INSTRUMENTATION THAT SETS THE TREND

l;ANS:,.ATI®N inc: I
ROCHESTER, N.Y. U.S.A.
INS TRUC TI ON BOO K

1040
1040 PPS DIGITAL POTENTIOMETER
(PART NO. 100724 - 000)

I.S. NO.: 100724-900

DATE: OCTOBER 1974

SUPERSEDES: APRIL 1973

FILE: TESTER

CUSTOMER ·P. 0. NO.:

TRANSMATION REF . NO.:

.
. '

INTERFACE INSTRUMENTATION - DIGITAL/ANALOG

Analysis • Specifications • Design • Production

977 MT. READ BLVD. 0 ROCHESTER, N.Y. 0 14606

RANSMATieN inc. TELEX 97-8314 0 TELEPHONE 716 254-9000
 TABLE OF CONTENTS

SECTION PAGE

I GENERAL DESCRIPTION 1

II SPECIFICATIONS 1-2

III OPERATION 2-7

IV TROUBLE SHOOTING GUIDE 7-8

v FACTORY SERVICE AND WARRANTY 8

VI THEORY OF OPERATION 9-10

VII CALIBRATION PROCEDURE 10-11

VIII RECOMMENDED SPARE PARTS LIST 12

IX FIGURES 12-21
 SECTION I

1040 GENERAL DESCRIPTION

1.1 DESCRIPTION:

The TransmatiorliD Precision Pocket Source (PPS) Digital Potentiometer is a pocket sized, high
accuracy portable test instrument in an anodized case intended for field use. It will directiy
measure unknown voltages and currents with a 4-1/2 digit digital voltmeter.

The PPS Digital Potentiometer also provides high accuracy test signals of 0 to 11 V, 0 to 110 MV,
0 to 22 MA, and 0 to 54 MA, for use in calibration of electronic equipment.

Simulation of two-wire transmitters for 0 to 22 MA and 0 to 54 MA output is standard. The tester

is battery powered and uses rechargeable nickel-cadmium batteries with built-in recharger.

The Model 1040 is protected against misconnection by the use of fuses and internal protective
circuits. The anodized case has a watersealed switch and gasketing provided so that the instrument
may be used in light rain or mist. The rotary switches have rolled gold contacts instead of the
more common gold flashed contacts for increased resistance to corrosive atmospheres, reliability
and accuracy. The instrument case is rugged anodized aluminum with a padded vinyl case for carrying
or handing from a pipe. Industrialized silicon solid state electronics and integrated circuits
assure long term reliability in industrial environments.

SECTION II

1040 DIGITAL POTENTIOMETER

SPECIFICATIONS

(Part No. 100724-000)

2.1 INPUT: BY MEANS OF 5-WAY COLOR CODED BINDING POSTS

0-11 VOLTS DC WITH 10 MEGOHMS MIN. INPUT IMPEDANCE, CONSTANT INPUT BIAS CURRENT OF
70 NA MAX.
0-110 MV DC WITH 2 MEGOHM MIN. INPUT IMPEDANCE, CONSTANT INPUT BIAS CURRENT OF 50 NA
MAX. EQUIVALENT TO 1°F ERROR WITH 1000 FEET OF 20 GAUGE J THERMOCOUPLE WIRE
0-22 MA DC WITH 100 OHMS INPUT IMPEDANCE
0-54 MA DC WITH 100 OHMS INPUT IMPEDANCE

2. 2 MEASUREMENT CALIBRATED ACCURACY:

0-llV: +0.04% OF RANGE +0.03% OF READING MAX.

0-110 MV: +o.06% OF RANGE +o.06% OF READING MAX.
0-22 MA: +0.12% OF RANGE +o.06% OF READING MAX.
0-54 MA: +0.06% OF RANGE +o.06% OF READING MAX.
- -
2.3 MEASUREMENT METHOD: 4-1/2 DIGIT INTEGRATING DIGITAL VOLTMETER WITH 5 DIGIT LED DISPLAY TO 11,000
COUNTS MAX.

2.4 OUTPUT: BY MEANS OF 5-WAY COLOR CODED BINDING POSTS

0-11 V DC: 5 OHM OUTPUT IMPEDANCE MAX.

0-110 MV DC: 25 OHM OUTPUT IMPEDANCE MAX.
0-22 MA: 0 TO 1300 OHMS LOAD
0-52 MA: 0 TO 500 OHMS LOAD
0-22 MA: TWO WIRE TRANSMITTER SIMULATOR. EXCEEDS ALL POWER AND LOAD REQUIREMENTS OF
0-54 MA: ISA SP-50 WITH lOOV MAXIMUM DC SUPPLY VOLTAGE

2. 5 OUTPUT CALIBRATED ACCURACY:

0-11 V: +0.04% OF RANGE +0.03% OF READING MAX,

0-110 MV: +o.06% OF RANGE +o.06% OF READING MAX,
0-22 MA: +0.12% OF RANGE +o.06% OF READING MAX.
0-54 MA: +o.06% OF RANGE +o.06% OF READING MAX.
XMTR SIM: SAME AS 0-22 MA AND 0-54 MA

PAGE 1
2.6 REFERENCE: STABILIZED ZENER DIODE

2.7 RECOMMENDED OPERATING TEMPERATURE RANGE: 0 TO +110°F, -18 TO +45°C

STORAGE TEMP: -40 TO +120°F, -40 TO +50°C

2. 8 TEMPERATURE EFFECT: ±4 uv/°F TYP ., ±6 uv/°F MAX. MV IN: . 0015%/°F ALL OTHER RANGES

2.9 SENSITIVITY: 0-llV IN/OUT, 0-llOMV IN/OUT: .01% F.S.

0-22 MAIN/OUT: .05% F.S.
0-54 MAIN/OUT: . 02% F.S.

