Burster 86-2500 User manual

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · Capitale sociale Euro 49.920,00 ·R.E.A. di Bergamo 276749
Apparecchi di misura di precisione. Sensori e Sistemi
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Operation Manual for
Torque Sensors
For below and similar Types
86-2500 / 86-2600

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · 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... Torque Sensor Type 86-2500 / 86-2600
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 the
device.
4 Mechanical Assembly; Page 8
Caution: During the assembly inadmissibly large forces may not act on the sensor or the
couplings. At small torques (< 20 N·m) connect the sensor electrically during the assembly and
observe the signal, the measurement signal may not exceed the limit values.
During the assembly the sensor must be supported to protect it from falling down.
At torques < 20 N·m always start the assembly at the low torque resistance side
Admissible assembly offset from rotor to stator: axial ±1 mm.
4.1.3 Alignment of the Measurement Arrangement; Page 9
For further references see coupling manual of the coupling producer and/or the data sheet.
4.2 Assembly Possibility Stator; Page 9
The thread depth must be considered (possible damage of the stator electronics).
See data sheet.
4.5 Installation Instruction; Page 10
Treat the sensor with utmost care.
Do not apply bending moment or torque to the sensor.
Store or transport the sensor with fixing half shells only.
Only use single-jointed couplings on both sides.
6.1 Engaging; Page 15
Warming-up period of the torque sensor is approx. 5 min.
6.4.2 Natural Resonances; Page 15
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 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · 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
Contents
1Read First......................................................................................................................................................5
1.1 Safety and Caution Symbols..................................................................................................................5
1.2 Intended Use..........................................................................................................................................5
1.3 Dangers..................................................................................................................................................5
1.3.1 Neglecting of Safety Notes.............................................................................................................5
1.3.2 Remaining Dangers........................................................................................................................5
1.4 Reconstructions and Modifications ........................................................................................................5
1.5 Personnel...............................................................................................................................................5
1.6 Warning Notes .......................................................................................................................................5
2Term Definitions.............................................................................................................................................6
2.1 Terms.....................................................................................................................................................6
2.2 Definition of the Pictograms on the Torque Sensor ...............................................................................6
3Product Description .......................................................................................................................................6
3.1 Mechanical Setup..................................................................................................................................6
3.2 Electrical Setup ......................................................................................................................................7
3.2.1 Sensors with Analog Output...........................................................................................................7
3.2.2 Sensors with Interface RS485........................................................................................................7
3.2.3 The Serial Communication .............................................................................................................7
4Mechanical Assembly....................................................................................................................................8
4.1 Couplings ...............................................................................................................................................8
4.1.1 Examples for Single-Jointed Couplings........................................................................................8
4.1.2 Misalignment Possibilities of Single-Jointed Couplings..................................................................8
4.1.3 Alignment of the Measurement Arrangement.................................................................................9
4.2 Assembly Possibility Stator....................................................................................................................9
4.3 Fixing Half Shells ...................................................................................................................................9
4.3.1 Nominal torque up to 10 N·m..........................................................................................................9
4.3.2 Nominal Torque 20 N·m up to 150 N·m........................................................................................10
4.4 Basic Assembly....................................................................................................................................10
4.5 Installation Instruction ..........................................................................................................................10
4.5.1 Installation Steps ..........................................................................................................................11
5Electrical Connection...................................................................................................................................13
5.1 Pin Connection.....................................................................................................................................13
5.2 Cable....................................................................................................................................................14
5.3 Shielding Connection ...........................................................................................................................14
5.4 Running of Measuring Cables..............................................................................................................14
5.5 Electrical Calibration ............................................................................................................................14
5.5.1 Switch-On of Calibration Control at Analog Output ......................................................................14
5.5.2 Calibration Control at RS485........................................................................................................14
5.6 Speed Sensor (Option) ........................................................................................................................14
6Measuring....................................................................................................................................................15
6.1 Engaging..............................................................................................................................................15
6.2 Direction of Torque...............................................................................................................................15
6.3 Static / Quasi-Static Torques ...............................................................................................................15
6.4 Dynamic Torques.................................................................................................................................15
6.4.1 General.........................................................................................................................................15
6.4.2 Natural Resonances.....................................................................................................................15
6.5 Speed Limits ........................................................................................................................................15
6.6 Disturbance Variables..........................................................................................................................15
7Maintenance................................................................................................................................................16
7.1 Maintenance Schedule.........................................................................................................................16
7.2 Trouble Shooting..................................................................................................................................16
8Decommission .............................................................................................................................................17
9Transportation and Storage.........................................................................................................................17
9.1 Transportation......................................................................................................................................17
9.2 Storage.................................................................................................................................................17
10 Disposal ...................................................................................................................................................17
11 Calibration................................................................................................................................................17

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · 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
11.1 Proprietary Calibration......................................................................................................................17
11.2 DKD-Calibration ...............................................................................................................................17
11.3 Re-Calibration ..................................................................................................................................17
12 Data Sheet........................................................................................................................................18

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · 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.
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 the
device.

