Burster 86-2113 User manual

burster Italia s.r.l. ·
· ·
· Sede legale ed operativa ·
· ·
· Via Cesare Battisti, 16/18 · 2403 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 110484001 1 · Capitale sociale Euro 49.920,00 ·
··
· R.E.A. di Bergamo 276749
Apparecchi di misura di precisione. Sensori e Sistemi
per grandezze elettriche, termiche e meccaniche
Operation Manual for
Torque Sensors
For below and similar Types
86-2113
86-2413
86-2493
86-2153
86-2453
86-2494

burster Italia s.r.l. ·
· ·
· Sede legale ed operativa ·
· ·
· Via Cesare Battisti, 16/18 · 2403 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 110484001 1 · Capitale sociale Euro 49.920,00 ·
··
· R.E.A. di Bergamo 276749
Apparecchi di misura di precisione. Sensori e Sistemi
per grandezze elettriche, termiche e meccaniche
Imprint
Valid for... 86-2113; 86-2413; 86-2493;
86-2153; 86-2453; 86-2494
and similar.
Reprint-Interdiction Reprint, even in extracts, only with written authorization.
Modification Technical changes reserved.
References in this Text
1.6 Warning Notes; Page 5
Attention must be paid to the accident prevention regulations of the trade associations.
Coverings and casings are necessary before operating the sensor. This is also valid for
commissioning, maintenance and trouble shooting.
Duties of the coverings and casings are:
⇒Protection from detaching parts
⇒Protection from contusion and shear
⇒Prevention from reaching rotating parts
⇒Prevention from being tangled up and/or getting caught by parts
Coverings may
⇒Not grind
⇒Not rotate
Coverings are also necessary outside of operating and motion travel areas of persons.
These demands can be modified if other sufficient safety devices are available. During
operation, the safety precautions must be operative. By vibrations, damages can occur at
hand-guided devices which can lead to injuries.
4 Mechanical Assembly; Page 7
Caution:
During the assembly inadmissibly large forces may not act on the sensor or the
couplings.
During the assembly the sensor must be supported to protect it from falling down.
4.1 Typical Application; Page 8
Caution: Do not use pulse or impact wrenches!!
6.1 Engaging; Page 10
Warming-up period of the torque sensor is approx. 5 min.
6.4.2 Natural Resonances; Page 11
An operation of the device in natural resonance can lead to permanent damages.

burster Italia s.r.l. ·
· ·
· Sede legale ed operativa ·
· ·
· Via Cesare Battisti, 16/18 · 2403 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 110484001 1 · Capitale sociale Euro 49.920,00 ·
··
· R.E.A. di Bergamo 276749
Apparecchi di misura di precisione. Sensori e Sistemi
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Contents
1Read First ......................................................................................................................................................4
1.1 Safety and Caution Symbols..................................................................................................................4
1.2 Intended Use..........................................................................................................................................4
1.3 Dangers..................................................................................................................................................4
1.3.1 Neglecting of Safety Notes.............................................................................................................4
1.3.2 Remaining Dangers........................................................................................................................4
1.4 Reconstructions and Modifications ........................................................................................................4
1.5 Personnel...............................................................................................................................................4
1.6 Warning Notes .......................................................................................................................................5
2Term Definitions.............................................................................................................................................5
2.1 Terms.....................................................................................................................................................5
2.2 Definition of the Pictograms on the Torque Sensor ...............................................................................5
3Product Description .......................................................................................................................................5
3.1 Mechanical Setup...................................................................................................................................6
3.2 Electrical Setup ......................................................................................................................................6
3.2.1 Sensors with Analog Output...........................................................................................................7
3.2.2 Sensors with RS485 Interface........................................................................................................7
3.2.3 The Serial Communication .............................................................................................................7
4Mechanical Assembly....................................................................................................................................7
4.1 Typical Application .................................................................................................................................8
4.2 Housing Fixation ....................................................................................................................................8
5Electrical Connection.....................................................................................................................................9
5.1 Pin Connection.......................................................................................................................................9
5.2 Calibration Control .................................................................................................................................9
5.2.1 Calibration Control at Analog Output............................................................................................10
5.2.2 Calibration Control at RS485........................................................................................................10
5.3 Cable....................................................................................................................................................10
5.4 Shielding Connection ...........................................................................................................................10
5.5 Running of Measuring Cables..............................................................................................................10
5.6 Angle (Option).....................................................................................................................................10
6Measuring....................................................................................................................................................11
6.1 Engaging..............................................................................................................................................11
6.2 Direction of Torque...............................................................................................................................11
6.3 Static / Quasi-Static Torques ...............................................................................................................11
6.4 Dynamic Torques.................................................................................................................................11
6.4.1 General.........................................................................................................................................11
6.4.2 Natural Resonances.....................................................................................................................11
6.5 Speed Limits ........................................................................................................................................11
6.6 Disturbance Variables..........................................................................................................................11
7Maintenance................................................................................................................................................12
7.1 Maintenance Schedule.........................................................................................................................12
7.2 Trouble Shooting..................................................................................................................................12
8Decommission .............................................................................................................................................12
9Transportation and Storage.........................................................................................................................13
9.1 Transportation......................................................................................................................................13
9.2 Storage.................................................................................................................................................13
10 Disposal ...................................................................................................................................................13
11 Calibration................................................................................................................................................13
11.1 Proprietary Calibration......................................................................................................................13
11.2 DKD-Calibration ...............................................................................................................................13
11.3 Re-Calibration ..................................................................................................................................13
12 Data Sheet...............................................................................................................................................13

