Measurement DBK Part 2 User Manual

USER’S MANUAL

DBK Options

Option Cards and Modules

DBK41 through DBK609

Part 2 of 2

DBK Option Cards & Modules

457-0912 rev 8.3 (Part 2 of 2)

*372414B-01*

372414B-01

IOtech

25971 Cannon Road

Cleveland, OH 44146-1833

[phone]

Fax: [phone]

[e-mail]

[e-mail]

www.iotech.com

ii

DBK Cards & Modules

Part 2 of 2

DBK Cards & Modules

DBKs Covered in Part 2 of 2 (with exception of DBK70)

DBK41, 10-Slot Expansion Module
DBK42, 16-Slot 5B Signal Conditioning Module
DBK43A and DBK43B, 8-Channel Strain-Gage Modules
DBK44, 2-Ch. 5B Signal-Conditioning Card
DBK45, 4-Ch. SSH and Low-Pass Filter Card
DBK46, 4-Channel Analog Output Card
DBK48, Multipurpose Isolated Signal-Conditioning Module (supports up to 16 8B Modules)
DBK50 and DBK51, Voltage Input Modules
DBK55, 8-Channel Frequency-to-Voltage Input Module
DBK60, 3-Slot Expansion Chassis
DBK65, 8-Channel Transducer Interface Module
DBK70, Vehicle Network Interface, Analog Multiplexer Module (see p/n 1056-0901)
DBK80, 16-Ch. Differential Voltage Input Card with Excitation Output
DBK81, 7-Ch. T/C Card
DBK82, 14-Ch. T/C Card
DBK83, 14-Ch. T/C Card, uses external connection pod
DBK84, 14-Ch. T/C Module
DBK85, 16-Ch. Differential Voltage Module
DBK90, 56-Ch. T/C Module
DBK100 Series, (DBK100/D, 100/T,101)

In-Vehicle Thermocouple Measurement System

DBK200 Series Matrix
DBK200, P4-to-P1 Adapter Board
DBK202, DBK203, DBK204 Series

P4-to-P1/P2/P3 Adapters

DBK206, P4-to-P1/P2/P3 Adapter Board with Screw Terminals
DBK207 and DBK207/CJC, 16-Channel,

5B Carrier Boards

DBK208, Relay Carrier Board,
Opto-22 Compatible

DBK209, P4 to P1/P2/P3 Mini-Adapter Board
DBK210, 32-Ch. Digital I/O Carrier Board
DBK213, Screw-Terminal & Expansion Module

3-Card Slot, P1/P2/P3/P4 Compatibility

DBK214, 16-Connector BNC Interface Module

P1/P2/P3/P4 Compatibility

DBK215, 16-Connector BNC Connection Module

with 68-Pin SCSI Adaptability

DBK601 thru DBK609, Termination Panels

967194 DBK Cards & Modules

Discontinued DBKs

The following DBKs have been discontinued.

However, documentation for them may be read or downloaded from our website.

DBK12 and DBK13, A/I Multiplexer Cards
DBK19, 14-Channel Thermocouple Card
DBK33, Triple-Output Power Supply Card
DBK34, Vehicle UPS Module
DBK40, 18-Connector BNC Analog Interface
DBK52, 14-Ch. Thermocouple Input Module
DBK53 and DBK54, Analog Multiplexing Modules
DBK201, P4-to-P1/P2/P3 Adapter Board
DBK603, Termination Panel, Safety Jacks, SE
DBK605-B, Termination Panel, T/C, B Type, DE
DBK605-R, Termination Panel, T/C, R Type, DE
DBK605-S, Termination Panel, T/C, S Type, DE
DBK605-U, Termination Panel, T/C, U Type, DE
DBK609, Termination Panel, 5-Pin DIN

iv 917594 DBK Option Cards & Modules User’s Manual

DBK41 10-Slot Expansion Module

Overview …… 1
Hardware Setup …… 2

Card Configuration …… 2
Power Configuration …… 2
Card Insertion …… 3

EMI Shield Plates for CE Compliance …… 4
System Connection …… 5
DBK41 – Specifications …… 5

Overview

The DBK41 is a metal enclosure that holds up to 10 DBK cards. The exterior front panel has a male DB37
connector that leads to the LogBook or Daq device or further expansion via a CA-37-x cable. On the
inside of the front panel, a backplane printed circuit board (PCB) uses 10 female DB37s with their pins
connected in parallel to distribute the P1 interface (can also be used with P2 or P3). From the rear panel,
the DBKs’ signal input lines exit to their respective transducers.

Reference Notes:

o Chapter 2 includes pinouts for P1, P2, P3, and P4. Refer to pinouts applicable to your

system, as needed.

o In regard to calculating system power requirements, refer to DBK Basics located near

the front of this manual.

An optional EMI kit provides shield plates for the rear panel to make the DBK41 CE-compliant and
prevent EMI from DBKs entering the test environment (or vice-versa). The EMI kit also functions as an
electrical safety barrier.

Some DBK cards require a lot of power, in relation to other cards, and the use of power is an important
concern. DBK cards can obtain power externally from a LogBook, DaqBook, DaqBoard; or internally
from a DBK32A or DBK33 card. Refer to Power Requirements in the DBK Basics section, as well as the
sections for the DBK32A and/or DBK33, as applicable.