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · 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
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.
Low Torque Resistance Side:
The shaft of the arrangement (drive, load) which can be turned considerably smaller with torque than the nominal torque of
the torque sensor M << Mnenn .
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
The sensor measures static and dynamic torques. The mounting position of the torque sensor is horizontally.
Caution: it is to be differentiated between measuring side and drive side, see data sheet of the sensor: http://www.burster.it
3.1 Mechanical Setup
The sensor consists of a stationary part, the stator and a rotary part, the rotor.
Stator Electronics
supply and measuring
amplifier
Rotor Electronics
supply of the strain
gauge full bridge and
the measuring amplifier
Stator
Rotating Transformer
signal transmission from stator
to rotor and contrariwise
Measuring Body
with strain gauge full
bridge
Cable Connection
electrical connection
Speed Sensor
Measuring Side
M

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · Capitale sociale Euro 49.920,00 ·R.E.A. di Bergamo 276749
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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.
DC / DC Oscillator
4
MHz
Signal
Conditioning
Signal Adaption
Analog or
Digital
Signal
Conditioning
A
/ D - Converter
± 15 bit
µ - Processor
µ-Processor
Speed (Option)
SG
Supply
Voltage
Calibration
Control
Signal
Output
Speed
Output
( Option )
Amplifier
Stator Rotor
Rotating Transformer
Serial Data Transmission
A
B
A
C
DC
Filter for
Control Signal
Cycle and
Control Signal
Supply and
Control Signal
Rotating Transformer
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 Interface RS485
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.

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · 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
4 Mechanical Assembly
Caution: During the assembly inadmissibly large forces may not act on the sensor or the couplings.
At small torques (< 20 N·m) connect the sensor electrically during the assembly and observe the
signal, the measurement signal may not exceed the limit values.
During the assembly the sensor must be supported to protect it from falling down.
At torques < 20 N·m always start the assembly at the low torque resistance side
Admissible assembly offset from rotor to stator: axial ±1 mm.
4.1 Couplings
4.1.1 Examples for Single-Jointed Couplings
For this torque sensor we recommend the couplings intended
by burster which must be able to balance an axial, radial or
angular offset of the shafts and not allow large forces to act on
the sensor.
4.1.2 Misalignment Possibilities of Single-Jointed Couplings
Note: Radial misalignments are only possible in the combination of
single-jointed coupling - torque sensor (as adapter) - single-jointed coupling.
Thus, with both single-jointed couplings the torque sensor forms a double-jointed coupling.
Angular Misalignments Axial Misalignments
Single-jointed Coupling Sin
g
le-
j
ointed Cou
p
lin
g
Torque Sensor
Radial Misalignments

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · Capitale sociale Euro 49.920,00 ·R.E.A. di Bergamo 276749
Apparecchi di misura di precisione. Sensori e Sistemi
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4.1.3 Alignment of the Measurement Arrangement
Precisely alignment of the couplings reduces the reaction forces and increases the durability of the couplings. Disturbance
variables are minimized as well.
Due to the multitude of applications, an alignment of the coupling with a straight edge in two levels, vertical to each other, is
sufficient.
However, in drives with high speed an alignment of the coupling (shaft ends) with a dial gauge or a laser is recommended.
Further points to consider
•The axis height of the torque sensor (data sheet) must be considered as well.
•An air gap between rotor and stator must be existent. The rotor may not touch the stator in any operating state.
•Axial position of the rotor to the stator, see data sheet.
For further details see the manual for couplings and/or the data sheet.
4.2 Assembly Possibility Stator
Thread holes for fixation are available at the stator housing.
The thread depth must be considered (possible damage
of the stator electronics). See data sheet.
4.3 Fixing Half Shells
4.3.1 Nominal torque up to 10 N·m
Since the shaft has no bearings, the sensor is delivered with fixing half shells. The fixing half shells are used for the
positioning and the fixation of the shaft in the stator. At mounted half shells the shaft can be turned and it can also be
damaged by forces.
Remove the fixing half shells as described hereafter in chapter Installation Instruction.
Fixing Half Shells
Fixing Screws
M 2,5 x 4
Remove the fixing half shells after the sensor assembly
Torque Sensor
Shaft
Fixing half shells mounted

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · Capitale sociale Euro 49.920,00 ·R.E.A. di Bergamo 276749
Apparecchi di misura di precisione. Sensori e Sistemi
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4.3.2 Nominal Torque 20 N·m up to 150 N·m
Since the shaft has no bearings, the sensor is delivered with fixing half
shells. The fixing half shells are used for the positioning and the fixation
of the shaft in the stator. At mounted half shells the shaft can still be
turned.
4.4 Basic Assembly
4.5 Installation Instruction
Measuring Range: 0,005 N·m up to 150 N·m
Treat the sensor with utmost care.
Do not apply bending moment or torque to the sensor
Store or transport the sensor with fixing half shells only.
Only use single-jointed couplings on both sides.
The two coupling connections at customers side must be aligned exactly to each other. With the use of BSD THOMAS-
Miniature Couplings Type 966 the axial tension may not exceed the maximum of 0,2 mm and the angular offset may not
exceed the maximum of 0,5°.
First assure that the couplings can be easily shifted on the shaft ends.
The fixing half shells (shaft to housing) must stay in mounted condition at the beginning of the assembly.
The housing may be positioned firmly only after the fixing half shells have been removed.
86-2500
Measurin
g
Side
Specimen Load Machine
Single-Jointed
Coupling Single-Jointed
Coupling
Angle Support for Stator
O-Ring
Fixing Half Shells
Sensor