Part Number 2078-08

Revision B

INSTALLATION, CALIBRATION, AND OPERATION

4 - 20 mA
Signal Conditioner
P/N 2078-Series

Manufacturers of Precision Instruments

Printed in U.S.A. May 19, 1997

 Manual 2078-08 contains 24 pages, divided as follows:

Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . May 1997

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . May 1997
TOC-1 through TOC-2 . . . . . . . . . . . . . . . May 1997
Pages 1 through 18 . . . . . . . . . . . . . . . . . May 1997

All product, brand, or trade names used in this publication are the trademarks or registered
trademarks of their respective owners. Information in this manual is subject to change without
notice.
 IMPORTANT SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment.
The service procedures recommended by M/D TOTCO and described in the technical manuals
are recommended methods of performing service operations. When these service operations
require the use of tools specially designed for the purpose, those special tools should be used as
recommended. Warnings against the use of specific service methods that can damage equipment
or render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D TOTCO
could not possibly know, evaluate and advise service people of all conceivable ways in which ser-
vice might be done or of all possible associated hazardous consequences. Accordingly, anyone
who uses service procedures or tools which are not recommended by M/D TOTCO must first sat-
isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized
by the method selected.

May 19, 1997 iii

M/D TOTCO
 LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY
WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

Martin-Decker TOTCO (“Company”) warrants to Buyer (“Purchaser”) of new products manufactured or

supplied by the Company that such products are, at the time of delivery to the Purchaser, free of material and
workmanship defects, subject to the following exceptions:

A. Any product which has been repaired or altered in such a way, in the Company's judgement, as to affect
the product adversely, including any repairs, rebuilding, welding or heat treating outside of Company
authorized facility.

B. Any product which has, in the Company's judgement, been subject to negligence, accident, or improper
storage.

C. Any product which has not been installed, operated and maintained in accordance with normal practice
and within the recommendations of the Company.

D. For all items of special order by Buyer which are not manufactured by Company, Buyer should submit
warranty claims directly to the manufacturer thereof.

The Company's obligation under this warranty is limited to repairing, or at its option, replacing any products
which in its judgement proved not to be as warranted within the applicable warranty period. All costs of
transportation of products claimed not to be as warranted to authorized Company service facility shall be
borne by Buyer. Costs of return transportation to Buyer of products accepted for repair or replacement by
Company under the warranty provisions of the Sales Agreement shall be borne by the Company. Company
may, at its sole option elect to refund the purchase price of the products, and Company shall have no further
obligation under the Sales Agreement.

The cost of labor for installing a repaired or replacement part shall be borne by Buyer. Replacement parts
provided under the terms of this warranty are warranted for the remainder of the warranty period of the
product upon which installed to the same extent as if such parts were original components thereof.

The warranty periods for various products are:

A. Hydraulic, Mechanical, Electronic Equipment: one (1) year from date of installation or fifteen (15) months
from date of shipment from Company, whichever occurs first.

B. All Elastomer Diaphragms: six (6) months from date of shipment from Company.

No deviations from the Company's standard warranty terms or period as stated herein will be honored unless
agreed to in writing by an authorized Company representative prior to acceptance of the order.

EXCLUSIVITY OF REMEDY AND LIMITATION OF LIABILITY. THE REMEDIES PROVIDED FOR IN THIS
WARRANTY SHALL CONSTITUTE THE SOLE RECOURSE OF BUYER AGAINST COMPANY FOR
BREACH OF ANY OF COMPANY'S OBLIGATIONS UNDER THE SALES AGREEMENT WITH BUYER,
WHETHER THE CLAIM IS MADE IN TORT OR IN CONTRACT, INCLUDING CLAIMS BASED ON
WARRANTY, NEGLIGENCE, OR OTHERWISE.

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR

CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT,
STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.

iv May 19, 1997

M/D TOTCO
 TABLE OF CONTENTS
Paragraph/Title Page

1.0 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1. Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2. Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.3. Special Features/Capabilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1.4. List of Supplied Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1. List of Supplied Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2. Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.3. Operating Specifications for Standard Configuration . . . . . . . . . . . . . . . . . . . . . 3
1.2.4. Physical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.5. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.0. INSTALLATION/SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2. Unpacking/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3. Installation/Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4. Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5. Power/Signal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5.1. Connector Pin and Signal List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5.2. Typical Transducer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5.3. Wiring.Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6. Shunt Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.0. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2. Turn-On/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3. Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.0. PRINCIPLES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2. Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3. Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.0. MAINTENANCE/CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2. Installation Note. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3. Anti-Static Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.4. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.5. Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.0. PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2. Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

May 19, 1997 TOC-1

M/D TOTCO
2078 Signal Conditioner
Manual 2078-08 Table of Contents
Paragraph/Title Page

7.0 REFERENCE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

PCB Assembly, Signal Conditioner, Current Output. . . . . . . . . . . . . . . . . . Drawing #2078-01
Block Diagram, Signal Conditioner, Current Output . . . . . . . . . . . . . . . . . . Drawing #2078-02
Signal Conditioner, Current Output, Schematic Diagram . . . . . . . . . . . . . . Drawing #2078-03
Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drawing #2078-08

TOC-2 May 19, 1997

M/D TOTCO
 2078-Series Signal Conditioner
Installation, Operation, and Maintenance