A power card in any slot (other than the slot leftmost from rear view) will power the
other cards via the backplane. A front panel LED will light whenever power from any
source is on the backplane. DBK41’s JP1 jumper can be positioned to disable the +5 V
power line from the external DB37. This prevents a DBK33 power supply from
interfering with other devices.

DBK Option Cards and Modules 877095 DBK41, pg. 1

Hardware Setup

Setup concerns include card and power configuration, proper card insertion, the use of EMI shields for CE
compliance, and mounting [or stacking] of hardware components.

In regard to mounting: metal splice plates can be used to rigidly mount a LogBook or DaqBook on top of a
DBK41 or other device that shares the same footprint. For applications in which temporary mounting is
convenient: a LogBook, DaqBook or notebook PC can be temporarily mounted to a DBK41 with the use
of industrial-strength dual-lock pads or strips.

Card Configuration

Each DBK card should be checked for proper configuration, and re-configured if needed, before being
inserted into the DBK41. Refer to the individual DBK Document Modules that are applicable to your
system.

Power Configuration

Power must be configured to prevent multiple power supplies from interfering with each other via the P1
interface. DBK41, LogBook/360, DaqBook/100 Series & /200 Series, and ISA-type DaqBoard each have
JP1 jumpers that must be properly configured in regard to power. Details for each follow.

JP1 in the DBK41

On the DBK41 backplane, JP1 is a 3-pin jumper positioned between
DB37 connectors for card number 4 (CN4) and card number 5
(CN5). Two settings are possible, as follows:

ENABLE +5 VDC JP1 1-2
When JP1 pins 1 and 2 are jumpered, the +5 VDC line to the
external P1 connector is enabled. The 5 V (VCC) is externally
supplied to pin 1 for cards 1 through 10 (CN1 through CN10). The
+5 VDC power can come from a LogBook, DaqBook, or DaqBoard
through a CA-37-x cable on pin 1 of P1. If not using a DBK33, JP1
should be enabled.

DISABLE +5 VDC JP1 2-3
When JP1 pins 2 and 3 are jumpered, the +5 VDC line to the
external P1 connector is disabled. When using a DBK33 power
card in the DBK41, the JP1 jumper must be set on pin 2 and 3. The
JP1 2-3 setting prevents the DBK33’s +5 V from interfering with
external devices via the P1 interface.

JP1 in the DaqBook/100 Series & /200 Series and DaqBoard [ISA type]

CAUTION

DBK power cards must not be connected until JP1
jumpers have been removed. Otherwise, equipment
damage could result.

If a DBK32A or DBK33 is used, you must remove the shunt jumpers
from the JP1 header located inside the DaqBook/100 Series & /200 Series
device or DaqBoard [ISA type]. DaqBook/100 Series & /200 Series
devices and DaqBoards [ISA type] are shipped with these shunts
positioned to deliver ±15 V analog power to P1.

Note: The jumpers can be placed on the -OCTOUT and -OCLKIN pins but should be removed if there is

interference with card operation (counter-timer).

DBK41, pg. 2 877095 DBK Option Cards and Modules

JP1 and JP2 in LogBook/360

Proper jumper configuration limits LogBook/360’s P1 bus to one power source. There should never be
more than one power source. The jumpers are located inside the chassis, on the unit’s P1 Interconnect

Board.

JP1. Only remove LogBook/360’s JP1 jumper if a DBK33 is used with the system.
JP2. Only remove the LogBook/360’s JP2 jumper if DBK cards are to be powered from LogBook/360’s

DaqBook/2000 Series & DaqBoard/2000 Series Configuration

No jumper configurations are required for these /2000 series devices.

Card Insertion

Each DBK card has a DB37 male connector which mates with the DB37 female connectors inside the
DBK41 chassis. To insert DBK cards into the DBK41 chassis, refer to the figure and perform the
following steps.

Note: Cards using screw-connectors for signal input lines must be wired before insertion.

1. Disconnect power from all units to be connected.

internal PCB.

Reference Note:

Refer to the LogBook User’s Manual, 461-0901 for information regarding LogBook systems.

2. Place the DBK41 on a flat surface; loosen the two thumbscrews on rear of the case; and remove the
top cover by sliding it off.

3. Align the DBK card with the DBK41 connector to be used (CN1 to CN10). The first slot must always
be occupied; however, a DBK32A or DBK33 power card may not occupy the first slot. Any of the
remaining 9 slots can be used or unused.

4. To clear the lip on the rear panel, tilt the rear of the card upward. Engage the P1 connectors of the
card and chassis, and press together gently to avoid damage to the pins.

5. Press down the rear of the card, aligning it within the metal dimples at the rear of the DBK41.

6. After cards are in place, reassemble the DBK41’s top cover and attach optional shield plates
(described next); then re-connect and power up the system.

DBK Option Cards and Modules 877095 DBK41, pg. 3

EMI Shield Plates for CE Compliance

To reduce electro-magnetic interference (EMI) escaping from (or entering into) the enclosure, a CE kit
provides shield plates that attach to the rear of the DBK41. The kit also functions as an electrical safety
barrier. With shield plates attached (a combination of 3 types supplied), the system meets CE standards.
The kit includes:

• Full shield plates to cover empty (unused) slots

• Partial shield plates to surround DBKs in a slot (except a power card)

• Partial shield plates to surround a DBK32A or DBK33 power card

• Screws and star washers to secure the shields to the chassis

Note: The CE kit is included with the DBK41/CE and an optional accessory for a DBK41.

