometer styles. The Gain

and Zero adjustments located on the front of the amplifier are more likely to be adjusted over
the life of the product. For that reason they are physically larger and more robust. The
industry standard “pot tweaker” is an ideal tool. The adjustment tool should have dimension
on the order of 0.5mm (.020 inches) blade thickness and be 2.5 mm wide (0.1inches).

• The adjustments that are usually made only once during initial setup are located behind a

snap on access cover. This less obvious location helps to discourage alteration by
unqualified persons. The infrequent adjustment of these potentiometers has warranted the
use of smaller surface mount technology devices (SMT). A correspondingly narrower blade
is needed (1.4 mm wide, 0.055”inches).

• When changing the internal jumper-switch settings, it is always advisable to change the

settings with the 24 VDC power removed. If this is not possible, it becomes particularly
important to use a non-conductive tool to alter switch positions. Be sure that jumper-switch
settings are fully positioned, to avoid accidentally putting it in an “in-between” state.

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3.6 A

Two individual coarse offset adjustments have been provided. There is an adjustment for each Instrumentation
Amplifier channel because each transducer can have unique offset voltages. Keep in mind that the Coarse Zero
adjustments are usually only adjusted one time, typically when the amplifier is installed, or transducers are replaced.

1. Ensure that the IA gain settings have been set as described in section 2.5.

2. Set the Zero pot on the front cover to mid-way (approximately 9 turns from either clutch actuation).

3. Set the Gain POT from fully counter clockwise.

4. Temporarily place jumper switch J8 to the (2-3) position. This position excludes the RCH signal from

contributing to the analog outputs so that only the LCH zero is represented on the analog output.

5. Connect a DC Voltmeter to inspect the +/- 10 VDC output signal for the “Zero”

condition (NO calibration force on the transducers ).

6. Adjust the LCH coarse POT (P5) to achieve the desired “Zero” voltage. As this is a coarse adjustment, a

voltage within 50 millivolts of the intended “Zero” should be adequate.

7. Return jumper-switch J8 to the (1-2) position for normal operation (where the sum of both channels is

reported on the analog outputs).

DJUSTING AMPLIFIER COURSE ZERO

8. Adjust the RCH offset using the RCH Coarse Zero POT (P3).

3.7 A

This adjustment has been factory set for a “50/50” balance between channels. We recommend that you only adjust
the LCH-RCH balance if it is necessary to better match the signals from transducers having substantially different
output signals. To discourage unintended adjustment, the Balance POT is located behind the access cover and is
recessed slightly behind the LCH and RCH offset POTS, requiring a more deliberate placement of the adjustment
tool.
Turning the Balance POT clockwise, will boost the signal for the LCH and reduce the signal for the RCH. Because
of this, we recommend that you make any needed balance adjustments early in the calibration cycle. Adjust the
Balance POT by observing the affect of an unequal application of calibration force upon the analog outputs. When
adjusted correctly, the measured force reported by the analog outputs should be insensitive to the non-equal sharing
of force between transducers.

DJUSTING THE

LCH-RCH B

ALANCE

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3.8 G

Use the following steps to make your final calibration adjustments:

1. Verify Zero on the analog Outputs for the “unloaded” condition and adjust the (Fine) Zero POT to correct

for any minor offset voltage.

2. Apply the calibration force to the transducer(s) and adjust the Gain potentiometer to achieve the desired

span.

3. Verify linear operation of the transducer and amplifier by applying a force that falls somewhere between

the zero and full-scale endpoints. The intent is not to conduct any calibration per se, but to confirm the
hardware’s ability to accurately report a measured force.

We recommend that you focus only on achieving a particular voltage “span” between the load and unloaded forces
by alternating between the two force levels. Do not repeatedly adjust the Zero POT between measurements unless
the offset voltage becomes excessive and interferes with achieving a valid output signal on the analog output. You
should only adjust the final Zero after the desired Gain setting has been achieved.

These final calibration steps represent the minimal adjustments that might be required at periodic calibration
intervals and
front cover.

AIN AND FINE ZERO CALIBRATION

typically involves only the Zero and Gain potentiometers accessible through the small holes in the

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3.9 EMC C

ONNECTIONS AND INSTALLATION

Compliance with the specified EMC directive, for immunity in a heavy industrial environment and emissions in a
light industrial environment, requires correct installation and wiring of the MWI-13262 Ultra Series amplifier. The
most important precaution to be taken in the wiring is to use double screened (shields) cabling for the cables from
the transducers (load-cells) to the amplifier, and from the amplifier to the amplifier load. The outer screen of each
cable must be firmly bonded to the enclosure that contains the amplifier, the transducer (load-cell) housing and the
enclosure of the output load device. Large loops of unshielded cables must be avoided and effective cable glands
providing 360 degree grounding of the outer screen of the transducer and output cables to the enclosure must be
used. Refer to Figure 13 - EMC Connections for further details.

