Model 109C12 ICP® Pressure Sensor Installation and Operating
Contents
1. gt CPCB PIEZOTRONICS Model 109C12 ICP Pressure Sensor Installation and Operating Manual For assistance with the operation of this product contact PCB Piezotronics Inc Toll free 800 828 8840 24 hour SensorLine 716 684 0001 Fax 716 684 0987 E mail info pcb com Web www pcb com PCB PIEZOTRONICS A PCB GROUP COMPANY Warranty Service Repair and Return Policies and Instructions The information contained in this document supersedes all similar information that may be found elsewhere in this manual Total Customer Satisfaction PCB Piezotronics guarantees Total Customer Satisfaction If at any time for any reason you are not completely satisfied with any PCB product PCB will repair replace or exchange it at no charge You may also choose to have your purchase price refunded in lieu of the repair replacement or exchange of the product Service Due to the sophisticated nature of the sensors and associated instrumentation provided by PCB Piezotronics user servicing or repair is not recommended and if attempted may void the factory warranty Routine maintenance such as the cleaning of electrical connectors housings and mounting surfaces with solutions and techniques that will not harm the physical material of construction is acceptable Caution should be observed to insure that liquids are not permitted to migrate into devices that are not hermetically sealed Such devices should o2. 30 VDC 2 to 20 mA s 100 ohm 8to 14 VDC Compression Quartz C 300 C 300 Epoxy 10 32 Coaxial Jack 17 gm OPTIONAL VERSIONS Optional versions have identical specifications and accessories as listed for the standard model except where noted below More than one option may be used H Hermetic Seal Housing Material 17 4 Stainless Steel 17 4 Stainless Steel Maximum Shock 20 000 g pk 196 133 Sealing Welded Hermetic Welded Hermetic M Metric Mount N Negative Output Polarity W Water Resistant Cable NOTES 1 Zero based least squares straight line method 2 Ceramic coated 3 See PCB Declaration of Conformance PS023 for details SUPPLIED ACCESSORIES Model 065A06 Seal ring 0 318 OD x 0 250 ID x 0 010 thk 316L SS material 3 boo be b nubem s PCB PIEZOTRONICS PRESSURE DIVISION 3425 Walden Avenue Depew NY 14043 Phone 716 684 0001 Fax 716 686 9129 E Mail pressure pcb com 4 3 2 l PCB Piezotronics Inc claims proprietary rights in R EVIS O NS the information disclosed hereon Neither it nor any reproduction thereof will be disclosed to others DESCRIPTION DIN without the written consent of PCB Piezotronics Inc CHANGE 248 TO 244 36542 ELECTRICAL CONNECTOR COAXIAL 10 32 UNF 2A RETAINING RING n 21948 FLUSH INSTALLATION RECESS INSTALLATION MODEL 060A22 CAPTIVATED FLOATING CLAMP NUT 312 7 93 HEX MAT L ST STL 3 8 24 UNF 2A
3. Inc are covered by a limited warranty against defective material and workmanship for a period of one year from date of original purchase Contact PCB for a complete statement of our warranty Expendable items such as batteries and mounting hardware are not covered by warranty Mechanical damage to equipment due to improper use is not covered by warranty Electronic circuitry failure caused by the introduction of unregulated or improper excitation power or electrostatic discharge is not covered by warranty Contact Information International customers should direct all inquiries to their local distributor or sales office A complete list of distributors and offices can be found at www pcb com Customers within the United States may contact their local sales representative or a factory customer service representative A complete list of sales representatives can be found at www pcb com Toll free telephone numbers for a factory customer service representative in the division responsible for this product can be found on the title page at the front of this manual Our ship to address and general contact numbers are PCB Piezotronics Inc 3425 Walden Ave Depew NY 14043 USA Toll free 800 828 8840 24 hour SensorLine 716 684 0001 Website www pcb com E mail info pcb com OPERATION MANUAL FOR ICP HIGH PRESSURE SENSORS Models 109A A02 A11 A12 Models 109B11 B12 1 0 INTRODUCTION The Model 109A is a