The shields have a support tab that slides over the edge of the bottom plate and a screw hole for
attachment to the top plate. When tightened, the screws cause the washers to pierce the surface
coating into the metal to make a good contact with chassis ground.

Reference Note:
The Signal Management chapter contains additional information pertaining to CE Compliance.

DBK41, pg. 4 877095 DBK Option Cards and Modules

System Connection

A short ribbon cable (CA-37-x) attaches the DBK41 to the main unit. Connecting the DBK41 to any port
other than P1 may damage devices in the system. Likewise, only analog expansion cards may be installed
in the DBK41.

Note: For CE compliance, the CA-37-x cable must be replaced with a CA-143-7 or

CA-143-18. Multiple chassis require a “T” connector (part # CN-143) for branching.

Examples of DBK41 Connections [with DBK32A] and Cascading Power

DBK41 - Specifications

Name/Function: 10-Slot Analog Expansion Module

Card Capacity: 10 slots to hold standard DBK option cards

Weight: 4 lb (with no cards installed)

Cable (optional): 8" ribbon with DB37 female to DB37 female (CA-37-x)

Power Indicator: LED powered by external device’s 5 VDC

Connection: Male DB37, mates via CA-37-x cable with P1

DBK Option Cards and Modules 877095 DBK41, pg. 5

DBK41, pg. 6 877095 DBK Option Cards and Modules

DBK42 16-Slot 5B Signal Conditioning Module

Overview …… 1
Hardware Setup …… 2

DBK42 Connection …… 2
DBK42 Configuration …… 2
5B Module Connection …… 2
Power Considerations …… 2
Terminal Block Connections …… 3
DaqBoard/2000 Series and cPCI DaqBoard/2000c Series Connections …… 5
DaqBook/100 Series & /200 Series and ISA-Type DaqBoard Configuration …… 5
DaqBook/2000 Series and DaqBoard/2000 Series Configuration …… 5

Software Setup …… 6
DBK42 – Specifications …… 8

Reference Notes:

o Chapter 2 includes pinouts for P1, P2, P3, and P4. Refer to pinouts applicable to your

Overview

The DBK42 allows LogBook or Daq device systems to work with up to 16 5B signal conditioning
modules. Modules are available for various signal types (e.g., low-level thermocouple signals, strain-gage
signals, etc). The DBK42 offers 500 V isolation from the system and between channels. The DBK42 is
compatible with all 5B output modules, and the configuration is very flexible. You can select the type of
signal attached to each channel.

system, as needed.

o In regard to calculating system power requirements, refer to DBK Basics located near

the front of this manual.

An accessory cable connects the DBK42’s output to the P1 analog input connector. One LogBook or Daq
device can support up to 16 DBK42 units with a maximum of 256 isolated analog input channels. The

LogBook or Daq device scans the DBK42 channels at the same 10 µs/channel rate as other DBKs (256
scans in 2.56 ms in a full system).

The DBK42 can obtain power from an included AC adapter, an optional DBK30A rechargeable battery
module, or directly from a 12 VDC source (such as a car battery). The built-in power supply can serve a
fully-configured system using bridge excitation.

For DaqBoard/2000 Series applications, DBK42 is typically powered from an included AC adapter. The
unit’s built in power supply can serve a fully-configured system using bridge excitation.

DBK Option Cards and Module 967694 DBK42, pg. 1

Each terminal block contains 4 terminals (per channel) for access to input and excitation features of 5B
modules.

The optional CN-71 and CN-72 signal connection blocks provide a convenient way of connecting analog
signals to the DBK42.

• The CN-71 is for non-thermocouple use.

• The CN-72 (with cold junction sensors) is for thermocouple use. The CN-72 has a clear

Hardware Setup

DBK42 Connection

The DBK42 has screw-terminal connectors for easy access to the analog inputs. 2-wire and 4-wire
hookups are shown later in this section.

Note: Analog channels are isolated from each other, and no analog ground is provided.

DBK42 Configuration

Up to 16 DBK42s can connect to a LogBook or a Daq device. As a daisy-chain interface,
each module must appear unique and use a different channel.

To configure the module, locate the 16×2-pin header (JP1) near the front of the DBK42
board. Note the 16 jumper locations labeled CH0 through CH15 representing the base
Analog Input Channels. Place the jumper on the channel you wish to use.

plastic shield over its screw terminals to protect you from high voltage on the input terminals.

Only one jumper is used on a single DBK42. No two cards in a system
can use the same JP1 setting.

5B Module Connection

Each input of the DBK42 is processed through a user-installed 5B signal-conditioning module. Different
5B modules are used with different transducer and signal sources. To install the modules:

1. Match the footprint of the module with the footprint on the circuit board (see figure).

2. Gently place the module into the footprint, and screw it down.

3. When installing current input modules (SC-5B32 series), install the supplied current-sense resistor
(SC-AC-1362) in the resistor footprint adjacent to the module mounting footprint.

4. Record the module’s channel number; label all units and connectors for identification.

Power Considerations

The DBK42 has an internal, isolated switching-type power supply that operates on 10-20 VDC at varying
input currents depending on the input voltage and 5B-module loading. The power drain at a given output
load is constant; input current will vary inversely with the input voltage.