burster Italia s.r.l. ·
· ·
· Sede legale ed operativa ·
· ·
· Via Cesare Battisti, 16/18 · 2403 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 110484001 1 · Capitale sociale Euro 49.920,00 ·
··
· R.E.A. di Bergamo 276749
Apparecchi di misura di precisione. Sensori e Sistemi
per grandezze elettriche, termiche e meccaniche
1 Read First
1.1 Safety and Caution Symbols
Caution:
Injury Risk for Persons
Damage of the Device is possible
Note:
Important points to be considered
1.2 Intended Use
Torque sensors are intended for the measurement of torques. This measurand is further suitable for control tasks. The valid
safety regulations should be absolutely respected. The torque sensors are not safety components in the sense of the
intended use. The sensors need to be transported and stored appropriately. The assembly, commissioning and
disassembling must take place professionally.
1.3 Dangers
The torque sensor is fail-safe and corresponds to the state of technology.
1.3.1 Neglecting of Safety Notes
At inappropriate use, remaining dangers can emerge (e.g. by untrained personnel). The operation manual must be read and
understood by each person entrusted with the assembly, maintenance, repair, operation and disassembly of the torque
sensor.
1.3.2 Remaining Dangers
The plant designer, the supplier, as well as the operator must plan, realize and take responsibility for safety-related interests
for the sensor. Remaining dangers must be minimized. Remaining dangers of the torque measurement technique must be
pointed out.
Human mistakes must be considered. The construction of the plant must be suitable for the avoidance of dangers. A
danger-analysis for the plant must be carried out.
1.4 Reconstructions and Modifications
Each modification of the sensors without our written approval excludes liability on our part.
1.5 Personnel
The installation, assembly, commissioning, operation and the disassembly must be carried out by qualified personnel only.
The personnel must have the knowledge and make use of the legal regulations and safety instructions.

burster Italia s.r.l. ·
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· Sede legale ed operativa ·
· ·
· Via Cesare Battisti, 16/18 · 2403 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 110484001 1 · Capitale sociale Euro 49.920,00 ·
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· R.E.A. di Bergamo 276749
Apparecchi di misura di precisione. Sensori e Sistemi
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1.6 Warning Notes
Attention must be paid to the accident prevention regulations of the trade associations.
Coverings and casings are necessary before operating the sensor. This is also valid for commissioning,
maintenance and trouble shooting.
Duties of the coverings and casings are:
⇒Protection from detaching parts
⇒Protection from contusion and shear
⇒Prevention from reaching rotating parts
⇒Prevention from being tangled up and/or getting caught by parts
Coverings may
⇒Not grind
⇒Not rotate
Coverings are also necessary outside of operating and motion travel areas of persons. These demands
can be modified if other sufficient safety devices are available. During operation, the safety precautions
must be operative. By vibrations, damages can occur at hand-guided devices which can lead to injuries.
2 Term Definitions
2.1 Terms
Measuring Side:
Mechanical connection of the torque sensor in which the torque to be measured is applied. Usually this side has the
smallest moment of inertia.
Drive Side:
Mechanical connection of the torque sensor on the opposite side of the measuring side, usually with the largest moment of
inertia. At static torque sensors the housing is fastened on this side.
2.2 Definition of the Pictograms on the Torque Sensor
The measuring side of the torque sensor is designated as follows:
Measuring side:
or
M
More information can be found on the data sheet, if needed.
3 Product Description
These sensors measure static and dynamic torques.
Caution: it must be differentiated between drive side and measuring side, see data sheet of the sensor: www.burster.it
M

