Cooper Instruments DCM495 Installation Manual

DCM 495

SIGNAL CONDITIONING MODULE

USER’S GUIDE

www.cooperinstruments.com

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CONTENTS

1.0 INTRODUCTION.............................................................................................................................. 1

1.1 Overview ....................................................................................................................................................... 1

1.2 Specification................................................................................................................................................. 1

1.3 Layout............................................................................................................................................................ 1

2.0 INSTALLATION/SET UP................................................................................................................. 1

2.1 Wiring ............................................................................................................................................................ 1

2.2 Excitation and Coarse Gain Switch .......................................................................................................... 2

2.3 Panel Mounting Information....................................................................................................................... 3

3.0 CALIBRATION................................................................................................................................. 3

3.1 Calibration..................................................................................................................................................... 3

3.2 Using Shunt Calibration.............................................................................................................................. 3

3.3 Formula to Calculate Output Voltage ....................................................................................................... 3

3.4 Formula to Calculate Display Units........................................................................................................... 4

4.0 WARRANTY REPAIR POLICY....................................................................................................... 4

CF 52 ii V 06/98 Rev.A

1.0 INTRODUCTION

1.1 Overview

The Cooper Universal Inline Amplifier is housed in a small plastic package, which is connected between the transducer
and a readout instrument. The DCM 495 amplifier supplies a highly regulated bridge excitation voltage for the transducer
and converts the millivolt signal of the transducer to a +/- 10-volt, high level output. The inline features include three
selectable excitation voltages, programmable gain settings, a wide adjustment range on the zero and a buffered solid state
shunt cal relay for quick calibration.

1.2 Specification

Power Requirements 18-32 volts DC
Bridge Excitation 10, 5 or 3 volts DC @ 70ma (User selectable)
Output Voltage Range +/- 10 volts @ 2.5 ma
Frequency Response DC - 3000 Hz
Zero Balance Range ± 30% coarse, ± 15% fine adjustment range
Gain Adjustment Range Switch selectable (1 to 10 mV/V), ± 25% fine adjust
Short Circuit Protection (+)Output to (-) Output/Common
Environment Protection IP-66 or NEMA 4
Shunt Calibration Solid State Relay
Long Term Zero Drift .1% of Full Scale per 6 months

1.3 Layout

Fig. 1-1. Layout of Inline Amplifier

2.0 INSTALLATION/SET UP

2.1 Wiring

The INLINE amplifier can be powered from an 18 to 32 volt single voltage supply. The following diagrams show the wiring
to the supply and readout.

Cables should be stripped back 3 inches with the wires stripped and tinned 1/2 inch. Connections to the terminal block are
made by pressing the orange levers and inserting the wires into the hole next to the levers. The terminal block will accept
wire up to AWG 20.

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Figure 2-1. Transducer to Inline Wiring

Figure 2-2. 18 to 32 Volt Power Supply to Inline Wiring

NOTE: (-) OUTPUT and SUPPLY RETURN are connected together internally

2.2 Excitation and Coarse Gain Switch

PROCEDURE FOR SETTING UP EXCITATION AND COARSE GAIN SWITCH:

1. Determine the EXCITATION VOLTAGE required by the transducer being used.

2. Set the EXCITATION SELECT JUMPER as shown below: (See Fig. 1-1 for location of jumper).

3. Determine the sensitivity of the transducer in mV/V from the transducer calibration sheet.

4. Set the COARSE GAIN SWITCH (See Fig. 1-1 for location of switch) to the nearest mV/V setting in the corresponding
excitation column in Figure 2-3.

SWITCH POSITION

on

1 1 mV/V 2 mV/V 3.3 mV/V

2 & 4 1.5 mV/V 3mV/V 5 mV/V

2 2 mV/V 4mV/V 6.6 mV/V

3 & 6 2.5 mV/V 5 mV/V 7.5 mV/V

3 3 mV/V 6 mV/V 10 mV/V

4 & 7 3.5 mV/V 7 mV/V 1.6 mV/V

4 4 mV/V 8 mV/V 13.3 mV/V

5 & 8 4.5 mV/V 9 mV/V 15 mV/V

5 5 mV/V 10 mV/V 16.6 mV/V
6 6 mV/V 12 mV/V 20 mV/V
7 7 mV/V 14 mV/V 23.3 mV/V
8 8 mV/V 16 mV/V 26.6 mV/V

10 5 3

Figure 2-3. Coarse Gain Setup Table

EXCITATION

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2.3 Panel Mounting Information

The inline can be easily mounted to a panel by using the template in Appendix A for marking the holes in the panel. The
cover must be removed to get access to the mounting holes. Use #6 or #8 screws for mounting box to panel.