DBK42, pg. 2 967694 DBK Option Cards and Modules

A DBK42 populated with strain-gage modules will draw more current than with other types of input
modules. The table shows the DC input requirements for the worst-case setup (with 16 strain-gage
modules or 16 thermocouple modules).

Input Volts

With Strain-Gage Modules With Thermocouple Modules

10 VDC 3.0 A 0.60 A

11 VDC 2.7 A 0.54 A

12 VDC 2.4 A 0.48 A

13 VDC 2.2 A 0.44 A

14 VDC 2.0 A 0.40 A

15 VDC 1.9 A 0.38 A

16 VDC 1.8 A 0.36 A

17 VDC 1.7 A 0.34 A

18 VDC 1.6 A 0.32 A

19 VDC 1.5 A 0.30 A

20 VDC 1.4 A 0.28 A

Input Amperes

Power sources include:

• The standard TR-25 AC plug-in power pack (provided with the DBK42) can supply 900 mA at
15 VDC. The optional TR-40U can supply 2700 mA at 15 VDC.

• The DBK30A battery pack can supply power for a typical DBK42 configuration; however, in a
fully-populated strain-gage configuration, the battery run-time will be limited to about 1½ hours.

• A 12 V lead-acid gel-cell type battery can easily power a fully-populated strain-gage
configuration. The battery drain will be about 2.4 A-hr; battery size should be considered for
systems with long run-times. (For example, a common-size 5.0 A-hr battery will operate for
about 2 hours). A typical automotive 12-V lead-acid battery (e.g., 60 A-hr) can easily power a
DBK42 for long run-times (about 24 hours).

The input fuse is a 4-A Slo-Blo 1-1/4" × 1/4" glass-type such as Littelfuse 313004 or Bussman MDL-4.

Terminal Block Connection

Input signals (and excitation leads) must be wired to the DBK42 signal termination panel. Sixteen
4-terminal blocks accept up to 16 inputs. These connectors are located on a removable PC board that plugs
into two DIN96 rectangular connectors on the rear panel.

Terminal blocks are connected internally to their corresponding signal conditioning module. The terminal
blocks accept up to 14-gage wire into quick-connect screw terminals. Terminals on each block are
numbered 1 through 4. Each type of input signal or transducer (such as a thermocouple or strain gage)
should be wired to its terminal block as shown in the figure. Wiring is shown for RTDs, thermocouples,
20 mA circuits, mV/V connections, and for full- and half-bridge strain gages.

DBK Option Cards and Module 967694 DBK42, pg. 3

WARNING

Shock Hazard! The DBK42 is designed to sense signals that may carry dangerous
voltages. De-energize circuits connected to the DBK42 before changing the wiring or
configuration.

P1 Connection. The DBK42 attaches to the P1 analog I/O connector or to a DBK200 series P4-Adapter

P1 analog I/O connector. (Up to 16 units can be attached to one LogBook or Daq device.) Connect the
appropriate ribbon cable (with -x indicating the number of cards to be connected) from the LogBook,
Daq device, or adapter P1 port to the DB37 connector at the end of the option card.

Note: A series of interface cables are available for connecting up to sixteen DBK42s.

DBK42, pg. 4 967694 DBK Option Cards and Modules

DaqBoard/2000 Series and cPCI DaqBoard/2000c Series Connections

DBK42 can be connected to the P1 connector of DaqBoard/2000 Series P4-adapters. Up to 16 units can be
attached to one DaqBoard/2000 Series board.

Connect the appropriate ribbon cable (with -x indicating the number of cards to be connected) from the
adapter’s P1 port to the DB37 connector at the end of the option card.

Note: A series of interface cables is available for connecting up to 16 DBK42s.

DaqBook/100 Series & /200 Series and ISA-Type DaqBoard Configuration

The DBK42 requires two setup steps in DaqBook/100 Series & /200 Series devices and DaqBoards
[ISA type]—jumpers JP1 and JP4.

1. If not using auxiliary power, place the JP1 jumper in the expanded analog mode.

Note: This default position is necessary to power the interface circuitry of the DBK42 via the internal

±15 VDC power supply. If using auxiliary power (DBK32A, or DBK33), you must remove
both JP1 jumpers. Refer to Power Requirements in the DBK Basics section of the manual.
Also, refer to the DBK32A and DBK33 sections as applicable.

2. For DaqBook/100, /112, and /120 only, place the JP4 jumper in the DaqBook/100 & /200
or ISA-type DaqBoard in single-ended mode. Analog expansion cards convert all input signals to
single-ended voltages referenced to analog common.

DaqBook/2000 Series and DaqBoard/2000 Series Configuration

No Jumper configurations are required for these /2000 series devices.

DBK Option Cards and Module 967694 DBK42, pg. 5

Software Setup

You will need to set several parameters so DaqView can best meet your application requirements.
After the 5B module type is identified, DaqView figures out the m and b (of the mx+b equation) for proper
engineering units scaling. An example of the mx + b equation follows shortly.

The mx + b calculations for most 5B modules are included within LogView software.

PDF Note:

Reference Note:

o For DaqView information refer to chapter 3, DBK Setup in DaqView and to the DaqView

PDF included on your data acquisition CD.

o For LogView information refer to chapter 4, DBK Setup in LogView and to the LogView

section of the LogBook PDF included on your data acquisition CD.

o The API includes functions applicable to the DBK42. Refer to related material in the

Programmer’s Manual (p/n 1008-0901) as needed.