4. representative or factory customer service representative Returning Equipment Following these procedures will insure that your returned materials are handled in the most expedient manner Before returning any equipment to PCB Piezotronics contact your local distributor sales representative or factory customer service representative to obtain a Return Materials Authorization RMA Number This RMA number should be clearly marked on the outside of all package s and on the packing list s accompanying the shipment A detailed account of the nature of the problem s being experienced with the equipment should also be included inside the package s containing any returned materials A Purchase Order included with the returned materials will expedite the turn around of serviced equipment It is recommended to include authorization on the Purchase Order for PCB to proceed with any repairs as long as they do not exceed 50 of the replacement cost of the returned item s PCB will provide a price quotation or replacement recommendation for any item whose repair costs would exceed 50 of replacement cost or any item that is not economically feasible to repair For routine calibration services the Purchase Order should include authorization to proceed and return at current pricing which can be obtained from a factory customer service representative Warranty All equipment and repair services provided by PCB Piezotronics
5. second figure illustrates an optional connection scheme which can be used during calibration to take full advantage of the sensor discharge time constant With this arrangement the readout is direct coupled to the sensor and the output signal will be added to the 11 volt Nom bias level The discharge time constant will now be determined only by the sensor and should be in the order of 2000 seconds This is sufficient for most types of static calibration methods See calibration section 4 0 Drawing Number 21113 Revision NR Model 484B DC DVM L 109A Oscilloscope Typical Connection The figure above shows the 109A connected to the Model 484B Power Unit The 484B is a dual mode power unit i e the output signal can be AC or DC coupled from the sensor In the DC mode a level shifting circuit removes the bias level and provides a zero adjust feature at the front panel In the DC mode the system discharge time constant is determined by the sensor An AC coupled mode is provided for normal AC coupled operation 4 0 CALIBRATION Static calibration methods may be employed using the set up shown in the alternate connection figure or by use of the Model 484B Power Unit as shown in above figure Use 484B in DC mode Use high pressure pump with dial reference sensor or a dead weight tester to apply pressure in desired increments
6. E ma Mo oO MODEL 082A10 SPACER WASHER MAT L ST STL MODEL 065A06 SEAL Oo 95 318 8 08 O D pee 24 2 X 010 0 25 THICK lt a MAT L 316 ST STL EN 89 1 02 D gt 248 249 42 30 439 T T 31 3 10 7 10 7 244 250 6 20 6 35 MOUNTING HOLE DIMENSIONS MOUNTING HOLE DIMENSIONS Ee Ev 252 001 6 40 03 THRU AD 9 252 001 6 40 03 7 850 21 59 E dod p L 140 332 001 8 43 03 Y 590 14 99 D 5 gt L 1 332 001 8 43 03 F 590 14 99 519 260 3 8 24 UNF 2B Y 510 12 95 a gt 3 8 24 UNF 2B V 510 12 95 8 10 8 13 8 caution DO NOT TOUCH SEAL SURFACE WITH TAP WHEN TAPPING HOLE p DIMENSIONS A AND B TO SUIT USERS REQUIREMENTS 2 KEEP DIMENSION A AS SHORT AS POSSIBLE SEE OPERATING GUIDE FOR OPTIMUM PASSAGE LENGTH 3 mese DIAMETERS TO BE CONCENTRIC TO WITHIN 001 0 03 TIR UNLESS OTHERWISE SPECIFIED TOLERANCES ARE prawn CHECKED ENGINEER o DIMENSIONS IN INCHES DIMENSIONS IN MILLIMETERS 2 PCB PIEZOTRONICS inaran bmoe Ay perl Zr me ors 3425 WALDEN AVE DEPEW NY 14043 eet e cun ds 716 684 0001 E MAIL sales pcb com INSTALLATION DRAWING ANGLES 2 DEGREES ANGLES 2 DEGREES MODEL 109C1 1 amp 109C 1 2 EE DWG NO 9 948 PRESSURE SENSOR 52681 FILLETS AND RADII FILLETS AND RADII 4 3 2 DA SURFACE MUST BE FLAT AND FREE OF TOOLMARKS WITH A MINIMUM 63 1 4 FOR BEST RESULTS gt DIMENSION