2.10 REPEATABILITY : 0.02% OF RANGE

2 .11 POWER REQUIREMENTS: BUILT-IN RECHARGEABLE NICKEL CADMIUM BATTERIES - BUILT-IN CHARGER OPERATES
FROM 115VAC 50/60 HZ. SUPPLY

2 .12 BATTERY LIFE: 1. 9 HOURS - 50 MA CONTINUOUS OUTPUT 'l ~'*" d---.

2 . 7 HOURS - 20 MA CONTINUOUS OUTPUT I
3 .1 HOURS - V, MV CONTINIOUS IN/OUTPUT

2.13 WARMUP TIME TO RATED ACCURACY: 30 SEC MV IN; 5 SEC MAX. ALL OTHER RANGES

2 .14 AREA CLASSIFICATION: DESIGNED FOR CLASS I, GROUP D, DIV. 2 SERVICE EXCEPT FOR RECHARGING

2.15 PROTECTION: ZENER DIODE AND FUSE PROTECTED ON ALL RANGES AGAINST MISCONNECTION AND OVERVOLTAGE
UP TO 110 VOLTS

2 .16 WEIGHT: 3 LBS. INCLUDING BATTERY (1.4KG)

2 .1 7 SIZE: 8.25" HIGH X 2.67" DEEP X 4.5" WIDE

2 .18 RANGE SELECTION: MANUAL WITH DECIMAL POINT SWITCHING AND LEADING ZERO BLANKING BUILT-IN

2.19 BATTERY CHECK: BUILT INTO ON - OFF SWITCH. DISPLAY INDICATES BATTERY VOLTAGE DIRECTLY

2.20 POWER SUPPLY EFFECT: LESS THAN +2 COUNTS SHIFT FROM 5 .3-4.7V BATTERY VOLTAGE

2 . 21 NORMAL MODE REJECTION: 70 DB 0-llV IN, 101 DB 0-llOMV IN

2 . 22 COMMON MODE REJECTION: NO EFFECT UP TO 140 VAC 60 HZ

2.23 READING RATE: 700MS/READING

SECTION III

OPERATION

3 .1 DESCRIPTION OF OPERATING CONTROLS (Refer to Figure 1 Page 13)

A. Function Switch "A"

This switch selects the desired mode and range of operation. There are seven positions.

1. 0-llV in: In this position an unknown DC voltage in the range of 0-llV may be measured.

2. 0-110 MV in: In this position an unknown DC voltage in the range of 0-110 MV may be
measured.

3. MA in: In this position, an unknown DC current in the range of 0-54 MA may be measured.

4. 0-11 V out: In this position, the instrument provides a DC voltage output in the range
of 0-11 volts.

5. 0-110 MV out : In this position, the instrument provides a DC voltage output in the
range of 0-110 MV.

6. MA out : In this position, the instrument provides a DC current output in the range of
0-22 MA, and 0-54 MA out .

PAGE 2
 7. XMTR SIM: In this position, the instrument simulates a two-wire transmitter and may
be inserted in a DC loop with a supply of 22 to lOOV DC meeting the requirements of ISA
SP-50. The instrument will provide an output of 0-54 MA in this function.

B. Coarse Decade Adjustment: "B"

This switch in conjunction with the fine adjustment control "C", determines the output
signal. The dial is calibrated from 0-100 with each position representing the following:

0-llV in: 1.00 volt per step

0-110 MV in: 10.00 MV per step
MA in or XMTR SIM: 10.00 MA per step

This control is not used in the measurement mode.

C. Fine Adjustment: "C"

This control in conjunction with the coarse decade control "B" determines the output signal.
The control is a ten-turn potentiometer with the full range of the control equal to one step
of the coarse control. One turn of control "C" is equal to the following:

0-llV 100 MV
0-110 MV 100 uv
MA lMA
XMTR SIM lMA

This control is not used in the measurement mode.

D. Power Switch: "D"

This switch is a special locking type to prevent accidental power application. It has three
positions. When the switch is in the center position, the instrument is off. To apply power
to the instrument, pull the switch handle straight up and move it to the lower position,
labeled "ON". To turn the instrument off, reverse the procedure. To test the batteries,
pull the switch handle straight up and move it to the upper position, labeled "BAT.CHK.".
This position is a momentary spring return position, so the handle will have to be held in
place while checking batteries. When the switch is in the "BAT.CHK." position, the display
"L" will indicate the battery voltage.

E,F. Xmtr Sim Output: "E" and "F"

These binding posts are used to connect the instrument into a control loop to substitute for
a two wire transmitter.

G,H. MA Out Output: "G" and "H"

These binding posts are used to connect the instrument ~or current output.

I,J. MA In Input: "I" and "J"

These binding posts are used to apply a current input to the instrument.

J,K. Vin/Out: "J" and "K"

These binding posts are used for voltage and millivolt input and output.

3.2 USE OF FIVE WAY BINDING POSTS

All connections to the PPS "Digital Potentiometer" are made with 5-way binding posts.
These posts allow almost any type of wire or test lead to be connected to the post. A miniature
banana jack may be inserted into the top of the post. A wire may be connected by turning the plastic
top of the post, counter clockwise, and inserting the wire in the exposed hole or wrapping the wire
around the post and tightening down the post. A spade lug or the end of a test prod may be cpnnected
in the same manner as the wire. An alligator clip may be clipped to the top of the post.

3.3 USE OF PPS "DIGITAL POTENTIOMETER"

PAGE 3
3 . 3 .1 GENERAL OPERATION : (Refer to Figure 1 Page 13)

The PPS " Digita l Potentiometer" i s designed to gi ve years of t roub l e free operation wi th li tt l e or
no maintenance . The instrument is pr otected aga i nst fa l se connection and wrong swi tch pos i t i ons by
internal protective circuitry and fuses, so that damage will not occur to the instrument, if a wrong
connection is made.

It i s a good practice to position funct i on switch ''A'' to its proper position before any connections
are made to the instrument. When changing functions, it is recommended that a l l wires going to the
instrument are disconnected first. Then the function switch is set to its new position and the wire
connected to the proper terminal .