®

During software installation, Adobe

PDF versions of user manuals automatically install onto

your hard drive as a part of product support. The default location is in the Programs group,
which can be accessed from the Windows Desktop. Refer to the PDF documentation for
details regarding both hardware and software. Note that you can also access PDF documents
directly from the data acquisition CD via the <View PDFs> button on the CD’s opening
screen.

mX +b, an Example

The Customize Engineering Units dialog box can be
accessed via the DaqView Configuration main
window by activating the Units cell [for the desired
channel], then clicking to select mX+b.

From the Customize Engineering Units dialog box
(see figure at right), you can enter values for m and b
components of the equation that will be applied to
the data. There is also an entry field that allows you
to enter a label for the new units that may result from
the mX+b calculation.

An example of mX + b equation use follows.

DBK42, pg. 6 967694 DBK Option Cards and Modules

Engineering Units Conversion Using mx + b

Most of our data acquisition products allow the user to convert a raw signal input (for example, one that is
in volts) to a value that is in engineering units (for example, pressure in psi). The products accomplish this
by allowing the user to enter scale and offset numbers for each input channel, using the software associated
with the product. Then the software uses these numbers to convert the raw signals into engineering units
using the following “mx + b” equation:

(1) Engineering Units = m(Raw Signal) + b

The user must, however, determine the proper values of scale (m) and offset (b) for the application in
question. To do the calculation, the user needs to identify two known values: (1) the raw signal values, and
(2) the engineering units that correspond to the raw signal values. After this, the scale and offset
parameters can be calculated by solving two equations for the two unknowns. This method is made clear
by the following example.

Example

An engineer has a pressure transducer that produces a voltage output of 10.5 volts when the measured
pressure is 3200 psi. The same transducer produces an output of 0.5 volt when the pressure is 0 psi.
Knowing these facts, m and b are calculated as follows.

A - Write a pair of equations, representing the two known points:

(2) 3200 = m(10.5) + b

(3) 0 = m(0.5) + b

B - Solve for m by first subtracting each element in equation (3) from equation (2):

(4) 3200 - 0 = m(10.5 – 0.5) + (b - b)

(5)

Simplifying gives you: 3200 = m(10)

(6)

This means: m = 320

C - Substitute the value for m into equation (3) to determine the value for b:

(7) 0 = 320 (0.5) + b

(8)

Therefore: b = - 160

Now it is possible to rewrite the general equation (1) using the specific values for m and b that we just
determined:

(9) Engineering Units = 320(Raw Signal) - 160

The user can then enter the values of m and b into the appr opriate location using the facilities provided by
compatible data acquisition software, for example: WaveView, DaqView, Personal DaqView, LogView, and
TempView. The software uses equation (9) to calculate signal values in engineering units from that point
on.

DBK Option Cards and Module 967694 DBK42, pg. 7

DBK42 – Specifications

Name/Function: 16-Slot 5B Signal Conditioning Module

Module Capacity: 16 (input only) 5B modules

Size: 8.5" × 11" × 3.5" (11" × 11" × 3.5" with optional CN-71 or CN-72)

Weight: 4 lb (with no modules installed)

Cable (optional): CA-37-1

Power Requirements: 10-24 VDC @ 2.6 - 0.3 A

With 16 thermocouple-type modules:

12 VDC @ 0.50 A
15 VDC @ 0.40 A
18 VDC @ 0.35 A

With 16 strain-gage type modules:

12 VDC @ 1.9 A
15 VDC @ 1.5 A
18 VDC @ 1.3 A

DC Input Fuse: 3A
Power Indicator: LED powered by internal 5 VDC
Power Connection: DIN5 ×2 for daisy-chaining
AC Power Pack::

120 VAC to 15 VDC converter
120 VAC to 15 VDC @ 2.0 A (optional)

Input Connections: DIN96 rectangular, standard, screw terminal adapter (optional)

Connection: Male DB37 mates via CA-37-1 cable with P1

DC/DC Converter: 10-24 VDC to 5 VDC (isolated)

Isolation:

Input Power to System: 500 VDC
Signal Inputs to System: 1500 VDC
Input Channel-to-Channel: 500 VDC

DBK42, pg. 8 967694 DBK Option Cards and Modules

DBK43A and DBK43B 8-Channel Strain Gage Modules

Overview …… 1
Hardware Connection …… 3

Power Connection …… 3
Signal Connection …… 3

Hardware Configuration …… 4

Bridge Applications …… 5
AC Coupling and Low-Pass Filter Options …… 11
P1 Output Channel and Card Address Selection …… 12
DaqBook/100 Series & /200 Series and DaqBoard [ISA type] Configuration …… 12
DaqBook/2000 Series and DaqBoard/2000 Series Configuration …… 13

Hardware Adjustment …… 13

Trimpots …… 13
CAL/NORM, CAL1/RUN, and CAL2/RUN Switches …… 13

Software-Controlled Setup …… 14

Selecting Channel Types in DaqView, or <odes in LogView ……14
A Typical Setup Procedure with Embedded Examples ……16

GageCal, Calibration Program for DBK16, DBK43A, & DBK43B in Daq Applications ……21
Calibrating DBK16, DBK43A, & DBK43B for LogBook Applications ……25

Overview …… 25
Calibration Methods …… 26
Procedures Common to All Calibration Steps (Required) …… 27
Nameplate Calibration and Manual Calibration …… 30
Channel Calibration Procedure …… 33
2-Point Calibration …… 36
Shunt Calibration …… 38
Creating a Units Conversion Transfer Function …… 40
Periodic Calibration Without Trimpots …… 41

Specifications …… 42

Reference Notes:

o In regard to calculating system power requirements, refer to the section Power

Requirements in the DBK Basics section located at the beginning of the manual.

o Chapter 2, System Connections and Pinouts, includes pinouts for P1, P2, P3, and

P4. Refer to the pinouts that are applicable to your system, as needed.

