- July 31, 2025
Step-by-Step Guide to Installing and Calibrating Your Strain Gauge Signal Conditioner
Strain gauge signal conditioner is an essential tool in precision measurement systems. It is a device that amplifies, filters, and converts the electrical signal from a strain gauge into a format suitable for data acquisition systems. Its functions typically include:
- Excitation voltage supply
- Amplification circuitry
- Filtering components
- Analog-to-digital conversion (optional)
Whether you’re working in structural engineering, aerospace, or industrial automation, proper installation and calibration of your signal conditioner ensures accurate and reliable data.
Tools and Materials Needed
Before diving into the installation and calibration process, it’s essential to gather all the necessary tools and components to ensure a smooth and efficient setup. Having everything prepared in advance not only saves time but also helps prevent errors during installation. Here’s a checklist of what you’ll need:
- Strain gauge(s) – Choose the appropriate type and configuration (quarter, half, or full bridge) based on your measurement requirements.
- Signal conditioner – Select a model compatible with your strain gauge, such as the MAS10 or other industry-standard units.
- Power supply – Ensure it meets the voltage and current specifications required by your signal conditioner.
- Multimeter – Useful for verifying connections, checking resistance, and troubleshooting electrical issues.
- Data acquisition system (DAQ) – Required for capturing and analysing the conditioned signal.
- Calibration weights or a known load – Essential for performing accurate calibration and validation of your measurement system.
- Mounting hardware and wiring tools – Includes adhesives, soldering equipment, connectors, and cable management accessories for secure and reliable installation.
Step 1: Mount the Strain Gauge
Proper strain gauge installation is critical. Follow these steps:
- Surface Preparation: Clean and polish the surface where the gauge will be mounted.
- Gauge Placement: Align the gauge with the direction of strain.
- Adhesive Application: Use a suitable adhesive and allow it to cure fully.
- Wiring: Solder or connect the gauge leads to the signal conditioner input terminals.
Tip: Use a Wheatstone bridge configuration (quarter, half, or full) depending on your application and signal conditioner compatibility.
Step 2: Connect the Signal Conditioner
- Power Supply: Connect the conditioner to a stable power source as per the manufacturer’s specifications.
- Input Wiring: Connect the strain gauge leads to the input terminals (typically labelled +EX, -EX, +SIG, -SIG).
- Output Wiring: Connect the output terminals to your DAQ or monitoring system.
- Grounding: Ensure proper grounding to avoid noise interference.
Step 3: Configure the Signal Conditioner
Most modern signal conditioners allow configuration via software or onboard switches. Key settings include:
- Excitation Voltage: Set according to the strain gauge’s requirements (commonly 5V or 10V).
- Gain Settings: Adjust the amplification to match the expected signal range.
- Filter Settings: Apply low-pass filters to reduce noise.
Step 4: Perform a Zero Balance
Before applying any load:
- Ensure the system is at rest and unloaded.
- Use the zero or tare function on your conditioner or DAQ software.
- Adjust until the output reads zero or a known baseline.
This step eliminates any offset caused by installation stress or wiring resistance.
Step 5: Calibrate the System
Calibration ensures your system translates strain into accurate force or displacement values.
Method 1: Using Known Weights
- Apply a known load to the structure.
- Record the output voltage or digital reading.
- Repeat for multiple load levels.
- Plot the data and derive a calibration curve (linear or polynomial).
Method 2: Software Calibration
Many conditioners and DAQs offer built-in calibration routines:
- Enter known input values.
- Let the software auto-adjust gain and offset.
- Save the calibration profile.
Pro Tip: Always document your calibration process for traceability and repeatability.
Step 6: Validate and Monitor
After calibration:
- Apply a test load and verify the output matches expected values.
- Monitor for drift or noise over time.
- Recalibrate periodically, especially in critical applications.
Common Troubleshooting Tips
- No Signal Output: Check wiring, power supply, and gauge continuity.
- Noisy Signal: Improve grounding, use shielded cables, and adjust filter settings.
- Drifting Output: Ensure stable temperature and mechanical conditions.
Installing and calibrating a strain gauge signal conditioner may seem complex, but following a structured approach ensures accurate and reliable measurements. Whether you’re a seasoned engineer or a first-time user, this guide provides the foundation for a successful setup.
FAQs
Q: Can I use any strain gauge with any signal conditioner?
A: Not always. Check compatibility in terms of resistance, excitation voltage, and bridge configuration.
Q: How often should I calibrate my signal conditioner?
A: Ideally, before each critical measurement session or at least every 6–12 months.
If you’re looking for a high-performance solution for strain gauge applications, the MAS10 Strain Gauge Signal Conditioner is a reliable choice. Designed for industrial and research environments, the MAS10 offers:
- High-accuracy signal amplification with low noise
- Built-in excitation voltage (5V or 10V)
- Adjustable zero and span settings
- Multiple output options, including analog (0–10V, 4–20 mA) and digital
- Compact and DIN-rail mountable for easy integration
Or need help on calibrating your signal conditioner?
Contact MeasureX Australia to speak with one of our specialists, and we’ll guide you through it to achieve reliable and accurate measurements.