Since the instrument has instantaneous warmup to calibrated accuracy, the power does not have to be
left on. In order to obtain maximum life from the batteries, it is recommended that power switch
"D" is kept on only during actual use. Set up the measurement, make it, and then turn the switch off.
The electronics of the PPS "Digital Potentiometer" are separated from the battery compartment to
prevent any leakage from the batteries from damaging sensitive components.

3.3 . 2 BATTERY CHECKING:

The PPS "Digital Potentiometer" has a built-in provision for checking batteries . The batteries
should be checked each time the instrument is used .

To check the batteries, throw switch "D" upward to its "BAT.CHK." position. This switch has a spring
return so that it will have to be held in position. If the display "L" reads greater than 4.700,
the batteries are good. If the display does not light or lights briefly and then goes out, or reads
less than 4.700, the batteries are weak and should be recharged. See recharging instructions
Section 3.4 .

When the battery voltage drops below 4.7 volts, the display will begin to flash as a warning of the
low battery condition. After the display starts flashing the instrument will operate for approximately
15 minutes before the battery has exhausted below the point where operation is possible . The bat-
teries should be recharged immediately after the display begins to flash.

WARNING: To prolong battery life and avoid damage, avoid completely discharging the batteries . The
batteries should be recharged when the "BAT.CHK." reads 4. 700 or lower.

3.3.3 USING THE PPS "DIGITAL POTENTIOMETER" AS A SOURCE OF SIGNALS:

The output of the source may be set at any level within the range selected by the use of the coarse
and fine adjustment control "B" and "C".

3.3 . 3.1 VOLTAGE OUTPUT: (Refer to Figure 2 Page 14)

In this mode, the instrument will provide an output voltage of 0-llV DC .

1. Put the function switch "A" in the 0-llV out position.

2. Connect the input of the device under test to the Vin/Out binding posts.
3. Set the coarse and fine controls "B" and "C" to the desired voltage. The coarse control
has a sensitivity of 1 volt per step and the fine control has a sensitivity of 0 . 1 volt
per turn. The output voltage is read directly off the display "L".

3.3.3.2 MILLIVOLT OUTPUT: (Refer to Figure 2 Page 14)

In this mode the instrument will provide an output millivoltage in the range of 0-110 MV DC.

1. Put the function switch "A" in the 0-110 MV out position.

2. Connect the input of the device under test to the Vin/Out binding posts.
3. Set the coarse and fine controls "B" and "C" to the desired MV output. The coarse control
has a sensitivity of 10 MV per step and the fine control has a sensitivity of 1 MV per turn.
The output millivoltage is read directly off the display "L".

3.3.3.3 CURRENT OUTPUT: (Refer to Figure 2 Page 14

In this mode the instrument will provide an output current in the range of 0-22 MA DC or
0-54 MA DC.

1. Put function switch "A" in the MA out position.

PAGE 4
 2. Connect the input of the device under test to the MA out binding posts.
3. Set the coarse and fine controls " B" and "C" to the desired current. The coarse control
has a sensitivity of 10 MA per step, and the fine control has a sensitivity of 1 MA per
turn. The output current is read directly off the display "L".

3.3.3.4 TWO-WIRE TRANSMITTER SIMULATOR OUTPUT : (Refer to Figure 2 Page 14)

In this mode, the instrument will simulate the output from a two-wire transmitter when connected in
a loop having a supply voltage of between 22 and 100 volts .

1. Put function switch "A" in the xmtr sim position.

2. Disconnect the two-wire transmitter from the loop.
3. Connect the digital potentiometer in the loop with the xmtr sim binding posts.
4. Set the coarse and fine controls "B" and "C" to the desired current . The coarse control
has a sensitivity of 10 MA per position and the fine control has a sensitivity of 1 MA
per turn. The output current is read directly off the display "L".

3.3.4 USING THE PPS "DIGITAL POTENTIOMETER" TO MEASURE UNKNOWN SIGNALS:

The PPS "Digital Potentiometer" may be used to measure unknown signals within the range of the
instrument. The unknown signal is read directly on display "L".

3.3.4.1 MEASUREMENT OF UNKNOWN VOLTAGE: (Refer to Figure 3 Page 14 )

In this mode, the instrument will measure an unknown voltage in the range of 0-11 volts.

1. Put function switch "A" in the 0-11 volts in position.

2. Connect the unknown voltage to the Vin/Out terminals. Turn power switch "D" on. If
display "L" reads 0.00, reverse the input leads (negative polarity signal).
3. Read the unknown voltage directly off display "L".

3.3.4 . 2 MILLIVOLTS IN: (Refer to Figure 3 Page 14)

Ih this mode, the PPS "Digital Potentiometer" source may be used to measure an unknown signal in
the range of 0-110 MV DC.

1. Turn function switch "A" to the 0-110 MV in position.

2. Connect the unknown voltage to the Vin/Out terminals. Turn the power switch "D" on.
Reverse the input leads (negative polarity input), if display "L" reads 0.00.
3. Read the unknown voltage directly from display "L".

3 . 3.4.3 THERMOCOUPLE INPUT: (Refer to Figure 3 Page 14)

In this mode, the PPS "Digital Potentiometer" may be used to measure unknown temperature from a
thermocouple.

1. Turn function switch "A" to the 0-110 MV in position.

2. Connect the thermocouple to Vin/Out terminals . See connection diagram (Figure ).
The red thermocouple wire goes to the negative (black) binding post. Turn power switch
"D" on . If display "L" reads 0.00, reverse the input leads, (negative polarity input).
3. Obtain a reading from the display "L".
4. Using an instrument thermometer determine the ambient temperature of the input terminals.
5. Using the thermocouple tables in the pouch, determine the output signal in millivolts
from the thermocouple type in use at the measured ambient temperature of the terminals.
6. Add this value found in Step 5 to the signal found in Step 3.
7. On the thermocouple tables opposite the value found in Step 6, read the unknown
temperature .
8. Example: A type "J" thermocouple is connected and the unknown voltage is measured as
7.94 MV. The ambient temperature near the terminals is measured as 80°F. In the thermo-
couple tables for type "J", 80°F is found to be 1.36 MV. Addin§ 1.36 MV to the measured
voltage of 7.94 MV gives 9.30 MV. In the table, 9.30 MV is 344 F. Therefore, the
unknown temperature is 344°F.