Note: Due to flexibility in configuration, please review the entire section before attempting setup and

operation.

Overview

The DBK43A and DBK43B will condition signals from most bridge-circuit transducers that have a signal
output of less than 50 mV. Strain gages and load cells are common types. We will use the terms:
module(s), gage module(s), and strain gage module(s) to refer to both units, except when a feature or
function is exclusive to a specific module.

Primary Differences between the DBK43A and DBK43B

• Time Stamping – Can be used with DBK43B; Stamping should not be used for DBK43A*

• Event Marking – Can be used with DBK43B; Marking should not be used for DBK43A*

• Input Signal Connectors – DBK43A uses a mini-DIN6 connector for each channel.

DBK43B uses a removable screw terminal block for each channel.

• Calibration Switches – DBK43B has a two calibration slide switches (CAL1 and CAL2). The

DBK43A has one CAL/NORM switch.

• Power LED – The DBK43A and DBK43B have different locations for the Power LED.

In DBK43A – Time Stamping and Event Marking result in erroneous readings at the time of the stamping or marking.

*

DBK Option Cards and Module 899892 DBK43A & DBK43B, pg. 1

For half-bridge and quarter-bridge strain gages, the modules can accommodate user­supplied BCRs (bridge-completion resistors) that complete the bridge circuit. The bridge
circuit must be complete for the strain gage module to operate correctly.

Each channel of the strain gage module offers a selectable 3-pole, low-pass filter with a user-set cut-off
frequency. Remote-sense terminals are provided to make 6-wire Kelvin connections. Up to two modules
can be connected to each of 16 analog base channels for up to 256 input signals.

DBK43A and DBK43B Block Diagram

Note A: DBK43A uses Mini DIN-6 connectors for signal inputs. DBK43B uses removable screw-terminal blocks.

Note B: Channels 0 through 7 correspond with circuit board channels 100 to 800, as discussed in the Hardware

Configuration section.

Both strain gage modules provide an amplifier gain range of ×100 to ×1250 for use with strain gages having

0.4 to 10 mV/V sensitivities. Most strain gages are specified for a full-scale value of weight, force, tension,
pressure, or deflection with an output of mV/V of excitation. For example, a strain gage with a full-scale rating of
1000 lb of tension might output 2 mV/V of excitation at full load. With an excitation of 10 VDC, 1000 pounds of
load would produce an output of 20 mV.

The module’s 0 to 5 VDC offset and output-scaling permit nulling of large quiescent (inactive or motionless) loads
and expansion of the dynamic range for maximum resolution. Typically, the quiescent output is non-zero. Prior to
a force being applied, a mounted strain gage can be in a state of partial deflection resulting in an output. In the case
of a tension gage, this output may be due to the weight of a hook or empty container.

The modules include an internal excitation voltage source. The wide-range excitation regulator is adjustable from

1.5 to 10.5 VDC with a current limit of 50 mA.

DBK43A & DBK43B, pg. 2 899892 DBK Option Cards and Modules

Hardware Connection

Power Connection

The strain gage modules each require an input
voltage between +9 and +18 VDC. The DC
source should be filtered but not necessarily
regulated — a DBK30A Rechargeable
Battery/Excitation Module is recommended for
portable use. The DBK43A and DBK43B strain
gage modules have an isolated DC/DC converter­based power supply which provides all excitation
voltages and biasing for the amplifier circuits.
For both modules, each of eight on-board
excitation regulators can be adjusted from 1.5 to

10.5 VDC. These outputs have remote sensing terminals and feature 50 mA current limiting to prevent
damage from short-circuit or overload. The regulators’ wide voltage range can accommodate any resistive
or semi-conductive gage type.

The DBK43A and DBK43B can be powered with an AC adapter or from any isolated 9-18 VDC source of
16 W (see figure). Before plugging unit in, make sure the power switch is in the “0” (OFF) position.

If using an AC power adapter, plug it into an AC outlet and attach the low voltage end to the jack

on the DBK43A or DBK43B, as applicable.

If using a different 9 VDC to 18 VDC source, make sure the leads are connected to the proper

DIN terminals. Power connections for DBK43A and DBK43B are the same.

Signal Connection

CAUTION

POWER IN : The power connectors are rated at 5 amps maximum DC current. The
power supply provided with the module can power the unit but not any auxiliary
devices. If using the unit’s power supply, do not use the POWER OUT terminal.

If using another power supply to power auxiliary devices from the POWER OUT
terminal, make sure that power supply is current-rated for the units connected
(up to 5 amps DC).

POWER OUT : Maximum output current is 3 amps DC. Use a power supply capable of
supplying 5 amps DC at POWER IN.

CAUTION

The maximum channel signal input from plus Voltage (+V) to minus Voltage (-V) is
50 mV. There is no common-mode isolation between inputs (common-mode voltage
between inputs must be 0 V).