1.0. DESCRIPTION
1.1. General
This manual is intended to provide the user with the information necessary to set-up operate,
and maintain the Current Output signal Conditioner, M/D TOTCO Part Number 2078-00, designed
and manufactured by M/D TOTCO. Section 1 covers the equipment description and specifications
while Section 2 cover installation, set-up, and operating controls and indicators. The operating
modes are covered in Section 3. Section 4 describes the principles of operation on a functional
block diagram basis. Section 5 has all the maintenance and calibration instructions and Section 6
contains the parts lists. All reference drawings are located in Section 7.
It is recommended that the reader take the extra time to thoroughly familiarize himself with at least
the first three sections of this manual before attempting to operate the equipment.
The maintenance portion of this manual is written for an individual with a solid basic knowledge of
electronics.
We believe this manual is accurate and complete. All information needed for operation and main-
tenance should be present. We value you, the customer and your opinion, and encourage you to
contact us if you have any comments or questions regarding this manual.

1.1.1. Functional Description

The Current Output Signal Conditioner/Amplifier is designed for dedicated applications measuring
load, force, strain or any other parameter being sensed with a strain gage type transducer.
It is a small circuit board and can be mounted in a display or control console, junction box, or in the
transducer. The high accuracy and stability makes it ideal for virtually any application.
The 2078-00 provides excitation voltage to the strain gage bridge and amplifies the strain gage
output signal. Zero balance and span controls, and the calibration resistor are supplied on the
board. The full range output current can be specified either from 4 to 20 milliamperes for a unidi-
rectional input, or 12 ± 8 milliamperes for a bidirectional input.
High quality single turn zero balance and span pots are used so that, when they are sealed after
adjustment, the board accuracy is virtually immune to shock and vibration.
The amplifier output is both reverse voltage and short circuit protected, and is designed to drive
highly capacitive loads (such as encountered with long cables) without oscillation or excessive
ringing. Power supply requirements are very easy to satisfy. Only a single unregulated DC supply
voltage is needed. Typically any voltage between 9.5 VDC and 40 VDC is sufficient for proper
operation.

1.1.2. Physical Description

The model 2078-00 Strain Gage Signal Conditioner/Amplifier is completely contained on a single
2 1/2 inch square or round approximately 1 inch high printed circuit assembly. Heat sinking is pro-
vided for some components which require cooling. Adequate clearance is required for convection
air flow over this heatsink when mounting this subassembly.

May 19, 1997 Page 1

M/D TOTCO
 2078 Signal Conditioner
Installation, Operation, and Maintenance Manual 2078-08

1.1.3. Special Features/Capabilities

• Tough, Accurate, and Reliable.

• Full 7-wire transducer connection eliminates cable errors.
• True instrumentation amplifier with balanced differential input gives excellent com-
mon mode rejection and low drift.
• High input impedance, typically 200 megohms, prevents transducer loading and
prevents errors due to cable resistance.
• Highly accurate/stable transducer excitation supply eliminates error due to drift in
the transducer supply.
• Wide, easily adjusted balance controls, typically 50% of full scale input.
• Both course and fine span and zero adjustments provide for precise calibration
of gain.
• Very compact, rugged.
• Powered by a single, unregulated DC voltage or battery.
• Output load IR compliance is close to the supplied DC voltage.
• Output current parameter may be specified for either bidirectional or unidirectional
inputs.

1.1.4. List Of Supplied Equipment

(1) each Strain Gage Signal Conditioner . . . . . . . . . . . . . P/N 2078-00

(1) each owner’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . P/N 2078-08

1.2. Specifications

1.2.1. Electrical Specifications

Input Power . . . . . . . . . . . . . . . . . . . . . . 9.5 to 40 VDC, unregulated, maximum of 80 mA for

20 mA output, using a 350 ohm bridge, reverse polarity
protected.
Strain Gage Bridge Excitation . . . . . . . . 6.9 or 9.4 VDC. At input voltages below 12 VDC only
6.9VDC can be supplied. Protected against short circuit
conditions.
Input Voltages. . . . . . . . . . . . . . . . . . . . . .5 to 4 mv/V with unidirectional input.+0.5 to + 4 mV/V
using bidirectional input.
Output Current . . . . . . . . . . . . . . . . . . . . 4 to 20 mA unidirectional or 12 ± 8 mA bidirectional full
scale. Minimum compliance of 250 ohms with 9.5 VDC
input power to a maximum of 1775 ohms with 40 VDC
input power.
Span Adjustment Range . . . . . . . . . . . . + 10% of specified input typical, others available on
request.
Zero Balance (Tare Adj Range) . . . . . . . + 50% of full scale input typical.
Electrical Connections . . . . . . . . . . . . . . Reference attached drawing 2060-11.
Accuracy . . . . . . . . . . . . . . . . . . . . . . . . (.1%) of full scale at 25°C ± 10°C for 2 mv/v input
sensitivity and + 10% span adjustment range.

Page 2 May 19, 1997

M/D TOTCO
2078 Signal Conditioner
Manual 2078-08 Installation, Operation, and Maintenance

1.2.2. Operating Specifications For Standard Configuration:

Input Power . . . . . . . . . . . . . . . Voltage 9.5 to 40 Volts

Excitation . . . . . . . . . . . . . . . . . Voltage 6.9 Volts
Input Signal Range . . . . . . . . . . 0.0 mV/V to 4.0 mV/V
Output Current Range . . . . . . . 4.0 mA + 16.0 mA - 0.0 mA
Input F.S. Voltage . . . . . . . . . . . 2.0 mV/V + 10%
Gain Range (Overall) . . . . . . . . 8 mA/mV/V + 10%
Balance Range . . . . . . . . . . . . . ± 0.84 mV/V Input or ± 6.7mA
Output Board Size . . . . . . . . . . 2 1/2” Square
PJL . . . . . . . . . . . . . . . . . . . . . . closed

NOTE
High accuracy and high temperature units are available.