3.3.4.4 THERMOCOUPLE INPUT WITH REFERENCE: (Refer to Figure 5 Page 15)

If a Transmation Model 1010 Reference Cell of the proper type set to 32°F or 0°C is available,
the computation in the previous section for temperature can be considerable simplified.

PAGE 5
 1. Turn function switch "A" to the 0-110 MV in position.
2. Connect the thermocouple and PPS Reference Cell to the Model 1040 as shown in connection
diagram (Figure ) . The wire from the Reference Cell to the 1040 should be positive
thermocouple wire of the proper type. Turn power switch "D" on. If the display "L"
reads 0.00, reverse the input leads (negative polarity signal).
3. Obtain a reading from display "L".
4. Using the thermocouple tables on the rear of the instrument, for the proper thermocouple
type, determine the temperature for the unknown signal found in Step 3. This is the
unknown temperature.
5. Example: A type "J" thermocouple and reference cell are connected and the unknown voltage
is measured as 7.94 MV. From the type "J" thermocouple tables, the unknown temperature is
read as 300°F.

3.3.4.5 CURRENT INPUT: (See Connection Diagram, Figure 3 Page 14)

In this mode, the PPS "Digital Potentiometer" will measure an unknown current in the range from
0-54 MA DC,

1. Turn function switch "A" to the MA in position.

2. Connect the unknown current to the MA in terminals. Turn the power switch "D" to on.
If display "L" reads 0.00, reverse ~nput leads (negative polarity input).
3. Read the unknown current from display "L".

3.3.5 CURRENT LIMIT:

On some older transmitters of various manufacture, current limiting of the output signal was not
provided. As a result, a transmitter that would normally send a signal in the range of 10 to 50 MA
could provide an initial surge current in excess of 100 MA. This surge current, unless dissipated
or limited, will cause the input fuse to blow, protecting the instrument. To prevent this occurence,
attach a series limiting resistor, approximate value 100 to 200 ohms, to limit the surge current.

Newer transmitters produced with an intrinsically safe design do not have this problem. This is
due to the fact that intrinsically safe requirements, limit the surge current to a safe level.

3.4 RECHARGING OF BATTERIES:

If the battery check test described in Section 3.3.2 indicates the batteries need recharging,
they may be recharged in the following manner.

3.4.1 Remove instrument from its vinyl case.

3.4.2 Plug the charger cord into the receptacle on the bottom of the instrument.

3.4.3 Plug the other end of the cord into a 117V A,C, outlet, ±10%, 50/60 HZ. A complete charge takes
12 hours.

WARNING: DO NOT CHARGE IN HAZARDOUS AREAS

3.5 Because of the slight differences in capacity between cells, one or more cells may run out of energy
before the other cells in a multicell battery and reach zero voltage causing reverse charging of the
lowest capacity cells. Cell reversal will not occur if the instrument is recharged when the battery
test function indicates that recharging is necessary. A cell reversal could occur however, if the
power switch is inadvertently left on for long periods of time.

3.5.1 DETECTING CELL REVERSAL:

If it is suspected that a cell reversal has occurred, the following procedure may be used to detect
this condition. Verify that the one amp fuse in the battery circuit is good. Remove the battery
assembly from the battery compartment and with an A,C, voltmeter measure the voltage across the secon-
dary of the charging transformer, (across the yellow wires of the transformer). If the voltage across
the secondary is between 8 and 15 volts A,C, with the charger plugged in, the charger circuit is
working correctly. If this voltage is not present, the charger circuit is defective and is more than
likely to cause the problem. If everything checks out O.K. plug the instrument in and allow it to
charge for 24 hours. At the end of this time measure the D.C. voltage across the entire battery stack
with a D,C, voltmeter and tester power switch off. If this voltage is less than 3.5 volts a cell reversal
has probably occurred. A cell reversal cannot be corrected with the standard charging circuit.

PAGE 6
3 . 5.2 CORRECTION OF CELL REVERSAL:

There are two basic ways that a cell reversal problem can be fixed. The first and the most obvious
is to replace the defective cell. However, it is possible to restore a cell which has undergone
reversal. The following procedure is recommended:

Remove the cells from the instrument. Connect them all in series to a current limited D.C. power
supply capable of supplying 8 volts D.C. at 2 amps. Connect the batteries to the power supply and
turn the current limit to a minimum. While monitoring the voltage across the cells with a voltmeter,
increase the current limit to approximately 2 amps . After a few minutes, the voltage across the cell
should suddenly start to rise. When it reaches approximately 4 1/2 to 5 volts reduce the current
limit point to 200 milliamps . Allow the cells to charge at the 200 milliamp current level for 24
hours. This procedure should cure a cell reversal probelm. At the end of the 24 hours the open
circuit voltage of the cells should be approximately 5 . 2 to 5.5 volts. If this is the case, these
cells may be returned to service. If this procedure does not cure the reversal problem, these
cells must be replaced.

3.5 . 3 PREVENTION OF CELL REVERSAL:

Cell reversal may be prevented by not allowing complete discharge of the batteries . When using the
equipment always make sure tha·t the power switch is off after making the measurement. Use the battery
check function before each reading to assure that the batteries are not in need of charge . As soon as
the battery test function indicates that the batteries need recharging, IMMEDIATELY recharge the bat-
teries. Do not operate the instrument below the point where the battery test function indicates re-
charging is necessary.