The following two figures (next page) each represent one of the 6-pin signal connectors located on the
back of a DBK43A (left figure) and DBK43B (right figure). Both configurations are for a full-bridge with
remote sensing.

DBK Option Cards and Module 899892 DBK43A & DBK43B, pg. 3

DBK43A uses a mini-DIN6 connector with pre-defined wire color coding based on a CA-132 cable. Color
coding of wires for DBK43B is user-defined.

DBK43A

DBK43B

Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6

- Sense - Exc. - V + V + Exc. + Sense

+ Sense - Sense + V - V + Exc. - Exc.

DBK43A Connection Example

Full-Bridge with Remote Sensing

*Colors in this schematic are determined by the Mini-DIN6
connector pin and the color code of the CA-132 cable.

DBK43B Connection Example

Full-Bridge with Remote Sensing

Colors in this schematic are arbitrary.
Actual wiring color is user defined.

The connectivity aspect of DBK43A and DBK43B differs, as indicated in the two wiring
diagrams. Be sure to use the correct diagram for your specific hardware.

The DBK43B pinout and diagram above supersede the one found in the DBK Option Cards
and Modules User’s Manual rev 8.2.

Hardware Configuration

Factory Defaults:

Bridge configuration: Full

Coupling: DC

Low pass filter: Disabled (bypassed)

Unless special arrangements have been made, the cutoff frequency is disabled (bypassed) when
the strain gage module is shipped from the factory. If the low pass filter is enabled it will have a
default value of 3.7 Hz.* You can enable the low pass filter [on an individual channel basis] by
orienting the associated channel’s Filter Jumper (JP104 for channel 0 through JP804 for channel

7) to the vertical position. Refer to the following board layout in regard to jumper location and
orientation.

*DBK43A and DBK43B are shipped with a 100 kΩ resistor in each of eight channel filter locations. The

resistors are installed in locations R105-106-107 through R805-806-807 (for channels 0 through 7
respectively). Refer to the following board layouts.

Configuration options:

Bridge Applications using various bridge-completion resistors and jumpers

AC Coupling and Low-Pass Filter Options

P1 Output Channel and Card Address Selection

The following board layout can be referred to for jumper, switch, and resistor locations.

DBK43A & DBK43B, pg. 4 899892 DBK Option Cards and Modules

D

CH7 CH6 CH5 CH4 CH3 CH2 CH1 CH0

Power CAL1 CAL2
LED

BK43B Board (Rear PanelSection)**

DBK43B (Rear Panel)**

** With exception of the rear panel area, the DBK43B has the same board layout as the DBK43A. On the DBK43B the Power

LED is located between the Power switch and the Power In connector. Another difference is that the DBK43B has a two
calibration slide switches (CAL1 and CAL2). The DBK43A has one CAL/NORM switch. In regard to channel connectors,
DBK43B employs removable screw terminal blocks; DBK43A uses mini-DIN6 connectors.

DBK Option Cards and Module 899892 DBK43A & DBK43B, pg. 5

Bridge Applications

There are several ways to hook-up strain gages—all are configured into a 4-element bridge (the 4 legs in a
bridge circuit). The quarter-, half- or full- designation for a strain gage refers to how many elements in the
bridge are strain-variable.

quarter bridges - have 1 strain-variable element
half bridges - have 2 strain-variable elements
full bridges - have 4 strain-variable elements

DBK43A and DBK43B boards include a silkscreen pictorial aid, as indicated in the following figure. On
the boards, the image appears between the channel inputs and Headers H100 through H400.

FULL BRIDGE

DEFAULT

Each channel of the strain gage module has locations for bridge-completion resistors when using quarter­and half-bridge strain gages. These resistors are fixed values necessary to fill out the 4-element bridge
configuration.

FULL BRIDGE

WITH REMOTE

EXCITATION SENSING

3 WIRE QUARTER

BRIDGE

3 WIRE QUARTER

BRIDGE

FULL BRIDGE

WITH REMOTE

SHUNT CAL RESISTOR

On-Board Silkscreen Aid for Configuring Jumper Headers H100 through H800.

The following is a standard symbol for a 4-element bridge type strain gage. The figure makes use of
bridge-completion resistor designations for a module’s channel.

Any or all of the 4 resistive elements may be strain­variable. Where an element is a fixed resistor, the
fixed resistor may be installed in the internal location
provided. Note that n is the channel number +1.
For an internal resistor on channel 7, the location is
R800E.

If R1-R4 is a fixed resistor it may be placed internally in the Rn
locations on the resistor plug. “n” is the channel number + 1.
R1 = Rn00F; R2 = Rn00C; R3 = Rn00E; R4 = Rn00B.
Example: R3 in channel 7 = R800E location.

Bridge Completion Resistors

Connections are provided for Kelvin-type excitation.
The excitation regulators stabilize the voltage at the
points connected to the on-board sampling dividers.
Unless you run separate sense leads to the excitation
terminals of the strain gage, the voltage regulation is
most accurate at the terminal blocks on the DBK43A
or DBK43B. In a Kelvin-type connection, six wires
run to a 4-element strain gage, and the excitation
regulation is optimized at the strain gage rather than at
the terminal blocks. This connection works with as
little as 10 feet of 22 gauge lead wire if accuracy is
critical. (See Full-Bridge with Remote Excitation
Sensing Configuration in full-page figure.)