For 0 -10 VDC or frequency output signal conditioners request drawing 2060-00 or 2066-00
respectively.

1.2.3. Physical Specifications

Length/Width . . . . . . . . . . . . . . . . . . . . . 2 1/2” square or 2 1/2” diameter round.

Height . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.94” bottom mounting to top of heatsink. 0.1” bottom
mounting to lowest assembly extension.
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 oz.
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . See assembly drawing 2078-017.

1.2.4. Environmental Specifications

Humidity . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 95% non condensing.

Operating Temperature Range . . . . . . . . 0 to +50° C.
Storage Temperature Range . . . . . . . . . -20 to +100° C.

2.0. INSTALLATION/SET-UP
2.1. General
This section contains information to aid in installation and preparation for use. Included are instruc-
tions and information for visual inspection, installation in a suitable environment, setting controls,
interpreting displays and connecting cables and power.

CAUTION
DO NOT HYPOT or megger or perform high voltage tests on any cables
that are connected to this equipment, almost certain damage will result.
Disconnect all cables before tests are performed. Do not hypot or megger
the equipment.If any question exists concerning the compatibility of any
test with this instrument, contact M/D TOTCO before proceeding, to avoid
equipment damage and possibly voiding the warranty.

May 19, 1997 Page 3

M/D TOTCO
 2078 Signal Conditioner
Installation, Operation, and Maintenance Manual 2078-08

2.2. Unpacking/Inspection
When the equipment is received, examine the shipping container for evidence of damage. If none
is found, unpack the instrument carefully, watching for signs of damage.If evidence of damage is
apparent, stop unpacking immediately and notify the carrier. Save the damaged shipping container
for inspection by the carrier.The equipment underwent stringent quality inspection, burn-in, and
operational tests prior to shipment. It left the factory in perfect operating condition.
If the equipment shows no sign of damage, it may then be set-up and installed per the instructions
in this chapter.
Verify that all items listed in chapter one and on the packing slip have been received. Notify the
factory at once if any parts are missing.

2.3. Installation/Mounting
This is a modular component and is normally provided as part of a complete system. If this board
is customer mounted the following points should be considered:
Provide adequate clearance for convection cooling of the Heatsink. Route AC Power Wiring away
from this assembly. Avoid drafts or close proximity to heat producing components. The assembly
should be in a uniform thermal zone.
No calibration other than the normal adjustments for span and balance are required.

2.4. Controls And Indicators

For the location of all controls refer to the assembly drawing, 2078-01. There are no indicators.
Table 2.1 contains a description of the function of these controls.

Table 1. Control Function Description

CKT Name/ Description and Function

Designator Designation
R11 Course Span Potentiometer, Coarse adjustment
to gain.

R12 Fine Span Potentiometer, Fine adjustment to

gain.

R8 Coarse Zero Potentiometer, Coarse adjustment

to zero.

R9 Fine Zero Potentiometer, Fine adjustment to

zero.

2.5. Power/Signal Connection

The Strain Gage Signal Conditioner/Amplifier has 2 connectors for power, inputs and outputs.
These are:
• S1 . . . . . . . . . . Transducer (or signal) Input.
• P2 . . . . . . . . . . Power/Signal-Output/Control connections.

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M/D TOTCO
2078 Signal Conditioner
Manual 2078-08 Installation, Operation, and Maintenance

2.5.1. Connector Pin And Signal List

Table 2. S1 Transducer Input Connections

Pin Signal Comments

1 + Signal ---

2 - Signal ---

3 + RCAL Connect to - Signal at the transducer

4 - RCAL Normally connected to - Sense using PJ1

5 - Excitation Not at ground Potential

6 - Sense Connect to - Excitation at the transducer

7 + Sense Connect to + Excitation at the transducer

8 + Excitation ---

Table 3. P2 Power/Signal Output Control Connections

Pin Signal Comments

1 + Power In ---

2 RCAL Switch Connect to pin 3 through switch contacts for

shunt calibration.

3 RCAL Switch Connect to pin 2 through switch contacts for

shunt calibration.

4 - Power In Connected internally to pin 6.

5 + I out ---

6 - I out Connected internally to pin 4.

