HBM S2M Series Installation instructions

A3592-1.1 de/en/fr
Force transducer
Kraftaufnehmer
Capteur de force
S2M
Mounting Instructions
Montageanleitung
Notice de montage

English Page 3 - 22.................................................
Deutsch Seite 23 - 43...............................................
Français Page 35 - 65...............................................

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Contents Page
English
Safety instructions 4..............................................
1 Scope of supply 8.............................................
2 General application instructions 8..............................
3 Structure and mode of operation 9..............................
3.1 Measuring body 9.........................................
3.2 Strain gauge covering agent 9...............................
3.3 Disturbance variables 9....................................
4 Conditions on site 10...........................................
4.1 Ambient temperature 10.....................................
4.2 Moisture and humidity 10....................................
4.3 Deposits 10................................................
5 Mechanical installation 12.......................................
5.1 Important precautions during installation 12....................
5.2 General installation guidelines 12.............................
5.3 Mounting the S2M 14.......................................
5.3.1 Mounting with tension/compression bars 14..............
5.3.2 Mounting with direct connection 14......................
5.3.3 Mounting with knuckle eyes 14.........................
6 Electrical connection 18.........................................
6.1 Connection in a six‐wire configuration 18......................
6.2 Connection in a four‐wire configuration 18.....................
6.3 Shortening the cable 19.....................................
6.4 Extension cable 19.........................................
6.5 EMC protection 19..........................................
7 Specifications (VDI/VDE/DKD 2638) 20............................
8 Dimensions 22.................................................

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Safety instructions
Designated use
The force transducers in the type series S2M are solely designed for measur-
ing static and dynamic tensile and/or compressive forces within the load limits
specified by the technical data for the respective maximum capacities. Any
other use is not the designated use.
To ensure safe operation, the regulations in the mounting and operating
instructions, together with the following safety rules and regulations, and the
data specified in the technical data sheets, must be complied with. It is also
essential to observe the applicable legal and safety regulations for the applic-
ation concerned.
The force transducers are not intended for use as safety components. Please
also refer to the section: “Additional safety precautions". Proper and safe
operation of force transducers requires proper transportation, correct storage,
siting and mounting, and careful operation.
Loading capacity limits
The data in the technical data sheet must be complied with when using the
force transducer. In particular, the respective maximum loads specified must
never be exceeded. The following limits set out in the technical data sheets
must not be exceeded
Limit loads
Lateral load limits
Breaking loads
Permissible dynamic loads
Temperature limits
Limits of electrical loading capacity
Please note that when several force transducers are interconnected, the load
/force distribution is not always uniform.
Use as a machine element
The force transducers can be used as machine elements. When used in this
manner, it must be noted that, to favor greater sensitivity, the force transducer
was not designed with the safety factors usual in mechanical engineering.
Please refer here to the section “Loading capacity limits" and to the specifica-
tions.

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Accident prevention
The prevailing accident prevention regulations must be taken into account,
even though the nominal (rated) force values in the destructive range are well
in excess of the full scale value.
Additional safety precautions
The force transducers cannot (as passive transducers) implement any
(safety‐relevant) cutoffs. This requires additional components and construct-
ive measures for which the installer and operator of the plant is responsible.
In cases where a breakage or malfunction of the force transducer would
cause injury to persons or damage to equipment, the user must take appropri-
ate additional safety precautions that meet at least the requirements of applic-
able safety and accident prevention regulations (e.g. automatic emergency
shutdown, overload protection, catch straps or chains, or other fall protection).
The layout of the electronics conditioning the measurement signal should be
such that measurement signal failure does not cause damage.
General dangers of failing to follow the safety instructions
The force transducers are state‐of‐the‐art and reliable. There may be risks
involved if the transducers are mounted, sited, installed and operated inappro-
priately, or by untrained personnel. Every person involved with siting, start-
ing‐up, operating or repairing a force transducer must have read and under
stood the mounting instructions and in particular the technical safety
instructions. The force transducers can be damaged or destroyed by non‐des
ignated use of the force transducer or by non‐compliance with the mounting
and operating instructions, these safety instructions or any other applicable
safety regulations (BG safety and accident prevention regulations) when using
the force transducers. Force transducers can break, particularly in the case of
overloading. The breakage of a force transducer can also cause damage to
property or injury to persons in the vicinity of the force transducer.
If force transducers are not used according to their designated use, or if the
safety instructions or specifications in the mounting and operating instructions
are ignored, it is also possible that the force transducer may fail or malfunc-
tion, with the result that persons or property may be affected (due to the loads
acting on or being monitored by the force transducer).
The scope of supply and performance of the transducer covers only a small
area of force measurement technology, as measurements with (resistive)
strain gauge sensors presuppose the use of electronic signal conditioning. In
addition, equipment planners, installers and operators should plan, implement
and respond to the safety engineering considerations of force measurement
technology in such a way as to minimize residual dangers. On‐site regulations
must be complied with at all times.

