Analog Load Cells
All resistive load cells we sell are fundamentally analog load cells with a small DC voltage output. They are generally referred to as mV/V load cells and typically have 1 to 4 mV/V rated output. So, if you apply 10V supply power to them, the change in output is of the order of 10 mV to 40 mV total from zero to full scale loads. This is a tiny change in output. Typically industrial controls need a 0-5V, 0-10V or 4-20 mA outputs. In order to meet this need, we offer analog load cell interfaces that pair any resistive bridge type load cell (four-wire or six-wire) to an analog signal conditioner that amplifies the low level signal (mV/V) from a load cell into a higher level calibrated Voltage or Current signal. This setup makes it easy to connect it to a Programmable Logic Controller (PLC) or a Data Acquisition System (DAQ). A typical analog load cell configuration is shown below where a load cell is paired with an AI-1000 Analog Signal Conditioner and calibrated together with known NIST traceable dead weights or reference loads. This output can then be fed into a PLC or a DAQ.
Suggested Kit:
RSB2 Button Load Cell
AI-1000 Analog Load Cell Interface
Add Calibration
Add Accessories
For applications where the load cells and interfaces are far away from the interfaces (say over 20 feet), we recommend the AI-1000-CV with 4-20 mA calibrated output. For shorter distances, the AI-1000 with a 0.5 VDC to 4.5 VDC calibrated output from zero to full scale load, is sufficient for most needs.
What is an Analog Load Cell?
Why should one use an Analog Load Cell?
Some applications require force or weight data to be input into a PLC to control external devices or trigger alarms. The AI-1000 and AI-1000CV are single-channel signal conditioners designed to provide voltage (0.5 - 4.5 V DC or 1 - 9 V DC) output proportional to the applied load into a PLC or DAQ, allowing for data capture and recording for various experiments. This setup is ideal for real-time monitoring and control, ensuring accurate and consistent data transmission. The AI-1000CV analog interface can also be calibrated to provide current (4 - 20 mA) output. For long-distance applications, current outputs are preferable to avoid voltage drops and noise. Many of our customers use our Analog Load Cell solution to help automate counting and weighing solutions.
Most Popular Analog Load Cell Kits
For users requiring a high-level 0-5V analog DC output compatible with existing data acquisition systems or PLCs, our analog load cell signal conditioners can be mated/calibrated with any resistive bridge type load cell (four or six wire) for analog output. The AI-1000 Analog Load Cell Interface provides an amplified 0.5 to 4.5V output proportional to the applied loads. We also offer the AI-1000-CV with 4-20 mA output for applications that require current output.
Shown below are some of our most popular wireless load cell configurations.
RAS1 Resistive S-Beam Load Cell with Analog Voltage Output via AI-1000
Suggested Kit:
RAS1 S-Beam Load Cell
AI-1000 Analog Load Cell Interface
Add Calibration
Add Accessories
RSB2 Resistive Button Load Cell with Analog Voltage Output via AI-1000
Suggested Kit:
RSB2 Button Load Cell
AI-1000 Analog Load Cell Interface
Add Calibration
Add Accessories
RAPG Resistive Single-Point Load Cell with Analog Voltage Output via AI-1000
Some users want a high level 0-5V analog DC output in order to work with existing data acquisition systems or PLCs. Ih that case, you can use this load cell with our AI-1000 Load Cell interface which provides an amplified 0.5 to 4.5V output proportional to the applied loads. We can provide the system together with calibration and the formula to convert from voltage to loads/forces when ordered in this configuration. We also offer the AI-1000-CV with 4-20 mA output if you prefer current output. Please contact us for this kit.
Suggested Kit:
RAPG Single Point Load Cell
AI-1000 Analog Load Cell Interface
Add Calibration
Add Accessories
AI-1000-CV Load Cell Interface with Analog & Current Output
The AI-1000-CV Strain Gauge Transducer is a sensor interface designed for amplifying strain gauges configured in a Wheatstone bridge. It offers both voltage and current outputs, with trimmer potentiometers for setting outputs in the 0-5 VDC or 4-20 mA ranges. It can be used with PLCs that have analog voltage or current inputs. For long-distance applications, current outputs are preferable to avoid voltage drops and noise. The device operates on a 24V power supply, supports four-wire load cells with shielding, and is housed in a water-resistant, environmentally sealed enclosure.