May 19, 1997 Page 5

M/D TOTCO
 2078 Signal Conditioner
Installation, Operation, and Maintenance Manual 2078-08

2.5.2. Typical Transducer Connections

This instrument will operate with either a 4-wire, a 5-wire, or a 7-wire transducer connection.
However, a 7-wire connection is recommended because if its stability and accuracy. To realize the
full accuracy of this instrument a 7-wire transducer connections must be used and all performance
specifications are based on that configuration. See drawing 2060-11.
The 4-wire transducer connection is acceptable if short cables (20 feet maximum) are used, the
system is operated in a stable ambient temperature, and extreme accuracy is not required.
The 7-wire transducer connection is preferred because it eliminates most of the errors caused by
the resistance of the interconnecting cables and connectors, which will be referred to as RL
(in each wire). There are two distinct errors caused by RL. The transducer outputs caused by a
direct physical stimulus is decreased by a factor of 2RL/R, where R is the transducers input resis-
tance (typically 120 or 350 ohms). The transducer output caused by a shunt calibration increases
by a factor of approximately 2RL/R. Therefore, a total calibration error of 4RL /R will exist due to
the interconnecting cable resistance. Both of these errors are present in a 4-wire transducer con-
nection. A 5-wire transducer connection eliminates the shunt calibration error, therefore reducing
the 2RL/R. The 7-wire transducer connection eliminates both errors.
The decrease in output from physical stimulus results from the decrease in excitation voltage
actually applied to the transducer due to the voltage dividing action between the wire resistance
and the transducer resistance. The increase in shunt calibration output results from the fact that
calibration current is caused to flow through the RT in the negative signal output lead. This voltage
drop adds directly to the transducer output and causes the calibration error. A more detailed
explanation follows.
In a 4-wire measurement the excitation voltage is measured at the instrument end of the excitation
wires, but the large currents flowing in these wires can cause large voltage drops across them.
This causes an immeasurable reduction in the excitation voltage applied to the transducer end,
because the output of the transducer is directly proportional to the excitation voltage applied
across it, a gain error results. Due to the high temperature coefficient of resistance of copper wire,
ambient temperature changes cause the cable resistance to vary resulting in a temperature
dependent gain error. The remote sense lines eliminate these errors, because they permit mea-
surement and/or regulation of the excitation voltage at the transducer end of the cable. There is
almost no current flowing in the remote sense lines because of the measurement circuit’s high
input impedance, so there is a negligible voltage drop across those wires and the voltage mea-
sured at the instrument is virtually identical to the voltage at the transducer.
When performing shunt calibration, a resistor is shunted across one arm of the transducer’s bridge
(normally the arm between the (-)signal and (-)excitation leads for a positive output), so approxi-
mately one half the excitation voltage appears across this shunt calibration resistor which causes
a current to flow through it while shunt calibration is being performed. In a 4-wire measurement
this current flows through the (-)signal wire, causing a voltage drop across the wire that appears in
series with the transducers’s output. The shunt calibration output of the transducer thus becomes
dependent on the resistance of the (-)signal wire and varies with wire length and temperature. This
effect is eliminated by conducting the shunt calibration resistor’s current through the remote shunt
calibration lead, ensuring the (-)signal lead will remain a non-current carrying sensing lead for the
transducer output.

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M/D TOTCO
2078 Signal Conditioner
Manual 2078-08 Installation, Operation, and Maintenance

It should be noted for completeness that the remote shunt calibration lead reduces the effect of
this shunt calibration current to a very low value, but an 8-wire, while not normally required, is nec-
essary to completely eliminate it. This is true because the shunt calibration current still flows in the
(-)remote sense wire, causing a voltage drop across the wire that appears in series with the excita-
tion voltage being sensed. However, since the magnitude of the excitation voltage is much larger
than the magnitude of the transducer output, the error voltage is a much smaller percentage of the
excitation voltage than it is of the transducer output and its effect is greatly reduced, typically by a
factor of 500. This effect is normally negligible for all but the longest cables, widest temperature
ranges, and most sensitive applications.

2.5.3. Wiring Considerations

This signal conditioner will not operate correctly unless a transducer, or some other acceptable
signal is applied to the input.
Because of the low level signals normally involved, all transducers should be wired with twisted,
shielded pairs. The two signal leads, the two excitation leads, and the two remote sense leads
(when used) should each share a separate pair. See Drawing Figure 2.1.
Transducers manufactured by M/D TOTCO normally have no electrical connection to their case.
For those and other floating transducers, the transducer cable shield should be connected to
chassis (earth) ground at the signal conditioner end of the cable. For grounded transducers, the
transducer cable shield should be connected to chassis (earth) ground at the transducer end or as
close to it as practical, instead of at the signal conditioner end. Never connect to the shield of the
cable at more than one point, ground potential differences will cause ground loops and result in
transient errors.
It should be remembered that this signal conditioner, or the system into which it is connected, must
have a connection to earth ground. A completely floating system allows an uncontrolled common
mode voltage to develop. This is a potentially dangerous condition and can affect the accuracy of
the system. However, good instrumentation practices dictate a careful analysis of how that con-
nection is made or large errors may result.
In simple, single channel systems with a floating power supply, the connection to chassis (earth)
ground should be made at the power input terminal on the signal conditioner.
In multi-channel systems the connection (earth) ground is frequently accomplished through the
power common (-power input). Caution is advised, use a good single point ground (mecca) and
make all connections to chassis (earth) ground at that point. Route a separate wire from each
signal conditioner to mecca. Never connect digital circuits to mecca with the same wire used for
analog circuits.
The (-)output signal from the signal conditioner is internally connected directly to the (-)power input
signal, and so will normally be at chassis (earth) ground potential. Thus, in systems with proper
power and signal grounding, the signal conditioner output may be treated as a single ended
output. If a difference in ground potentials exists, or if currents are flowing in ground connections
that can effect the relative ground potentials of analog system components significantly, a differen-
tial connection should be used.
In noisy electrical environments and/or when a long cable is to be connected to the output of the
signal conditioner, a twisted pair, shielded cable should be used. Again, the shielded should be
connected to chassis (earth) ground at one and only one end.