7. S SHOWN ARE FOR A 850 21 59 THICK WALL COUNTERBORE FOR THICKER WALLS RECOMMENDED MOUNTING TORQUE ON 312 7 93 HEX 27 32 FT LB 37 43 N M gt MATERIAL C 300 MARAGING STEEL
8. VM Model 070401 Um T Adaptor 109A S Le It is convenient though not necessary to use coaxial cable such as PCB Model 002A to connect sensor to power unit Cable need not be low noise treated and in fact if it is desired to use lighter more flexible cable 070A09 solder connector adaptors may be used to employ twisted pair or other types of two wire cable OPERATION MANUAL FOR ICP HIGH PRESSURE SENSORS Models 109A A02 A11 A12 Models 109B11 B12 37 CIRCUIT CONNECTIONS The two following figures show two typical circuit connections normally used with the 109A series to connect to the power units The first figure is the most often used connection scheme for most applications In this set up the signal is AC coupled from the bias voltage by a 10 uF capacitor located in the power unit The voltage at the scope terminal will be at a O volt bias level Model 002A bus A80B Model 012A ix 109A SCOPE Readout Normal Connection AC Coupled Output In this case the system discharge time constant will be determined by the value of the input resistance R of the readout device and the 10 uF capacitor C in accordance with the following relationship TC seconds R ohms C farads Alternate Connection to take Advantage of Sensor Discharge TC The
9. flush mount installation there is no reduced area passage from the sensor diaphragm to the test chamber rather the sensor diaphragm is mounted flush with or slightly recessed from the inside surface of the test chamber Use this type of installation only if space or rise time considerations preclude the use of the recessed installation In severe pyrotechnic environments sensor life may be severely limited with flush installation Drawing Number 21113 Revision NR 3 55 FLASH EFFECTS TEMPERATURE The ceramic coating on the diaphragm of these sensors should render the flash thermal effect insignificant in most cases especially when recessed mounted However if more protection from flash thermal effects 1s required with the recessed mount the passage can be filled with silicone grease DC 4 or equivalent Several layers of black vinyl electrical tape directly on the diaphragm has proven effective in many cases Flash temperature effects are usually longer term and will show up as baseline shift long after the event to be measured has passed For flush mount installations a silicone rubber coating approximately 010 thick can be effective GE RTV type 106 is recommended Follow manufacturer s instructions to apply It is best to recess the diaphragm 010 for this type of protection 3 6 INSTALLING CABLES 480B 002A DC D
10. gle coaxial connector The signal is separated from the bias level about 11 V in the power unit by use of a decoupling capacitor when using power units Series 480B 482A 483A 485B and others The signal is separated from the bias level by DC voltage level shifting methods in power unit Model 484B This unit is useful for calibration See Guide G 0001B General Guide to ICP Instrumentation for more complete coverage of ICP Integrated Circuit Piezoelectric instruments 3 0 INSTALLATION The series 109A Sensors mount directly in existing ports machined for PCB Models 118A 108A and 119A Unlike conventional diaphragm type sensors the 109A is pressure sensitive over the entire frontal area For this reason extra care should be exercised to avoid bottoming in mounting hole when recessed mounted and especially when mounting into existing mounting ports A torque wrench should be used to monitor the mounting torque value when installing the series 109A The recommended range is given on the installation drawing 31 MOUNTING IN RECESSED PORTS EXISTING Before installing the sensor in previously used mounting ports clean out residue from previous tests as shown in figure below This can be accomplished by hand reaming the 1 4 diameter hole using a PCB Model 040A end cutting reamer or equivalent OPERATION MANUAL FOR ICP HIGH PRESSURE SENSORS Models 109A A02 A11 A12 Models 109B11 B12 Model 040A Rea