3.6 REPLACING BATTERIES:

To replace the batteries, remove the lower cover plate. Pull the battery holder assembly out.
Unsolder the leads from the batteries and solder in the new batteries. Connect two batteries in
series, then connect the red lead to (+) and the black lead to (-). Place the batteries in the
holder and replace the holder in the case.

SECTION IV

TROUBLE SHOOTING GUIDE

4.1 PREFACE:

Because of the extremely dense packaging and large number of prec1s1on components used in the Model
1040, it is recommended that any repairs or calibration other than replacing the batteries and
fuses should be done by returning the instrument to the factory for repair or replacement. Accom-
plishing repairs in this manner minimizes instrument down-time and enables the user to achieve
the maximum benefit of Transmation 1 s factory repair service. However, for experienced electronic
technicians who desire to repair their own unit, a careful reading of the description of OPERATION -
SECTION VI and their own electronics knowledge should enable repairs to be accomplished . When a
large number of instruments are in use, it is strongly recommended that a spare instrument should
be purchased as per the Recommended Spare Parts List in SECTION VIII.

4.2 TROUBLE SHOOTING GUIDE :

CAUSE
DIFFICULTY OF TROUBLE SOLUTION

Display dim, reads below Weak Batteries Recharge Batteries

4.700 on BAT.CHK., Display
flashes

Unit completely inopera- Power switch turned off

tive, no function works. Batteries weak or dead Replace or recharge Batteries
BAT.CHK. does not work. F3 Blown Replace F3

Unit completely inopera- Fuse Fl and/or F2 *

tive, BAT.CHK. works. Dis- Blown Replace Fuse(s) *
play reads correctly on Vout
and MV out.

*If ,fuses blow, read Paragraph 3.3.5 fully regarding surge currents and how to limit surges with
a series resistor in the test leads.

PAGE 7
 CAUSE
DIFFICULTY OF TROUBLE SOLUTION

MV IN/OUT, VIN/OUT, Fuse Fl Bl own * Rep l ace Fl *

MA IN, XMTR SIM does
not work, MA OUT works.

MA OUT does not work , al l

other functions working Fuse F2 Blown Replace F2
correctly .
* *
*If fuses b l ow, read Paragraph 3.3.5 fully regarding surge currents and how to limit surges with
a series resistor in the test leads.

4.3 REPLACING FUSES : (Refer to Figure 12 Page20

The instrument is protected against most electrical overloads by two fuses located in the instrument .
To replace these fuses, remove the upper cover plate. The blown fuse shoul d be replaced with a 1/10
amp fuse Littelfuse number 273.100 or equi valent for Fl and F2 and a 1 amp fuse Littelfuse number
273001 for F3. Refer to paragraph 3.3 . 5 for additional information on fuse blowing .

SECTION V

FACTORY SERVICE AND WARRANTY

5. 1 ·· .FACTORY SERVICE:

Should service become necessary and field repair is inconvenient or undesirable, the instr!liDent .
may be returned to the factory for repair or replacement as necessary. Please assist · OUT~ t -~ .•

Service Department by providing as complete a description of faulty operation as possib~ e . . Instru-

ments should be shipped via AIR PARCEL POST: SPECIAL HANDLING, or other means as the urgency of
services require, prepaid to :

FACTORY SERVICE DEPARTMENT

TRANSMATION, INCORPORATED

"CHECK YOUR LOCAL REPRESENTATIVl

FOR NEAREST REPAIR FACILITY."

5.2 WARRANTY:

Transmation, Inc. hereinafter referred to as the Company, warrants all equipment manufactured by
it and bearing its nameplate, and all repairs made by it, to be free from defects in material or
workmanship under normal use and service . If any part of the equipment herein described, and
sold by the Company, proves to be defective in workmanship or material and if such part is,
within twelve months from date of shipment from the Company's factory, returned to such factory,
transportation charges prepaid, and if the same is found by the Company to be defective in
workmanship or material, it will be replaced or repaired, free of charge, F.O.B. the Company's
factory. The Company assumes no liability for the consequence of its use or misuse by the
purchaser, his employees or others . A defect, in the meaning of this warranty, in any part of
said equipment shall not, when such part is capable of being renewed, repaired or replaced,
operate to condemn such equipment. This warranty is expressly in lieu of all other warranties,
guarantees, obligations or liabilities, expressed or implied by the Company or its representatives.
All statutory or implied warranties other than title, are hereby expressly negated and excluded.
This warranty excludes expendable parts such as batteries, fuses and test leads.

5.3 ORDERING INFORMATION:

Please specify, when ordering spare parts or replacement parts for an instrument, the following:

1. Series number - Model 1040

2. Options

PAGE 8
 SECTION VI

THEORY OF OPERATION

The 1040 is composed of two printed circuit boards. One printed circuit board has the input,
output, reference, switching and control functions while the other board houses a 4-1/2 digit
DVM.

6.1 INPUT BOARD OPERATION: (Refer to Figure 7 Page 16 and Figure 8 Page 17 )

In the voltage input mode, the input voltage is conditioned and switched directly to the input of
the DVM. In the millivolt input mode, the millivolt signal is first conditioned and amplified
by a millivolt amplifier A2. This amplifier brings the millivolt signal level up to a level high
enough to operate the DVM. For milliamp inputs, the input current must first pass through scale
factor resistor R40 which acts as a current shunt resistor to convert the current into a voltage
which then drives the DVM.

The output voltage from the voltage reference is coupled into the operational amplifier Al. The
gain of this amplifier is controlled by coarse switch S2 and 10 turn potentiometer R21. Fro~ Al,
the reference voltage is coupled into operational amplifier A3. This amplifier, in conjunction
with transistor Q2, serves as the output amplifier for the source. The function of A3 and Q4
depends upon the setting of function switch Sl. In the voltage out position, the amplifier acts
as a buffer amplifier coupling the signal from amplifier Al to the output terminals. In the
millivolt output mode, the amplifier again functions as a buffer amplifier. The voltage signal
must pass thru a precision voltage divider consisting of R38 and R39 so that the signal level
is reduced to a millivolt ~evel.
..
···..- --.·..
In the current output mode A3 and Q2 form a voltage to current converter with the output taken
'f rom the collector of Q2. The scale . factor for the voltage to current converter is determined by
the . ~cale factor resistor R40. In the transmitter simulator mode, the voltage supply of the
collector of Q2 is replaced by the voltage fro~ the controller in the field and may be anywhere
from 22 to 100 volts. Operation other than this is identical to the milliamp output range. In
all output modes, the output of amplifier A3 and transistor Q2 is monitored by the DVM so that
the output is displayed.