How to Select and Configure your Analog Load Cell Solution
Select Sensor
Pick a Load Cell
Pick the right load cell for your application based on:
Max Range, Accuracy, Operating Conditions & Certifications
Select Sensor
Select Interface
Pick an Analog Interface
Pick an Interface based on:
Whether you need voltage output or current output or both.
Select Calibration Mode
Pick a Calibration Mode
Pick a Calibration Mode:
Compression, Tension, Universal
Select Calibration Mode
Analog Calibration
Analog Calibration between your sensor and interface pair is necessary for analog output (4 - 20 mA, 0.4 - 4.5 V DC, or 1 - 9 V DC.)
When purchasing the AI-1000 or AI-1000-CV please select and add an analog calibration option in compression, tension or both and 4 - 20 mA, 0.4 - 4.5 V DC, or 1 - 9 V DC. In compression or in tension the voltage is adjusted to fall appoximately between 0.5 to 4.5V DC or as large a span as practical. For universal mode, the zero level force is set to 2.5 VDC approx. In one direction the voltage goes from 2.5CV to 4.5 VDC and in another direction it goes from 2.5V DC to 0.5V DC.
Explore our Calibration options for your application.
Learn More
Calibrate & Use AI-1000 Analog Signal Conditioner with Your Resistive Load Cell
How to Use Resistive Load Cells with Analog Output & Connecting with PLCs
Introduction to AI-1000CV Analog Interface with Voltage, Current, or Both Outputs
FAQ
The AI-1000 offers a span of 4V (4000 mv) from approx. 0.5V to 4.5V DC with a noise of +/- 1 mv or less. This offers a resolution of +/- 0.025% of full scale and easily provides accuracies of the order of +/- 0.1% accuracy of full scale or better.
If specially requested, the AI-1000 can also be calibrated to provide 1 - 9V DC.
The AI-1000 can connect with four wire resistive load cells (mV/V) made using strain gauges in bridge configurations (half bridge, full bridge). The connection is made via a terminal block. The output is typically a DC voltage that ranges between 0.5 V to 4.5V. If specifically requested, the AI-1000 can be calibrated to provide output ranges between 1 - 9 V DC.
The AI-1000CV can be calibrated to offer both volage and current (4 - 20 mA) outputs.
You need to power the AI-1000 with a 8-24 V power supply. We include this power supply with your unit and it usually comes pre-connected and ready to use if purchased as a kit with a calibration service.
The AI-1000CV works off a 24V power supply that you must provide.
The AI-1000 offers DC voltage output proportional to the applied force/torque. The AI-1000-CV offers either a 0 - 5 or 1 - 9 V DC voltage output or a 4-20 mA current output or both. You just have to select and add the appropriate calibrations to your order.
We do not offer such a display at the present time. But you can buy an LCD panel meter from other vendors and program it to display the output voltage converted into a force value. We offer several digital interfaces with USB or BLE output that can connect with our DS-3000-Pro-1 Single Channel or the DS-3000-Pro-4 Four Channel Touch Screen LCD displays.
Yes. We offer calibration service on new sensor purchases as well as recalibration service for previously purchased sensors. We use NIST traceable reference standards to perform and validate the calibration and provide a free calibration certificate as part of the service. We are NOT ISO certified.
In any circuit, the farther the signal has to travel over a conducting wire, the greater the drop of the voltage due to the inherent resistance of the cable. We recommend that you keep the distance between the AI-1000 and your PLC or DAQ under 6 feet. If you need to be farther away than that, then consider using the AI-1000-CV with current output or the digital USB or wireless versions of the interface.
The AI-1000/AI-1000CV can only be connected with one load cell at a time. You MUST mate the analog interface with a load cell and calibrate it before using it. The calibration is performed by setting the R1 and R2 resistors on the front of the AI-1000. The load cell and analog interface must then be used together as a pair. If you want to use it with another load cell then you MUST recalibrate the new pair prior to use.