11. k of PCB Piezotronics Model Number evision ICP PRESSURE SENSOR Performance Measurement Range for 7V output Sensitivity t 15 96 Maximum Pressure Resolution Resonant Frequency Rise Time Non Linearity Environmental Acceleration Sensitivity Temperature Range Operating Temperature Coefficient of Sensitivity Maximum Flash Temperature Maximum Vibration Maximum Shock Electrical Output Polarity Positive Pressure Discharge Time Constant at room temp Excitation Voltage Constant Current Excitation Output Impedance Output Bias Voltage Physical Sensing Geometry Sensing Element Housing Material Diaphragm Sealing Electrical Connector Weight CE ENGLISH 100 kpsi 0 07 mV psi 125 kpsi 2 0 psi 2 400 kHz lt 2 0 usec s2 09 6 FS lt 0 02 psi g 100 to 275 F lt 0 07 F 3000 F 2000 g pk 50 000 g pk Positive z 2000 sec 20 to 30 VDC 2to 20 mA lt 100 ohm 8 to 14 VDC Compression Quartz C 300 C 300 Epoxy 10 32 Coaxial Jack 0 6 oz All specifications are at room temperature unless otherwise specified In the interest of constant product improvement we reserve the right to change specifications without notice ICP is a registered trademark of PCB Group Inc SI 690 000 kPa 0 010 mV kPa 862 000 kPa 13 8 kPa 2 400 kHz lt 2 0 psec lt 2 0 FS s 0 015 kPa m s 73 to 135 C S 0 126 C 1650 C 19 620 m s pk 490 330 m s pk Positive 2 2000 sec 20 to
12. mer Residue Mo di Existing Recessed Ports During prolonged testing should waveform distortion occur remove sensor and remove residue as shown It is important to note that should the seal surface require remachining to clean up after prolonged use don t forge to deepen the 1 4 diameter hole by the same amount Otherwise the sensor may bottom when installed 32 PREPARING NEW MOUNTING PORTS Refer to installation drawing provided in this manual for instructions in mounting hole preparation For best results do not deviate from the steps outlined in this drawing Use good machining practice in preparation of the mounting port paying particular attention to the seal surface 323 diameter and keeping it free from tool chatter marks NOTE It is important that this surface be perfectly smooth and free from nicks or other discontinuities which might cause leaks at high pressures 33 RECESSED MOUNT The recessed installation is shown in figure below Drawing Number 21113 Revision NR This type of mounting protects the sensor diaphragm from the effects of high flash temperatures and particle impingement due to blast effects thereby prolonging sensor life The recommended range of passage diameters is 090 to 125 diameter The limitation in this type of installation lies in the frequency limiting effects of the passage due to its length The passage behaves like an underdamped seco
13. n acceleration compensated high pressure sensor designed to measure very fast transient pressure pulses as produced by detonations gas guns projectiles and closed bomb tests These types of tests are usually accompanied by very large acceleration pulses which can add considerable error to output signals of noncompensated sensors The Model 109A features a very high natural frequency minimizing ringing effects usually triggered by very short rise time input pulses The Model 109A02 is similar in all respects to the Model 109A except for range The 109A has a range of 80 000 psi while the 109A02 is rated at 100 000 psi full scale The 109A series is not intended for continuous duty such as in fuel injector pumps 2 0 DESCRIPTION The Model 109A see figure below contains a very rigid acceleration compensated quartz element coupled to a tiny microelectronic amplifier located near the electrical connector 10 32 Co Axial Connector ICP Amplifier 5 16 Hex 3 8 24 Thd Acceleration Compensated Element Ceramic Coating gm m Series 109A Sensor Drawing Number 21113 Revision NR This amplifier actually an impedance converter with unity gain converts the high impedance level voltage from the quartz package into a low impedance 100 ohms high level 6 V 109A 7 V 109A02 output signal The amplifier utilizes two wires i e signal and power are conducted through a sin