D
N
U
O

T

R
C
D
X
T
H
G

I
R

C

T

C

1

2

4

3

T

N

K

H

L

R

B

B

W

T

D
N
U
O
R
G

C

1

2

4

3

T

N

K

U
L
B

U

H

L

L

R

B

B

B

W

R

C

G

R
C
D

E

D

X

A

C

T

N

O

F

L

T

A

E

T

A

L

S
I

m

S

0

E

2

R

o
t

P

4

O
O
L

+

D
N
U
O
R
G

A
m

1

+

D
N
U
O
R
G

D
N

D

U

N
I

A

E

O

M

O

C

R

L

N

G

M

A

V

H

0

T

O

1

S
I

0

O

S

0

T

E

0
5

0

R

+

E

D

E

E

R

T

D

G

C

N

E

E

U

D

N

.

O

0

N

D

R

6

O

N

3

G

E

C

H

H

D

T
I

L

C

W

E

A

I

E

H

D

S

N

N

U

O

D

O

E

S

R

D

D

I

G

N

A
R

O

O

B

T

B

1

423

7

5

6

8

85762431

E
R
U
S
O

L
E
S
U
F

+

Y

V

V

L

0

4

P

2

P
U
S

C

R

A

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V

U

W

0

E

2

O

1

N

P

L

N

E
S
U
F

3

R

­T

2

E

3

N

T

3

L

E

I

N

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F

F

A

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V

R

I

N
I

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U

L

N

Q

F

T

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U

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P

O

H
N
I

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L

N

C
N
E

D
E
D
L
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I
H
S

Figure 13 - EMC Connections

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Appendix A. M

ANUFACTURERS DECLARATION OF CONFORMITY

Number: AO-90311

Manufacturer: Cleveland Motion Controls, Inc.
7550 Hub Parkway
Cleveland, Ohio 44125
U.S.A.

Product Ultra Line Series Loadcell Amplifier
Models: MWI-13261 and MWI-13262

Standards Used: EN 61326 (1998)
Electrical equipment for measurement, control and laboratory use
EMC requirements classification – Industrial locations

Test Report Number: EMR1686 of January 5, 2004

Tests Report: EU Compliance Services, Inc.

13275 Sperry Rd.

Chesterland, Ohio 44026

Declaration This product is in conformity with Council Directive 89/336/EEC

of 3 May 1989 on the approximation of the laws of the Member
States relating to electromagnetic compatibility based on test
results to the harmonized standards referenced.

_________________________________
Carl Richter
Engineering Manager

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Appendix B. C

ABLE GLANDS

Several manufacturers provide cable glands that can be used to ensure the integrity of the EMC requirements when
installing this equipment in the enclosure. The objective of the cable gland is to provide a good mechanical entry
into the enclosure to protect the cable and also provide an electrical bond the outer shield (screen) of the cable to the
enclosure.

The following is a list of cable gland venders and the range of cable sizes that each vender can provide. This is not
an endorsement or promotion of any particular vender or manufacturer; the information is provided only to assist
you in the application of the product described in this document.

Cable Gland Vendor Cables

EMI-Proof Grounded Nickel Plated Brass Liquid Tight Strain

Sealcon
14853 E. Hinsdale Ave., Suite D
Englewood, CO 80112, U.S.A.
Tel: [phone] Fax: [phone]
Tel: [phone]

GlobTek, Inc.
186 Veterans Drive
Northvale, NJ 07647
Tel: [phone] Fax: [phone]

[e-mail]

Email:

www.globtek.com

URL:

Relief Fittings
Standard and Feed-through types
Cable diameters from 0.11 inches to 1.38 inches
Metric (PG) or NPT thread types
Optional metric (PG) to NPT adapters

Standard, IP68 protection
Index EMC Cable Glands
Cable diameters from 6.0 mm to 20.0 mm
Metric threads

Wiedmuller
Tel: [phone] Fax: [phone]

Bulkhead Cable Glands for Braid/Armour Termination
Standard types KGC 1 Series
Cable diameters from 1.8 mm to 39.9 mm
Metric threads
Optional washers and locknuts

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