The battery check function applies voltage from the batteries to the input of the DVM. The DVM
then reads the battery voltage directly. Satisfactory operation will occur above battery voltages
of 4.7 volts. Zener diodes, VR3, VR4, VR5, VR6, diode CRl, and fuses Fl and F2 serve to protect
the instrument against accidental misconnection or overload which might otherwise damage the
instrument.

6.2 DVM .OPERATION: (Refer to Figure 9 Pagel8 and Figure 9 Page 19 )

The DVM is basically a voltage to frequency converter whose output pulse repetition rate is
proportional to the input voltage. These pulses are counted by a counter and displayed on a
display. The input signal is first applied to the input buffer amplifier Al. This amplifier
conditions the input signal and scales it to the proper magnitude to· operate the rest of the
DVM circuitry.

The output of the input buffer amplifier feeds the comparator A2. If the plus input of A2 is
higher than the minus input, the comparator output is high. If the plus input is lower than the
minus input, the output is low. The output from the comparator is used to gate a flip-flop A4.
When A2 is high, the flip-flop is enabled and clock pulses are allowed to pass thru to the output.
When A2 is low, the flip-flop is disables and no pulses can be present at the output. The out-
put of the flip-flop feeds a precision pulse shaper network. This precision pulse shaper net-
work generates a pulse of precise amplitude and width. One pulse is generated each time the flip-
flop toggles.

The output from this pulse shaper is integrated by resistor R56 and capacitor ClO and applied to
the negative input of comparator A2. If the input voltage to comparator A2 is more positive than
the feedback voltage on the minus input, the output of comparator is high, the flip-flop is
enabled and pulses from the precision pulse shaper pass to the integrator network. This causes
the voltage on the integrating network to rise. When this voltage reaches the value of the input
voltage, the comparator goes negative, the flip-flop is disabled and the precision pulse shaper
stops. Thus, this feedback network adjusts the pulse repetition rate until the average on the in-
tegration capacitor is equal to the input voltage. For larger input voltages, a greater repetition
rate is required. Therefore, the pulse repetition rate at the output of flip-flop A4 is directly
proportional to input voltage.

PAGE 9
 These pulses are coupled into counter A7 where they are accumulated . The clock output also
drives a divider chain consisting of A6. This divider chain divides the clock pulse by approxi-
mately 12,000. When this count is reached, the divider chain sends a transfer pulse in the counter,
which transfers the accumulated count into the display. Immediately following the transfer pulse,
a reset pulse also occurs which resets the counter and the divider chain to zero. Thus, the
amount of counts accumulated in the counter is directly proportional to the input voltage.

A7 also contains decoding circuitry to drive the LED display A9. Over-range and decimal point
switching are also handled by A7 and A8.

The DVM board also contains a D.C. to D.C. converter which supplies the necessary +40 volts,
+15 volts and -15 volts from the 5 volt rechargeable nickel cadmium batteries. This converter
runs at approximately 14KHZ. This board also contains the battery charging circuitry that
allows recharging of the nickel cadmium batteries with no external components.

SECTION VII

CALIBRATION PROCEDURE

This instrument has been carefully calibrated at the factory and recalibration should not be
attempted in the field unless equipment of sufficient accuracy is available to correctly ad-
just the instrument.

7.1 CALIBRATION OF DVM: (Refer to Figure 11 Page 20 )

The calibration controls for the DVM are located on the DVM board.

MATERIAL REQUIRED: Precision voltage source capable of producing 10 volts with an accuracy of
1/2 millivolt or better. (Electronic Development Corporation Model MVlOON
or equivalent)

7 .1.1 Remove the bottom cover from the instrument and carefully lift out the battery assembly. The
DVM board is the lower of the two P.C. boards in the case.

7 .1. 2 Set function switch "A" to the 0-llV in position. Connect the voltage source to the Vin/out
terminals.

7 .1. 3 Set the source to 0.010 volts. Turn on the 1040 and note the reading on the display. If the
reading is between 0.007 and 0.013, the DVM zero control is in adjustment and need not be calibrated.

7 .1.4 If the DVM reads out of tolerance, adjust potentiometer R9 on the DVM board for a reading of 0.010.

7 .1. 5 Set the voltage source to exactly 10 volts. Note the reading on the display. If the reading is
between 9.993 and 10.007 the DVM is in calibration and need not be adjusted. If outside of these
limits, adjust potentiometer Rl7 to read exactly 10.000.

7 .1. 6 Repeat Steps 7.1.3 thru 7.1.5 until no further improvement is obtained.

7 .1. 7 This completes calibration of the DVM. Potentiometer Rl8 should not be adjusted.

7.2 CALIBRATION OF V Our, MA OUT, MV OUT, AND XMTR SIM.:

MATERIAL REQUIRED: Precision voltmeter capable of measuring 10 volts to an accuracy of 1 MV.

(Hewlett-Packard 740B or equivalent.)

7.2.1 Set function switch "A" to 0-llV out position. Connect the voltmeter to the Vin/out terminals.

7.2.2 Set the coarse and fine controls fully counter clockwise.

7.2.3 Turn on the source and read the output on the voltmeter. If the voltmeter reads 0 volts +3 MV,
the instrument is in specification and should not be adjusted. If the instrument does not read
within specifications, adjust potentiometer R8 on the input board until the output is exactly
0 volts.