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Installation, Operation, and Maintenance Manual 2078-08

The signal conditioner has provisions for a shunt calibration resistor. To utilize this feature, an
external contact closure must be provided. This may be accomplished with a switch or a relay. The
contact should be gold plated and rated for dry circuit operation. If a relay is used it should be a
low thermal EMF type. AROMAT type SE relays, or equivalent, are a good choice, low thermal
EMF reed relays may also be used.
A Signal Conditioner Mother Board, M/D TOTCO part number 2077-00, is available that provides:
• plug in mounting of the signal conditioner
• Terminal blocks for cable wiring
• Calibration relays and resistors
Contact M/D TOTCO for more information.

2.6. Shunt Calibration

There are several ways to calibrate instruments, such as this signal conditioner (S/C), that mea-
sure the output of a Wheatstone bridge type of transducer. one method is to actually apply an
accurately known physical stimulus to the transducer and calibrate the S/C to output this physical
stimulus accurately. In many applications this method is virtually impossible because the trans-
ducer or system cannot be exercised. Even where access to the transducer is possible, accurate
calibration standards are frequently not available.
To avoid the inconvenience of a complete calibration, mechanical inputs to the transducer may be
simulated by electrical means, with no change to the parameter being measured. There are a
number of techniques for accomplishing this but, shunt calibration is used almost universally.
Shunt calibration is a very powerful technique for determining the accuracy of the S/C calibration
setting. Shunt calibration is performed by shunting one arm of the bridge with a precision resistor,
electrically unbalancing the bridge, and causing the output to change a precise and repeatable
amount. The S/C will measure this output change and the output will reflect the simulated mechan-
ical input to the transducer as if it were caused by actual mechanical stimulus. M/D TOTCO (and
many other manufacturers) will always specify, as part of the transducer calibration data, the
actual simulated transducer stimulus for a specific shunt resistor value. Every time shunt calibra-
tion is performed, the S/C should output the specified transducer output exactly. If the output value
is not correct, the system may be instantly recalibrated. Shunt calibration is also very useful as an
operator confidence check because virtually any failure or change in the transducer or instrumen-
tation will change the shunt calibration output.
When the transducer’s shunt calibration output is known, the following procedure may be used to
perform system calibration:

1. Remove all mechanical input from the transducer (zero input). Let the S/C warm up.
The S/C output should be zero. If not, adjust the FINE and COARSE ZERO POTEN-
TIOMETERS for a zero OUTPUT value.
2. Depress the CAL PUSHBUTTON. The OUTPUT should indicate the transducer’s
specified shunt calibration output. If not, adjust the FINE and COURSE SPAN
POTENTIOMETERS.
3. Steps 1 & 2 may interact and should be repeated until both are correct.
4. The system is now calibrated and ready to use.

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Manual 2078-08 Installation, Operation, and Maintenance

NOTE
Make sure the shunt calibration resistor (RCAL) in the S/C is the same
resistance specified in the transducer calibration data.

When the transducer shunt calibration output is not known, a physical calibration must be per-
formed. Once the calibration is performed, and while the system is still in calibration, the shunt cal-
ibration value may be empirically determined as follows:

1. Remove all mechanical input from the transducer (zero input). Let the S/C warm up.
The S/C output should be zero. If not, adjust the FINE and COARSE ZERO POTEN-
TIOMETERS for a zero OUTPUT value.
2. Depress the CAL PUSHBUTTON and record the OUTPUT value. This is the shunt
calibration constant for the connected transducer. This calibration constant may now
be used to check or perform calibration of the system at any time. If, when the CAL
PUSHBUTTON is depressed, the OUTPUT does not indicate a reading between 80%
and 100% of full scale, the internal shunt calibration resistor may have to be replaced
with one of more suitable value. Contact M/D TOTCO for more information on this
subject.

3.0. OPERATION
3.1. General
This section contains information and instructions relating to equipment operation. Correct set-up
and installation, as described in Section 2, must be performed prior to equipment operation.

3.2. Turn-On/Operation
This information will normally be provided at a system level.

3.3. Checkout Procedure

This information will normally be provided at a system level.

4.0. PRINCIPLES OF OPERATION

4.1. General
This section describes the manner in which the equipment performs its different function. This dis-
cussion is keyed to both the functional block diagram and the schematic diagram. An overall func-
tional description and a detailed circuit analysis are provided. Functional block diagrams show
function only and do not reflect all details shown on the schematic diagrams.

4.2. Functional Description

The signal conditioner is designed to convert the output of a Wheatstone bridge type of sensor
(such as a strain gage bridge load cell or a platinum RTD) into a high level current from
4 to 20 mA. The conditioner generates a highly stable excitation voltage to power the sensor and
provides amplification to raise the sensor signal output to a noise immune level. The amplifier
output is both short circuit and reverse voltage protected and is designed to drive very highly

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Installation, Operation, and Maintenance Manual 2078-08

capacitive loads (such as encountered with long cables) without oscillation or excessive ringing.
Power supply requirements are very easy to satisfy. Only a single, unregulated DC supply voltage
is needed. Typically any voltage between 9.5 VDC and 40 VDC is sufficient for proper operation.
The output current range may be specified to operate from 4 to 20 mA for unidirectional inputs or
12 + 8 mA for bidirectional inputs. The output compliance is equal to the DC supply voltage minus
4.5 volts.
At a functional block diagram level the signal conditioner may be partitioned into 10 blocks:

1. Reverse power protection diode.

2. Reference
3. Excitation power supply
4. Voltage doubler
5. Tare (zero) circuit
6. Input filter
7. Instrumentation amplifier
8. Output circuit
9. Feedback circuit
10. RCAL

A true instrumentation amplifier is used for high input impedance, high common mode rejection
ratio, low noise, and low drift. This instrumentation amplifier amplifies microvolt level signals with a
gain of 100. High frequency noise at the input is filtered out by the input filter. This filter also pro-
vides series resistance for protection of the signal inputs of the instrumentation amplifier.
The reference circuit provides a very stable reference voltage which is used by the power supply
to generate a very stable excitation supply voltage to the transducer. The reference voltage is also
used in generation of a stable tare voltage.
The output current is sensed with a precision series resistance. This sensed output is amplified by
the feedback circuit. The feed-back circuit’s output is then used as one control input to the instru-
ment amplifier. The Tare circuit provides the second control input to the instrumentation Amplifier.
Signal conditioner gain is adjusted by varying the amount of gain in the feed-back circuit.
When the signal conditioner is used with a bridge type sensor, a full seven wire connection is sup-
ported. This includes remote sense for the excitation voltage and remote shunt calibration. The
remote sense feature eliminates the errors caused by voltage drops in the cables and connectors
going to the sensor. The shunt calibration permits convenient field calibration of the signal
conditioner.

4.3. Circuit Description

This description is keyed to the block diagram, 2078-02, and the schematic diagram, 2078-03.
The reverse power protection diode, CR4, is connected in series with the input power and
becomes reverse biased if power is connected backwards preventing damage. Capacitors C11
and C12 provide input power filtering.
The reference circuit generates a very stable voltage that does not vary with time or temperature.
This voltage is used by the excitation power supply and the tare circuit. There are two options for
the reference, one for 6.9V excitation and one for 9.4V excitation. (The excitation is equal to the
reference voltage). CR1 and CR2 are precision reference diodes. A 1.5 mA current for the refer-
ence circuit and associated circuitry is supplied by CR3 current source. This provides proper
biasing for all input voltages ranging from 9.5 to 40 VDC. At 6.9 VDC reference voltage, reference
diode CR1 is not used. For this reference value, input power voltage as low as 9.5 VDC may be

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2078 Signal Conditioner
Manual 2078-08 Installation, Operation, and Maintenance

supplied. for 10 VDC reference, both CR1 and CR2 are used and input power voltages above
12 VDC must be used.
The excitation power supply generates a stable voltage source to power the transducer and the
voltage doubler, Z6. The excitation voltage is normally equal to the reference voltage (+ 0.1%).
This circuit consists of a deferentially connected comparator, Zl, and a series pass element, Z2.
The comparator senses the excitation voltage at the bridge itself via the remote sense lines (when
used) and compares it to the reference voltage. The output of the comparator is an error signal
that tends to drive Z2’s output in a direction that will keep the excitation voltage constant at the
transducer. This eliminates errors caused by line drops in long cables. The four resistors from RN1
connected to Zl are 100K ohm resistors with a ratio match of 0.1% and a TCR (ratio) of 5PPM
maximum. This helps guarantee the stability of the excitation voltage. Resistors Rl and R2 prevent
the excitation voltage from rising to the supply voltage is one of the sense lines inadvertently gets
disconnected. The series pass element, Z2, is a three terminal voltage regulator that has internal
short circuit protection and thermal shutdown circuitry.Some combinations of power input voltage,
ambient temperature and bridge resistance will require the use of adequate convection cooling
for Z2.
The voltage converter uses a monolithic CMOS power supply circuit, Z6, and associated circuitry
to produce a negative voltage of about one volt less than (+)Vex and a positive voltage of about
2 volts less than (+)2Vex. The operation of this device may best be understood by considering
Figure 4-1, 4-2, and 4-3. Figure 4-1 shows a simplified block diagram of Z6 connected as an ideal-
ized negative converter. The DPDT switch toggles at the 10KHZ rate of the oscillator. During the
first half of the cycle, while the switch is in the ‘UP’ position, capacitor C13 is charged to voltage
(+)Vex. During the second half cycle of operation the switch toggles to the “DOWN” position which
grounds the positive side ofC13 and connects the negative side of C13 to C16. Thus chargingC16
to a voltage (-)Vex with respect to ground. The switch is actually implemented with four MOS
power transistors in the integrated circuit.

Figure 4-1. Ideal Negative Converter

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 2078 Signal Conditioner
Installation, Operation, and Maintenance Manual 2078-08

In Figure 4-2, Z6 is shown connected as an idealized voltage doubler. In this case only one half of
the switch is used. In the first half cycle of operation, when the switch is in the “DOWN” position,
capacitor C14 is charged through diode CR7 to a voltage (+)Vex (minus the drop across CR7).
During this half cycle diodeCR8 is reverse biased. During the second half cycle of operation, when
the switch is in the “UP” position, (+)Vex is connected to the negative terminal of capacitor C14.
This adds (+)Vex volts in series with the voltage across C14 (+Vex) which applies approximately
(+)2Vex volts to the junction of CR7 and CR8. This reverse biases CR7 and forward biases CR9,
charging capacitor C15to a voltage of (+)2Vex (minus two diode drops). Figure 4-3 shows the
combined circuit. C16 and C18 are added to improve high frequency ripple.