Figure 2-4. Panel Mounting Layout

3.0 CALIBRATION

3.1 Calibration

Step 1. Apply power and allow unit to stabilize for 10 minutes
Step 2. With zero load or pressure on the transducer adjust the ZERO potentiometers to indicate zero on the readout

instrument.

Step 3. Apply full scale pressure or load to the transducer and adjust the SPAN potentiometer to indicate full scale on the

readout instrument.

Step 4. Recheck zero and full scale (repeat steps 2 & 3)

3.2 Using Shunt Calibration

Cooper transducers feature a calibration technique called shunt calibration. This method applies a known resistance
across one leg of the transducer, which simulates an output, as if a load or pressure was applied to the transducer. When
performing shunt calibration the transducer should be at ZERO pressure or load. The full scale output and shunt cal output
is found on the TRANSDUCER CALIBRATION SHEET. This information can be sued to calibrate the amplifier’s output
voltage and the readout’s display with the following equations.

TRANSDUCER CALIBRATION DATA

Full Scale Output = _______________________ mV/V

Shunt Resistor Value of _____________________ Ohms

Shunt Cal Output =_______________________ mV/V

The following equations are used to calculate output voltage and display units:

3.3 Formula to Calculate Output Voltage

SHUNT CAL OUTPUT X FULL SCALE VOLTAGE (10 V) = OUTPUT VOLTAGE
FULL SCALE OUTPUT
______________________ X 10V = _______________________

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3.4 Formula to Calculate Display Units

SHUNT CAL OUTPUT X FULL SCALE UNITS = DISPLAY UNITS
FULL SCALE OUTPUT

______________________ X _________________ ____ = _______________________

Step 1. Apply power and allow the amplifier to warm up
Step 2. With zero load or pressure on the transducer adjust the ZERO potentiometer to indicate zero on the readout

instrument.

Step 3. Connect a jumper across PINS 5 & 6 of the power terminals (See Fig. 1-1 ) or wire in a switch as shown in wiring

section. Adjust the span potentiometer to the calculated voltage or calculated units on the readout instrument.

Step 4. Disconnect the shunt cal jumper or release the shunt cal switch and repeat steps 2 & 3 if needed.

4.0 WARRANTY REPAIR POLICY

Limited Warranty on Products

Any Cooper Instruments product which, under normal operating conditions, proves defective in material or in workmanship
within one year of the date of shipment by Cooper will be repaired or replaced free of charge provided that a return
material authorization is obtained from Cooper and the defective product is sent, transportation charges prepaid, with
notice of the defect, and it is established that the product has been properly installed, maintained, and operated within the
limits of rated and normal usage. Replacement or repaired product will be shipped F.O.B. from our plant. The terms of
this warranty do not extend to any product or part thereof which, under normal usage, has an inherently shorter useful life
than one year. The replacement warranty detailed here is the buyer’s exclusive remedy, and will satisfy all obligations of
Cooper whether based on contract, negligence, or otherwise. Cooper is not responsible for any incidental or
consequential loss or damage which might result from a failure of any and all other warranties, express or implied,
including implied warranty of merchantability or fitness for particular purpose. Any unauthorized disassembly or attempt to
repair voids this warranty.

Obtaining Service under Warranty

Advance authorization is required prior to the return to Cooper Instruments. Before returning the item, contact the Repair
Department c/o Cooper Instruments at [phone] for a Return Material Authorization number. Shipment to Cooper
shall be at buyer’s expense and repaired or replacement items will be shipped F.O.B. from our plant in Warrenton,
Virginia. Non-verified problems or defects may be subject to a $100 evaluation charge. Please return the original
calibration data with the unit.

Repair Warranty

All repairs of Cooper products are warranted for a period of 90 days from date of shipment. This warranty applies only to
those items that were found defective and repaired; it does not apply to products in which no defect was found and
returned as is or merely recalibrated. It may be possible for out-of-warranty products to be returned to the exact original
specifications or dimensions.

* Technical description of the defect: In order to properly repair a product, it is absolutely necessary for Cooper to receive
information specifying the reason the product is being returned. Specific test data, written observations on the failure and
the specific corrective action you require are needed.

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