PCB Signal Conditioner Provides Versatile Solution for DC Sensor Measurements

PCB Piezotronics, a leading manufacturer of sensors and instrumentation, has introduced a new signal conditioner designed specifically for use with DC-output sensors. The PCB Signal Conditioner Model 682A05 provides a versatile solution for amplifying and conditioning the output of various types of DC sensors, including pressure transducers, load cells, torque sensors, and more.

Key Features of the PCB 682A05 Signal Conditioner

The PCB 682A05 Signal Conditioner offers several key features that make it an ideal choice for DC sensor applications:

• Wide input voltage range: 7-30 VDC
• Programmable voltage and current excitation
• Adjustable gain and filtering
• Analog voltage and current outputs
• Digital RS-232 and USB outputs
• Compact DIN rail mountable housing

These features provide flexibility to interface with a variety of DC sensors and integrate the conditioner into existing data acquisition systems.

Programmable Sensor Excitation

One of the standout capabilities of the 682A05 is its programmable excitation for powering connected sensors. The conditioner can provide either constant voltage excitation from 0-12 VDC or constant current excitation from 0-20 mA. This is beneficial for maximizing the measurement range and resolution of the sensor.

The excitation level is easily adjustable using the free configuration software provided with the unit. Different voltage or current levels can be set for each of the two available channels.

Gain and Filtering Options

To further optimize the sensor signal, the 682A05 offers adjustable gain and low-pass filtering. The gain is switch-selectable from 1 to 2000, allowing the output range to be matched to the input range of the connected DAQ hardware. This is useful for scaling lower output sensors to higher levels for improved measurement resolution.

There are also two low-pass filter settings to eliminate high frequency noise that may be present on the sensor signal. The filter cutoff frequencies can be set to 1 kHz or 10 kHz.

Multiple Output Formats

The conditioned DC sensor signal can be output from the 682A05 in several analog and digital formats:

• ±5 V and ±10 V analog voltage
• 4-20 mA analog current loop
• RS-232 serial
• USB

This allows the signal to be used by a variety of data acquisition devices such as DAQs, PLCs, panel meters, etc. The analog outputs can be used for simple monitoring or control, while the digital interfaces enable connection to a PC for more advanced analysis using software like LabVIEW or MATLAB.

Output	Format	Application
Voltage	±5 V or ±10 V	Analog inputs, panel meters
Current	4-20 mA	PLCs, process control, SCADA
RS-232	ASCII or binary	Serial communication with PCs
USB	Virtual COM port	PC data logging and analysis

Easy Configuration Software

PCB includes free configuration software with the 682A05 to easily set all the programmable parameters of the signal conditioner. The PCB Sensor Setup software provides an intuitive graphical interface for setting the excitation, gain, filters, and output type.

The software communicates with the signal conditioner through either the RS-232 or USB interface. Configurations can be saved for repeatable testing and future reference. The software also provides real-time viewing of the sensor input and conditioned output for immediate feedback when making setup adjustments.

Applications of DC Sensor Signal Conditioning

There are many applications across various industries that utilize DC output sensors and can benefit from proper signal conditioning. Some common examples include:

Pressure Measurements

Pressure transducers with mV/V outputs are widely used to monitor pressures in liquid and gas pipelines, hydraulic and pneumatic systems, tank levels, and more. Typical DC pressure sensors have ranges from 1 bar to 1000 bar or more. Signal conditioning is required to scale the mV/V signal to volts for a DAQ system.

Load and Force Measurements

Strain gage based load cells are used to measure weight or force in applications like weighing scales, force testing machines, or filling equipment. Load cells typically have low level mV/V output signals in the 1.5 mV/V to 3 mV/V range. Signal conditioners are needed to amplify the mV signal to higher voltages.

Torque Measurements

Torque transducers, also typically mV/V output, are used to measure rotational forces in automotive, aerospace, and industrial applications. They are used for engine and motor testing, dynomometers, and process monitoring. The 682A05 can provide the necessary excitation and amplification for torque sensor signals.

Current Loop Sensors

Many industrial sensors use a 4-20 mA interface because of its robustness and noise immunity. Pressure, temperature, flow, and other types of 4-20 mA sensors can be connected to the 682A05 to power the current loop and convert the signal to a voltage output for a DAQ.

Specifications

Specification	Value
Input	mV/V or 4-20 mA
Channels	2
Excitation Voltage	0-12 VDC
Excitation Current	0-20 mA
Gain	1-2000
Low-pass Filter	1 kHz or 10 kHz
Voltage Output	±5 V or ±10 V
Current Output	4-20 mA
Digital Interfaces	RS-232, USB
Operating Voltage	7-30 VDC
Operating Temp Range	-40 to 85 °C
Dimensions	114 x 99 x 23 mm

Frequently Asked Questions (FAQ)

What is a signal conditioner used for?

A signal conditioner is an electronic device used to convert a sensor signal into a form suitable for display on a meter, chart, recorder, or data acquisition system. It amplifies, filters, linearizes, and scales the low-level sensor signal to a higher-level signal that can be read by other instruments.

How does the PCB 682A05 interface with DC sensors?

The 682A05 has input connections for 4 or 6-wire mV/V sensor configurations, as well as a 2-wire 4-20 mA input. It provides the necessary constant voltage or constant current excitation to power the sensors. The sensor output is then scaled and filtered before being converted to the desired analog or digital output format.

What are the benefits of digital outputs on a signal conditioner?

Digital outputs like RS-232 or USB allow the signal conditioner to interface directly with a PC. This enables data logging and analysis using software. Digital communication also allows for remote configuration and setup of the signal conditioner parameters.

Can the 682A05 be used with non-PCB sensors?

Yes, the signal conditioner is compatible with any DC sensor that has a mV/V or 4-20 mA output, regardless of the manufacturer. As long as the sensor is scaled and calibrated properly, the 682A05 can be used to condition its signal.

What are some common applications for a DC sensor signal conditioner?

Signal conditioners are used with DC sensors in a wide variety of test and measurement applications such as:

• Structural and vehicle health monitoring
• Environmental monitoring
• Process monitoring and control
• Research and development
• Product testing and quality control

They are used anywhere a physical quantity like pressure, strain, force, torque, or temperature needs to be measured and the sensor output needs to be scaled and conditioned.

Conclusion

PCB Piezotronics’ 682A05 Signal Conditioner is a versatile instrument that simplifies the integration of DC output sensors into a measurement system. With programmable excitation, gain, and filtering, it can be optimized for use with a variety of mV/V and 4-20 mA sensors. The multiple analog and digital output options provide flexibility to connect to many different types of DAQ hardware.

By properly scaling and conditioning the sensor signal, the 682A05 ensures that the connected instrumentation receives a strong, low-noise signal for reliable and accurate measurements. This is critical for applications where precise monitoring of pressure, load, torque, and other parameters is required.

As with all of PCB’s instrumentation, the 682A05 is built to last with quality components, rugged housing, and a design backed by over 50 years of experience in the test and measurement industry.

For more information on the PCB Signal Conditioner 682A05 and to request a quote, visit www.pcb.com or contact an application engineer at [email protected].