Kelvin-type Excitation Leads

DBK43A & DBK43B, pg. 6 899892 DBK Option Cards and Modules

The Kelvin connection using the remote sensing lines performs best when the entire bridge is localized
(no bridge-completion resistors inside the DBK43A or DBK43B) and all leads are contained in a multi­conductor cable. If individual wire leads are used, the two sense wires should be tightly twisted to form a
pair. Likewise, the two excitation wires and the two bridge-output wires should be twisted together).

The internal excitation source is attached to a voltage regulator in the strain gage module’s circuitry. The
regulator provides the excitation to the actual transducer (there is a separate regulator for each transducer,
hence 8 regulators per strain gage module). Each regulator has a maximum current of 50 mA. The
maximum excitation voltage that can be provided by the module’s excitation regulator is:

V

MAX[EXC]

= 0.05 × R (where R = the resistance in ohms of 1 element in the bridge circuit).

CAUTION

The following full-page figure shows various strain-gage configurations.

Setting the excitation voltage above the maximum voltage allowed can cause the
DBK43A or DBK43B to fail. The maximum allowable excitation voltage is determined
by the following equation.

V

MAX[EXC]

= 0.05 x R

R is the resistance in ohms of 1 element in the bridge circuit.

DBK Option Cards and Module 899892 DBK43A & DBK43B, pg. 7

Bridge Configuration Settings for DBK43A and DBK43B

DBK43A & DBK43B, pg. 8 899892 DBK Option Cards and Modules

Input Configuration Headers

Eight 2×6 pin-headers with pin numbers 1 to 12 are on the board, 1 for each channel designated H100 (channel 0) to
H800 (channel 7). The user can position jumpers on this header to configure inputs from a variety of bridge types.

Jumping header pins 1-to-2 and 3-to-4 connects the +Vin and -Vin to the calibration MUX for different

bridge configurations.

Jumping pins 5-to-7 and 9-to-11 allows internal sense regulation of the excitation regulator.

Jumping pins 5-to-6 and 11-to-12 allows for remote excitation sensing.

Jumping pin 10-to-12 allows the use of a remote shunt-calibration resistor.

See previous figure for header configurations that correspond with different bridge-wiring schemes.

Resistor Sockets and Adapter Plugs

Eight 2×8 resistor sockets with rows numbered A to H are on the board; 1 socket for each channel and designated
R100 (channel 0) to R800 (channel 7). An adapter plug for soldering resistors is included for each channel; user­soldered plugs facilitate changing configurations as needed.

Bridge-completion resistors include: Rn00B, Rn00C, Rn00E, and Rn00F. Resistors Rn00A and Rn00G are

used to complete 3-wire strain-gage configurations.

Rn00D and Rn00H are internal shunt resistors from +V in and -V in respectively to -excitation.

Match the proper row as shown in the figure, Bridge-Configuration Settings
for DBK43A and DBK43B (previous page).

DO NOT just insert resistors into sockets. Such connections are unreliable.

To achieve a reliable connection, solder resistors to the adapter plug

Soldering should be done with the plug inserted into the resistor socket;
otherwise, heat from soldering can distort the shape of the plug.

After soldering, the resistor leads should be snipped off close to the support
to prevent contact with other components.

Handle the adaptor plugs with care to prevent pin damage.

Shunt-Calibration Resistors

DBK43A and DBK43B provide physical locations for internal shunt-calibration resistors. Each channel has resistor
locations that can be shunted across one or the other of the lower bridge arms by a hardware and software-accessible
solid state switch (FET transistor) to create a repeatable bridge imbalance with a precision resistor.

For any balanced bridge, a resistance value can be applied in parallel with one of the four bridge elements to create
a predictable imbalance and output voltage. For example, a 350Ω 2mV/V strain gage will deliver full output if one
arm drops by 0.8% (about 2.80Ω) to 347.2Ω. A 43.4 KΩ resistance shunted across one or the other lower bridge
elements will result in full-positive (Rn00H) or full-negative (Rn00D) output. For best results, Rn00H and Rn00D
should be across the strain element when it is switched in.

DBK Option Cards and Module 899892 DBK43A & DBK43B, pg. 9

A formula used to calculate the shunt-cal resistance value is:

R

Shunt

Where:

= [R

R

Shunt

R

Gage

Gage / FG

= the shunt calibration resistor value

= the resistance of the gage

(ε) ] - R

Gage

FG = the gage factor
ε = the strain value of the gage

Example:

An engineer wants to know the shunt calibration resistor value for a strain gage with the following
parameters.

resistance: 120 Ω
gage factor: 2.0
strain: 5000 micro-strain, i.e., 5000 x 10

Plugging the values into the equation, we get:

R

Shunt

In all cases, the resistance of the solid-state switch will be negligible when compared to the shunt
resistance. Changing the CAL/NORM switch (on the rear panel) to the CAL position while reading the
bridge will activate the shunt-calibration resistors. After reading the offset, return the switch to the NORM
position for normal bridge readings.

= [R

Gage / FG

= [120 / 2.0(5000 x 10-6)] - 120

= [120 / .01] – 120

= 12000 – 120

= 11,880 Ω

(ε) ] - R

Gage

-6

DBK43A & DBK43B, pg. 10 899892 DBK Option Cards and Modules