burster Italia s.r.l. ·
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· Via Cesare Battisti, 16/18 · 2403 Curno (BG) · Tel. [phone] · Fax [phone]
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3.1 Mechanical Setup
The sensors consist of a torsion shaft. Depending on design, the mechanical connection possibilities are square or hexagon
connections. The torsion shaft, applied with two strain gauge full bridges, is bedded in a housing through ball bearings. For
the signal transmission and/or the supply of the strain gauge full bridges, a rotating transformer, according to the principle of
a transformer, is arranged in the sensor. For supply and measuring signal conditioning, electronics are integrated in the
stator and the rotor.
3.2 Electrical Setup
The supply of the rotor electronics occurs by an alternating voltage, generated in the stator, which transfers to the rotor
through a rotating transformer. There, it is rectified and stabilized. With this supply, the strain gauge bridge is fed.
For the electrical calibration control of the sensor, a control signal is up-modulated to the supply by the µ-processor in the
stator and transferred to the rotor. There, it is filtered and evaluated by the µPC, which also activates the internal switch for
the detuning of the strain gauge bridge.
The measuring signal of the strain gauge bridge is conditioned in an amplifier and then converted into a digital signal, which
will be transferred to the stator by another rotating transformer. Compared to the analog signal, the measuring signal in
digital form is much more disturbance-free. The remaining distance of the measuring signal within the sensor occurs in
digital form, completely. Thus, the measuring system achieves a high reliability of operation.
This signal is further conditioned in the stator, comes into a µ-processor, then - depending upon sensor type - it is converted
to a voltage signal, digital signal or to current and will then reach the output of the sensor and can be directly measured at
the connector.
SG
Rotating transformer Shaft
Measuring sideDrive side
Electronics in the stator
Option
Angle Sensor
Electronics in the rotor

burster Italia s.r.l. ·
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DC / DC
Oscillator
4 MHz
Signal
Conditioning
Signal Adaption
Analog or Digital
Signal
Conditioning
A/D-Converter
± 11 bit
± 15 bit
µ - Processor
µ - Processor
Rotation Angle (Option)
SG
Supply
Voltage
Calibration
Control
Signal
Output
Rotation
Angle Output
( Option )
Amplifier
Stator Rotor
Rotating Transformer
Serial Data Transmission
A
B
AC
DC
Filter for
Control Signal
Cycle and
Control Signal
Supply and
Control Signal
Rotating Transformer
Block diagram for serial signal transmission
3.2.1 Sensors with Analog Output
At this output, the digital signal is converted into DC voltage of 0 V ±5 V, proportionally to the torque and is available at the
connector output.
3.2.2 Sensors with RS485 Interface
The torque sensor has a digital interface RS485 for the signal output and automatic sensor identification.
The protocol enables high dynamics.
See separate manual for further information.
3.2.3 The Serial Communication
See Protocol, Document Number 090110.
4 Mechanical Assembly
Caution:
During the assembly inadmissibly large forces may not act on the sensor or the couplings.
During the assembly the sensor must be supported to protect it from falling down.

burster Italia s.r.l. ·
· ·
· Sede legale ed operativa ·
· ·
· Via Cesare Battisti, 16/18 · 2403 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 110484001 1 · Capitale sociale Euro 49.920,00 ·
··
· R.E.A. di Bergamo 276749
Apparecchi di misura di precisione. Sensori e Sistemi
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4.1 Typical Application
Caution: Do not use pulse or impact wrenches!
4.2 Housing Fixation
The housing may not rotate. This must be avoided by a flexible fixation (axial and radial tolerance must be available). The
connection cable may not be used as a twist lock.
See data sheet for the exact position of the threaded holes.
Fixation examples:
Coil spring; thread rod with dead stop.
ACCU Schrauber
Fixation
Slip ring
sensor
Clip-on tool
Threaded holes for fastening of flexible housing fixation
Hazards by vibrations
must be avoided!