7.2.4 Turn the coarse dial to 100.

PAGE 10
7.2.5 If the voltmeter reads 10.00 volts +5 MV, the instrument is in specification and should not be
adjusted. If the instrument does n~t read within specification, adjust potentiometer Rll on
the input board until the output reads exactly 10.000 volts.

7.2.6 Repeat Steps 7.2.2 thru 7.2.5 until no further improvement can be obtained.

7.2.7 This completes calibration of the reference amplifier. Unless the MV in function is to be
calibrated, return the battery assembly to the case.

7.3 CALIBRATION OF MV IN:

MATERIAL REQUIRED: Precision millivolt source capable of supplying 0-110 MV to an accuracy of

+5 UV. (Leeds & Northrup 7554 Type K4 or equivalent.)

7.3.1 Calibrate the V out range and DVM as described in the preceding sections.

7.3.2 Set the function switch to 0-110 MV in. Connect the millivolt source to the Vin/out binding post.
Turn on the instrument.

7.3.3 Set the MV source to 100.00 MV.

7.3.4 Carefully adjust the potentiometer R28 on the input board until the readout reads 100.00 MV
+0.12 MV.

7.3.5 Set the MV source to 0.010 MV.

7.3.6 Adjust potentiometer R45 until the readout reads 0.010 MV ±.006 MV.

7.3.7 Repeat Steps 7.3.3 to 7.3.6 until no further improvement is obtained.

7.3.8 This completes calibration of the instrument. Disconnect the equipment and replace the battery
assembly and cover. ·

7.4 CHECK OF CURRENT OUTPUT:

MATERIAL REQUIRED: Precision voltmeter capable of reading 5 volts to an accuracy of 1 MV or better.

(HP 740B or equivalent.) Precision 100 ohm resistor .001% accuracy or better.

7.4.1 Calibrate the~ range and DVM as described in Section 7.1 and 7.2.

7.4.2 Set the function switch "A" to MA out. Connect the DVM to the MA out terminals. Connect the
100 ohm shunt resistor across the input to the DVM.

7.4.3 Set the coarse control to 20 and the fine control fully counter clockwise.

7.4.4 Turn on the power switch. The DVM should read 2 volts +3.6 MV. If the reading is not within
the specification, the instrument should be returned to-the factory for repair.

7.5 CHECK OF CURRENT INPUT:

MATERIAL REQUIRED: Current source and current measuring potentiometer capable of measuring 20 MA
to an accuracy of 2 UA. (L & N Type 7554 Type K4 with 4385 Shunt Box or
equivalent.)

7.5.1 Calibrate the V out range and DVM described in Section 7.1 and 7.2.

7.5.2 Set the function switch "A" to MA in. Connect the current source in series with the potentiometer
to the MA in binding posts. Turn-on the instrument.

7.5.3 Set the output of the current source to exactly 20.000 MA. The DVM on the 1040 should indicate a
reading of 20 MA ±.04 MA. If the instrument is not within specifications, it must be returned to
the factory for repair.

PAGE 11
 SECTION VIII RSPL 100724 - 911

RECOMMENDED SPARE PARTS LIST

RECOMMENDED QUANTITIES
PART NUMBER PART DESCRIPTION FOR 10 INSTRUMENTS

100724-000 INSTRUMENT MODEL 1040

A
1
759306-008 1/10 AMP FUSE 10
759306-019 1 AMP FUSE 5
759521-003 RED BINDING POST 1
759521-001 BLACK BINDING POST 1
759550-003 BATTERIES - NICKEL CADMIUM (SET OF 2) :_~, a 1
100724-019 INSTRUCTION-CONVERSION CARD . 1
100724-022 CONVERSION CARD 1
100724-023 J & K THERMOCOUPLE TABLES 1
100724-024 E & T THERMOCOUPLE TABLES 1
100001-006 KNOB, LARGE 1
100001-007 KNOB, SMALL 1
759995-010 CARRYING CASE 1
500143-000 TEST LEADS 5 PAIR
604000-001 THERMOMETER 1
100724-900 INSTRUCTION MANUAL 1
756023-001 POWER CORD 1
100724-003 220V 50/60 HZ ADAPTER 1
759008-004 POWER SWITCH 1

SECTION IX

FIGURES

FIGURE NUMBER DESCRIPTION PAGE

1 CONTROL IDENTIFICATION 13
2 CONNECTION - OUTPUT 14

3 CONNECTION - INPUT 14

4 CONNECTION - THERMOCOUPLE INPUT 14

5 CONNECTION - THERMOCOUPLE INPUT WITH REFERENCE 15

6 CONNECTION - THERMOCOUPLE INPUT WITH MODEL 1013 15

7 BLOCK DIAGRAM - INPUT BOARD 16

8 SCHEMATIC - INPUT BOARD 17

9 BLOCK DIAGRAM - DVM BOARD 18

10 SCHEMATIC - DVM BOARD 19

11 CALIBRATION CONTROL LOCATION 20

12 FUSE LOCATION 20

13 LOW BATTERY INDICATOR SCHEMATIC 21

PAGE 12
CONTROL IDENTIFICATION

lftANS:V.ATI®N inc. I
IOCHUTf •• N.Y. US.A

U.S. PATENT NO. 3.Sq10S

FIG. 1

PAGE 13
CONNECTION DIAGRAM CONNECTION DIAGRAM CONNECTION DIAGRAM
OUTPUT INPUT THERMOCOUPLE INPUT

THERMOMETER TO

'I
MEASURE TERMINAL
TEMPERATURE

VIN/OUT +
VOLTAGE OUIPUT ~ VIN/OUT
+
VOLTAGE INPUT
\ - I
~ MILLIVOLT OUTPUT ,..-...... MILL! VOLT INPUI
-·@
MAIN

+@
~

~ MA;@ I
-
CURRENT INPUT
+ }
MA IN '.:::::./

+@
RED WIRE ....:t
,......j

~
PS

+
CURRENT OUTPUT t @@
+
@@
- +
MA OUT MA OUT

TWO WIRE+TRANSMITTER \ @@ @@
SIMULATOR OUIPUT +-
XMTR SIM
-XMTR SIM
+

FIG 2 FIG 3 FIG 4

 CONNECTION DIAGRAM THERMOCOUPLE
INPUT WITH REFERENCE

RED

POS POS

+
RED

+
TRANSMATION
VIN/OUT
MODEL 1010
REFERENCE CELL

+0

FIGURE 5

TYPICAL ICE CELL HOOK- UP

THERMOCOUPLE MEASUREMENT

POS. T/C NEG. T/C

LEAD (YEL) LEAD (RED)