Figure 4-2. Ideal Voltage Doubler

Figure 4-3. Combined Circuit

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2078 Signal Conditioner
Manual 2078-08 Installation, Operation, and Maintenance

The input filter R3, R4 and C3 is a passive single pole RC low pass filter with a cutoff frequency of
around 200HZ. This filter is intended primarily for RFI suppression, and to provide current limiting
for excessive input signal voltage levels.
Z3 is a complete instrumentation amplifier with a fixed gain of 100. Z3 contains its own gain net-
work on chip. The output of Z3 is used to drive the output circuit series pass transistor, Ql.
The output circuit Ql, R17 and CR5 is a series pass circuit for the 4 to 20 mA output. The 4 to
20 mA output current is controlled by the output of the instrumentation amplifier connected to the
base of the darlington output transistor Ql. The amount of current delivered to the output is moni-
tored by R17 and fed to the feedback circuit. Diode CR5 prevents damage to the current output cir-
cuit in case an external positive voltage is inadvertently applied to the signal output connector pin.
Zener diode CR10 is used to limit the output current in case the input circuit is left open and also to
prevent a possible latch-up condition in case of an excessively large input signal with an intermit-
tent output connection. output compliance can be calculated by:

+ Supply (minus) 4.5V

Compliance = Ohms
20 mA

Voltage divider R6 and R7 provides a 4 mA output reference voltage (12mA for bidirectional appli-
cations), Zref.
The tare circuit is used to provide a precision adjustable voltage that may be used to offset the out-
put. The typical range is +50% of full scale for a 2 mV/V full scale input range. Z5 is connected as
a sign changer with a variable output. This circuit is best understood by visualizing R8 set in three
positions, fully CW, fully CCW and centered. With R8 centered, Z5 pin 3 is at a voltage approxi-
mately midway between I OUT ZERO reference and (-)Vref. Since Z5 pin 2 is at the same voltage,
and because both resistors connected to Z5 pin 2 are of equal value, the output of Z5 is approxi-
mately equal to I OUT ZERO reference. As the wiper of R8 is adjusted toward (-)Vref (CCW) Z5
becomes an inverting amplifier with a gain of (-)1 with an output at pin 6 of less than I OUT ZERO
reference. As the wiper of R8 is adjusted toward I OUT ZERO reference (CW) Z6 becomes a non-
inverting amplifier and the output at pin 6 becomes greater then I OUT ZERO reference. The out-
put of the tare circuit is connected to the sense input of the instrument amplifier, Z3, and acts as a
reference for the instrument amplifier.

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The feedback circuit, Z4, controls the signal conditioner gain. The amplified difference between the
output sense voltage from the output circuit and the I OUT ZERO reference is fed to the reference
input of the instrumentation amplifier. The sense input of the instrumentation amplifier is connected
to the tare circuit output reference. The output of the instrumentation amplifier controls the bias of
the output series pass circuit transistor, Ql, and maintains it at a level that satisfies the gain cir-
cuitry of the instrumentation amplifier. The amount of amplification in the feedback circuit controls
the gain of the signal conditioner. This amplification is controlled by the Fine and Course Span
adjustment pots (R11 and R12), R13 and R14. The value of R13 is selected during assembly to
establish the operational requirements of the signal conditioner. The gain range can be set to any
input from 0.5 mV/V to 4 mV/V (sensor sensitivity) for full scale output range. R11and R12 provide
an adjustment range of + 10% (typical). Use of larger span adjustments are available, but can only
be used at the expense of decreased system temperature stability. The feedback resistance for
the center if the gain range, R feedback, (R11/2 + R12/2 + R13) is calculated as follows:

R14 (x) R17 (x) Vex (x) mV/Vfs

R feedback = Ohms
Z3 gain (x) 16 mA

Since V3 gain is equal to 100 and the value of R17 is equal to100 ohms, these terms cancel and
the formula simplifies to:

R14 (x) Vex (x) mV/Vfs

R feedback = Ohms
16 mA

For bi-polar inputs (12mA + 8mA) the following formula is used to calculate the feedback
resistance:

R14 (x) Vex (x) mV/Vfs

R feedback = Ohms
8 mA

For minimum adjustment range R feedback = R11 + R12 + R13. For maximum adjustment range
R feedback = R13.

5.0. MAINTENANCE/CALIBRATION
5.1. General
The information provided in this section is intended to assist the qualified technician in performing
calibration and maintenance. It is not intended to be a substitute for qualified repair and mainte-
nance training. It is assumed that the maintenance technician is thoroughly familiar with the infor-
mation in Section 1 through 4 of this manual.
Repairs and maintenance that might be required within the warranty period should be referred to
the factory. Caution should be observed in attempting any repairs within the warranty period to
avoid voiding the warranty by causing additional damage to the equipment while attempting
repairs.

5.2. Note On Proper Installation

Before attempting to diagnose an apparent problem verify proper set-up and installation have
been performed as described in Section 2. This sometimes is the cause of the problem.

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Manual 2078-08 Installation, Operation, and Maintenance

5.3. Anti-Static Handling

This equipment contains CMOS circuitry. These integrated circuits can be destroyed by electro-
static discharge resulting from careless handling.To prevent this possibility it is important that the
following precautions be observed when calibrating and servicing the instrument.