burster Italia s.r.l. ·
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· Via Cesare Battisti, 16/18 · 2403 Curno (BG) · Tel. [phone] · Fax [phone]
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C.F. e P.IVA 110484001 1 · Capitale sociale Euro 49.920,00 ·
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5 Electrical Connection
5.1 Pin Connection
Also see test certificate
8-pin Analog
View: socket on soldering side
1 Excitation + 12 ... 28 VDC
2 Excitation GND 0 V
3 Signal ±5 V / (±10
V)
4 Signal GND 0 V
5 Calibration
control L<2,0 V; H>3,5 V
6 Option angle A TTL
7 Option angle B TTL
8 NC
12-
pin Analog
Digital
View: socket on soldering side
A NC NC
B Option angle B TTL Option angle B TTL
C Signal ±5 V / (±10
V) NC
D Signal GND 0 V NC
E Excitation GND 0 V Excitation GND 0 V
F Excitation + 12 ... 28 VDC Excitation + 12 ... 28 VDC
G Option angle A TTL Option angle A TTL
H NC NC
J NC Output B RS485
K Calibration
control L<2,0 V; H>3,5 V NC
L NC Output A RS485
M Housing Housing
5.2 Calibration Control
Only use calibration control in unloaded condition of the torque sensor

burster Italia s.r.l. ·
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8-pin 12-pin Function
Pin 2 E Excitation GND
Pin 5 K Calibration control
5.2.1 Calibration Control at Analog Output
Applying of voltage +5 V up to +28 V will enable the calibration
control.
Voltage below 2,8 V will disable the calibration control.
5.2.2 Calibration Control at RS485
The switch on of calibration control is carried out by a command.
For this, see command SCMD_WriteFullStroke from protocol (document no. 090110).
5.3 Cable
Only use a shielded cable with preferably small capacity. We recommend measuring cables from our product range. They
have been tested in combination with our sensors and meet the metrological requirements.
5.4 Shielding Connection
In combination with the sensor and the external electronics, the shield forms a Faraday Cage. By this, electro-magnetic
disturbances do not have any influence on the measurement signal.
5.5 Running of Measuring Cables
Do not run measuring cables together with control or heavy-current cables. Always assure that a large distance is kept to
engines, transformers and contactors, because their stray fields can lead to interferences of the measuring signals.
If troubles occur through the measuring cable, we recommend to run the cable in a grounded steel conduit.
5.6 Angle (Option)
At angle or speed measurement, the pulses / revolutions are acquired. By a
second transmitter trace, displaced by 90° and flank evaluation, the
pulses/ revolutions can be quadrupled. The trace, displaced by 90°, can
also be used for the rotational direction detection.
See corresponding data sheet for the output levels.
Supply for angle sensor
Stabilized supply voltage 5 V ±25 mV
Current consumption max. 20 mA
Connection example for 8-pin connector
3,5 VDC < U
kal
< 28 VDC
+
U
kal
Exc. GND
Cal. control

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6 Measuring
6.1 Engaging
The warming-up period of the torque sensor is approx. 5 min. Afterwards the measurement can be started.
The warming-up period of the torque sensor is approx. 5 min.
6.2 Direction of Torque
Torque means clockwise or clockwise torque if the torque acts clockwise when facing the shaft end. In this case a positive
electrical signal is obtained at the output.
Torque sensors by burster can measure both, clockwise and counter-clockwise direction.
6.3 Static / Quasi-Static Torques
Static and/or quasi-static torque is a slowly changing torque.
The calibration of the sensors occurs statically on a calibration device.
The applied torque may accept any value up to the nominal torque.
6.4 Dynamic Torques
6.4.1 General
The static calibration procedure of torque sensors is also valid for dynamic applications.
Note: The frequency of torques must be smaller than the natural frequency of the mechanical measurement setup.
The band width of alternating torque must be limited to 70 % of the nominal torque.
6.4.2 Natural Resonances
Estimate of the mechanical natural frequencies:







+⋅⋅
⋅
=
21
0
11
21JJ
cf
π
f
0
J
1
, J
2
c
= Natural Frequency in Hz
= Moment of Inertia in kg*m²
= Torsional Rigidity in Nm/rad
Further methods for the calculation of natural resonances are corresponding purchasable programs or books (e.g. Holzer-
Procedure, Dubbel, Taschenbuch für den Maschinenbau, Springer Verlag)
An operation of the device in natural resonance can lead to permanent damages.
6.5 Speed Limits
The maximum speed indicated in the data sheet may not be exceeded in any operating state..
6.6 Disturbance Variables
By disturbances, measured value falsifications can occur by
•Vibrations,
•Temperature gradients,
•Temperature changes,
•Arising disturbance variables during operation, e.g. imbalance,
•Electrical disturbances,
•Magnetic disturbances,
•EMC (electromagnetic disturbances),
Therefore avoid these disturbance variables by decoupling of vibrations, covers, etc.
c
J
1
J
2

burster Italia s.r.l. ·
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C.F. e P.IVA 110484001 1 · Capitale sociale Euro 49.920,00 ·
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7 Maintenance
7.1 Maintenance Schedule
Action Frequency Date Date Date
Control of cables and connectors 1x p.a.
Calibration < 26 months
Control of fixation (flanges, shafts) 1x p.a.
Have bearings exchanged by burster 20000 hrs
operating time
7.2 Trouble Shooting
This chart is used for searching for the most frequent errors and their elimination
Problem Possible Cause Trouble Shooting
No signal No sensor excitation
•
Outside of permissible range
•Connect excitation
•Cable defect
•No mains supply
Signal output connected wrong
•
Connect output correctly
•Evaluation electronics defect
Sensor does not react to torque Shaft not clamped
•
Clamp correctly
No power supply
•
Outside of permissible range
•Connect supply
•Cable defect
•No mains supply
Cable defect
•
Repair cable
Connector connected wrong
•
Connect correctly
Signal has dropouts Axial position rotor to stator outside
of tolerance
•
Align rotor
Cable defect
•
Repair cable
Zero point outside of tolerance Cable defect
•
Repair cable
Shaft mounted distorted
•
Mount correctly
Distorted shaft string
•
Release from distortion
Strong lateral forces
•
Reduce lateral forces
Distorted flanges
•
Check evenness of flange-
surfaces
Shaft overloaded
•
Send to manufacturer
Wrong torque indication Calibration not correct
•
Re-calibrate
Sensor defect
•
Repair by manufacturer
Torque shunt
•
Eliminate shunt
Oscillations Alignment of shaft not correct
•
Align correctly
Unbalance
•
Balance the corresponding
parts
8 Decommission
All sensors must be dismantled professionally. Do not strike sensor housings with tools. Do not apply bending moments on
the sensor, e.g. through levers. The torque sensor must be supported to avoid falling down during the dismantling.

burster Italia s.r.l. ·
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· Via Cesare Battisti, 16/18 · 2403 Curno (BG) · Tel. [phone] · Fax [phone]
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C.F. e P.IVA 110484001 1 · Capitale sociale Euro 49.920,00 ·
··
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9 Transportation and Storage
The transportation of the sensors must occur in suitable packing.
For smaller sensors, stable cartons which are well padded are sufficient (e.g., air cushion film, epoxy crisps, paper
shavings). The sensor should be tidily packed into film so that no packing material can reach into the sensor (ball bearings).
Larger sensors should be packed in cases.
9.1 Transportation
Only release well packed sensors for transportation. The sensor should not be able to move back and forth in the packing.
The sensors must be protected from moisture.
Only use suitable means of transportation.
9.2 Storage
The storage of the sensors must occur in dry, dust-free rooms, only.
Slightly lubricate shafts and flanges with oil before storing (rust).
10 Disposal
The torque sensors must be disposed according to the valid provisions of law.
For this, see our “General Terms and Conditions” www.burster.it
11 Calibration
At the time of delivery, torque sensors have been adjusted and tested with traceable calibrated measuring equipment at
factory side. Optionally, a calibration of the sensors can be carried out.
11.1 Proprietary Calibration
Acquisition of measurement points and issuing of a calibration protocol Traceable calibrated measuring equipment is being
used for the calibration. The sensor data are being checked during this calibration.
11.2 DKD-Calibration
The calibration of the sensor is carried out according to the guidelines of the DKD. The surveillance of the calibrating-
laboratory takes place by the DKD. At this calibration, the uncertainty of measurement of the torque measuring instrument is
determined. Further information can be obtained from burster.
11.3 Re-Calibration
The recalibration of the torque sensor should be carried out after 26 months at the latest.
Shorter intervals are appropriate:
•Overload of the sensor
•After repair
•After inappropriate handling
•Demand of high-quality standards
•Special traceability requirements
12 Data Sheet
See www.burster.it