14. nd order system the resonant frequency being determined by the passage length This can have a limiting effect of pressure pulse rise time while causing passage ringing in cases where the passage is too long Recessed Mount Willi 010 min d The following relationship determines this resonant frequency f V dur Hz EQ 1 Where f Resonant frequency of passage Hz V Velocity of sound in air ft sec L Length of column ft OPERATION MANUAL FOR ICP HIGH PRESSURE SENSORS Models 109A A02 A11 A12 Models 109B11 B12 For air at room temperature EQ 1 becomes 3000 T r L t Where L Passage length in The natural frequency and approximate fastest pressure step rise time for various length passages is shown in the following chart Medium air at 25 C PASSAGE PASSAGE APPROX LENGTH in RESONANCE FASTEST PULSE kHz RISE TIME Sec 050 66 5 100 33 10 200 16 5 20 50 6 6 50 1 0 3 3 100 Passage Resonance vs Passage Length Actual resonant frequencies measured in practice may differ slightly from the chart values due to variations in the velocity of propagation of sound in air caused by changes in temperature and pressure of the air in the passage For best matching of passage to diaphragm maintain the 010 clearance ahead of the diaphragm as shown in Recessed Mount figure 34 FLUSH MOUNT In the
15. nly be wiped with a dampened cloth and never submerged or have liquids poured upon them Repair In the event that equipment becomes damaged or ceases to operate arrangements should be made to return the equipment to PCB Piezotronics for repair User servicing or repair is not recommended and if attempted may void the factory warranty Calibration Routine calibration of sensors and associated instrumentation is recommended as this helps build confidence in measurement accuracy and acquired data Equipment calibration cycles are typically established by the users own quality regimen When in doubt about a calibration cycle a good rule of thumb is to recalibrate on an annual basis It is also good practice to recalibrate after exposure to any severe temperature extreme shock load or other environmental influence or prior to any critical test PCB Piezotronics maintains an ISO 9001 certified metrology laboratory and offers calibration services which are accredited by A2LA to ISO IEC 17025 with full traceablility to N LS T In addition to the normally supplied calibration special testing is also available such as sensitivity at elevated or cryogenic temperatures phase response extended high or low frequency response extended range leak testing hydrostatic pressure testing and others For information on standard recalibration services or special testing contact your local PCB Piezotronics distributor sales
16. to full scale Dump pressure after taking the reading and before proceeding to the next higher pressure level With a 2000 second discharge TC 196 of the signal will be lost in 20 seconds so it is imperative that the pressure setting and recording of output be accomplished quickly A calibration graph can then be plotted using output voltage vs input pressure OPERATION MANUAL FOR ICP HIGH PRESSURE SENSORS Models 109A A02 A11 A12 Models 109B11 B12 5 0 OPERATION Select desired mode of circuit connection and turn power unit on Observe fault monitor meter at the front panel of the power unit Normal operation is indicated by an approximate midscale reading Shorted cable or connections are indicated by a zero reading red area Open cable or connections are indicated by a full scale yellow area reading Allow instrument several minutes to warm up and thermally stabilize When output from power unit is connected to readout equipment a drifting of the voltage signal will be noticed This is normal It is due to the charging of the coupling capacitor in the power unit and will cease within several minutes 6 0 POLARITY The series 109A produces a positive going output voltage for increasing pressure at the diaphragm 7 0 MAINTENANCE The small size and sealed construction of the series 109A precludes field maintenance and repair Drawing Number 21113 Revision NR ICP is a registered trademar
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