1. Never remove, install or otherwise connect or disconnect PCB’s and/or components

without first turning the power switch to OFF.
2. All servicing should be performed at a static free work station. All work sur-
faces should be grounded. Pink poly bench top covering connected to earth ground is
recommended.
3. All service personnel should be connected to earth ground using wrist straps.
4. Keep plastic, vinyl, and Styrofoam out of the immediate work area.
5. Handle circuit boards and integrated circuits by their edges only.
6. Use a grounded tip soldering iron only.

5.4. Routine Maintenance

The only routine maintenance required is a visual inspection of the general condition and
cleanliness of the assembly.

5.5. Calibration
Calibration of this assembly consists of adjusting the balance and span controls. These adjust-
ments are normally specified at the system level.

6.0. PARTS LIST

6.1. General
Included in this section are lists of all components and assemblies. The list, compiled by reference
designator order, contains the find locator number, the part description, and the part number.
Spare parts and repair parts are available from M/D TOTCO. When specifying parts, please
include the following information (as applicable):

1. Enclosure model number or PCB assembly number, and serial number

2. Part description

CMOS devices must be protected from static discharge. All maintenance personnel must observe
proper handling and grounding procedures when handling them.

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Installation, Operation, and Maintenance Manual 2078-08

6.2. Parts List

Table 4. Parts List - 2078-014

Find Part Description Qty.

Number Number
C2, C13, C14 1520-10050 CAP, 10uF, 25V, ELCTLT, RDL 3
C11 1520-10051 CAP, 10uF, 50V, ELCTLT, RDL 1
C15, C16 1570-10052 CAP, 10uF, 25V, TANT, RDL 2
C3 1590-22070 CAP, .22uF, 63V, RDL 1
2060-10 HEATSINK 1
2078-00 PCB FAB, SIG COND, CURR 1
P2 2146-06300 CONN, STRIP, .1X6, GOLD 1
P1 2146-08300 CONN, STRIP, .1X8, GOLD 1
2800-04040 SCREW, #4-40X.25, PNH, SST 2
2800-04050 SCREW, #4-40X.312, PNH 1
2802-14000 WASHER, SPLIT C, #4, SST 1
2802-24000 WASHER, LOCK, INTL STAR 1
2820-04080 PHMS, NL 1
2822-44000 WASHER, SHLDR, #4, NYL 1
Z1, Z4, Z5 3132-11000 IC, LM11CN, OP AMP, LOW 3
CR2 3135-32900 IC, LM329, VOLTAGE REF 1
CR3 3135-33400 IC, LM334, CONST CURRENT 1
Z2 3152-33700 IC, LM337, TO-220, VOLT REG 1
Z6 3153-76610 IC, 7661, VOLT INVERT/DOUB 1
R11 4600-10020 POT, CERMET, 10K, 1T 1
R12 4600-20000 POT, CERMET, 200, 1T 1
R8 4600-20020 POT, CERMET, 20K, 1T 1
R9 4600-50020 POT, CERMET, 50K, 1T 1
R1, R2 4711-10002 RES, CRBNF, 100, 5%, .25W 2
R3, R4 4711-10022 RES, CRBNF, 10K, 5%, .25W 2
R10 4711-10052 RES, CRBNF, 10M, 5%, .25W 1
R16 4711-47012 RES, CRBNF, 4.7K, 5%, .25W 1
R5 4711-56R02 RES, CRBNF, 56, 5%, .25W 1
R15 4720-49923 RES, MF, 49.9K, 1%, .125W 1
R17 4730-10003 RES, WW, 100, .1% 1
R6 4730-20813 RES, WW, 2.083K, .1% 1
R7 4730-40023 RES, WW, 40K, .1% 1

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Manual 2078-08 Installation, Operation, and Maintenance

Table 4. Parts List - 2078-014

Find Part Description Qty.

Number Number
R14 4730-50024 RES, WW, 50K, .05%, MR500 1
RN1 4755-10031 RES NTWK, 16P, DIP, 100K 1
CR4, CR5 4800-40020 DIODE, RECTIFIER, 100V 2
CR7, CR8 4800-91400 DIODE, SIGNAL 2
CR10 4810-75101 DIODE, ZENER, 1N751A, 5.1 1
Q1 4830-90000 TRANSISTOR, PNP, D41K4 1
4890-00003 SIL-PAD, TO-220 2
R13 911435-057 RES, MF, 38.3K, 1%, .1W, RN 1
Z3 925086-002 IC, 624, DIP, INSTM AMPLI 1
C1, C4, C6,
C7, C9, C10, 1500-10070 CAP, .1uF, CER, +30/20% 10
C12, C17, C18
999502-006 BAG, STATIC SHLD, 6x10 1

7.0. REFERENCE DRAWINGS

The following drawings are attached to this manual for your reference.
2060-11. . . . . . . . . . . . . . . . . . . . . . . . . . Transducer Connection Diagram
2078-01 . . . . . . . . . . . . . . . . . . . . . . . . . PCB Assembly, Signal Conditioner, Current Output
2078-02 . . . . . . . . . . . . . . . . . . . . . . . . . Block Diagram, Signal Conditioner, Current Output
2078-03 . . . . . . . . . . . . . . . . . . . . . . . . . Signal Conditioner, Current Output, Schematic Diagram
2078-08 . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Diagram

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