eTe (!)0
J
~~~----------~+
QOFF
TKJ
V IN/OUT
V IN/OUT FIGURE 6

TRANSMATION MODEL 1040

TRANSMATION MODEL 1013 THRice CELL

PAGE 15
 INPUT BOARD BLOCK DIAGRAM
V IN 0

0---~-~:.A-MP-----~~
I..
_VM_.... --~I I
1

>>--:I_D
MV I N
DISPUY
..Lr-----&.lilll'v
-
•
MA IN
PRECISION
CURRENT
SHUNT

INPUTS --
---------------------
OUTPUTS
S2
•

+40V

VOLTAGE
REFERENCE

- • vour

MV OUT
DVM DISPLAY

--•
FIGURE 7
+4ov 0 0+
MA our
V TO I AMP
B'

A'

DVM
A

DISPLAY
y-
-
SIM

PAGE 16
- -
• •
 2 3 4 5 6 7 8 9 10
owe. . No.
1
. , 1 1 1 1 1 1 1 J-_ _:A.::,:PP~L:_:;IC:_:AT~IO:.:_:N_--t-u"-"-''_o'_"'_"w_
•s_
"_••_
c•_"'--1o ~ D
1'0•0 •7•2•4 • ' 1•0•3• A ~:::.;_;:=.:.:.__+-=...:;_-1 ~~~:~!~~~~ ~~[
I I I I 1 I • ' I I I' IN INCHES
lf'ANSM-~."-T.~e.,~••l•no.
-. ,. NOTES : (1) UNLESS OTHERWISE SPECIFIED, ALL RESISTORS ARE IN OHMS, AND ALL CAPACITOR
• ..., "" ANCLES ~----=s":":'"JM=P~L=JF=JED~s=c::-:-H=EM:-:-fi..n:;::;-::Jc::-i VALUES ARE IN MFD .
(2) F1 & F2 ARE 1/10 AMP~ (100 MA) FUSES, LITTELFUSE TYPE 273.100 OR EQUIVALENT. H
c 1040 (3) A1,A2, & A3 USE TRAN~MATION PART NO. 603004-006.
INPUT BOARD
MATERIAL FINISH

+15V.
0
G G

Rll

00

~
;::::1
F STABILIZED ~ENER F
c.!>
REFERENCE SUPPLY H
~

E E

VIN/OUT

+15V.
MAIN
D ..-....o
Rl4
IK + ~

~
c.!>
~
P-1-

+
MAOUT
c c

-15V.
s1 R44 FROM DVM
SWITCH POSITION S +t5V.~+I5V.
10
1. 0-11 V. IN IN459A
+
2. 0-110 MV. IN XMTR
3 . MA. IN SIM
B 4. 0-11V. OUT B
5. 0-110 MV. OUT ,__.....__ _......~ CONV TO D.C.
6. MA . OUT
7. XMTR. S IM. CONVERTER
~--'li.ll +5V.

A A

5 6 8 9
 A7 A9
INPUT
..., BUFFER GATED FLIP FLOP
INP UT COMPARATOR
+
A1
- ,....
-+
C10 *
.....
A2
A4

D Q CL
DISPLAY

I ... - ,... r-- CL Q 1-- TRANS

R56
PRECISION
-'\l·.·~ ~ RESET
PULSE SHAFER

REF .
VOLTAGE
I AS A6
~
CLOCK DIVIDER
CHAIN
+SV
COUNTER/
DC TO DC DECODER
CONVERTER

+40V
,:. BATTERY +15V
FIGURE 9
ov
--
• -15V

BATTERY
CHARGER
DVM BLOCK DIAGRAM
11 7 VAG
 I -----··_j_
?_ __ _ - 1_ __ --~ - - --- - l__ _ 4 _j__ __ 5_
+5V

•I

DC - DC CONVERTER

TO PIN 24 OF
MK5002P

TO PIN 25 OF
·- 6.2v MK5002P
0 1

foxj
H
GJ SO&K

c::
~
~

p;
0

;;- -- 10 12
CALIBRATION CONTROL LOCATION

R45 IRS R28

R18 R17 R9

E) eJ Jj
BOTTOM VIEW BATTERY PACK REMOVED DVM BOARD

FIGURE 11

FUSE LOCATION

VIEW TOP COVER REMOVED

FIGURE 12

PAGE 20
 0

-~

R3
B+ ~----~r-------~~--~~r---~~---------------
+5V. 100
R1
470

0
0
OJ ~

R8 )>

150K VRI 'U

IN4734 ~
t-+-+-+--+-+-+--l n)>
R7 c 0"'"
150K 0 z
0
z

N
.......
GND~--------------t-----------------~~------------_j

!lO i I r,: ( 1) UtH.tSS 8TIERW I SE s r :C I ; l tD. All. RESI)l Oq_ v.~LUES ARE IN Gill''~ t.l-.0 tiL (.'.f ' t.Ci l )R VI\LLJIS ,\Ri l'l 1·\ID.

( 2) U l~llSS CIH R\·J I SE c;rrc l : l ED ALL Rt.SI ')TJf{~ ARE CAR ;~O I~ CQI\f''(Jrlll!'l. 1/ :M .. '1 l

t"%j ( 3) R~! 1':; A FL.CTORY SilFCfEl ' RE'SISTOR .

H
Q
c::
~
......
w