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The marking below warns of a potentially dangerous situation in which failure
to comply with safety requirements can result in death or serious physical
injury.
WARNING
Description of a potentially dangerous situation
Measures to avoid/prevent the danger
The marking below warns of a potentially dangerous situation in which failure
to comply with safety requirements can result in slight or moderate physical
injury.
CAUTION
Description of a potentially dangerous situation
Measures to avoid/prevent the danger
The marking below draws your attention to a situation in which failure to com-
ply with safety requirements can lead to damage to property.
NOTE
Description of a situation that can lead to damage to property
The marking below draws your attention to important information about the
product or about handling the product.
Important
Important information
The marking below contains application tips or other information that is useful
to you.

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Tip
Information/application instruction
Conversions and modifications
The transducer must not be modified from the design or safety engineering
point of view except with our express agreement. Any modification shall
exclude all liability on our part for any damage resulting therefrom.
Maintenance
The S2M force transducer is maintenance free.
Disposal
In accordance with national and local environmental protection and material
recovery and recycling regulations, old transducers that can no longer be
used must be disposed of separately and not with normal household waste.
If you need more information about disposal, please contact your local author-
ities or the dealer from whom you purchased the product.
Qualified personnel
Qualified personnel means persons entrusted with siting, mounting, starting
up and operating the product, who possess the appropriate qualifications for
their function.
This includes people who meet at least one of the three following require-
ments:
- Knowledge of the safety concepts of automation technology is a require-
ment and as project personnel, you must be familiar with these concepts.
- As automation plant operating personnel, you have been instructed how to
handle the machinery. You are familiar with the operation of the equipment
and technologies described in this documentation.
- As system startup engineers or service engineers, you have successfully
completed the training to qualify you to repair the automation systems. You
are also authorized to activate, ground and label circuits and equipment in
accordance with safety engineering standards.
It is also essential to comply with the legal and safety requirements for the
application concerned during use. The same applies to the use of accessor-
ies.
The force transducer must only be installed by qualified personnel, strictly in
accordance with the specifications and with safety requirements and regula-
tions.

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1 Scope of supply
1 x S2M force transducer
1 x mounting instructions
1 x manufacturing certificate
Accessories (not included among the items supplied):
ZGW knuckle eye order no. 1-U1R/200KG/ZGW
2 General application instructions
The S2M type series force transducers are suitable for measuring tensile and
compressive forces. Because they provide highly accurate static and dynamic
force measurements, they must be handled very carefully. Particular care
must be taken when transporting and installing the devices. Dropping or
knocking the transducer may cause permanent damage.
The potting material (sealing for protection of sensitive strain gauge installa-
tions) must not be damaged, otherwise the transducer will become unusable.
The specifications list the permissible limits for mechanical, thermal and elec-
trical stress. It is essential that these are taken into account when planning the
measuring set‐up, during installation and, ultimately, during operation.

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3 Structure and mode of operation
3.1 Measuring body
The measuring body is an aluminum bending beam on which strain gauges
(SG) are installed. The SG are arranged so that two are stretched and the
other two compressed when a force acts on the transducer.
3.2 Strain gauge covering agent
To protect the SG, the S2M force transducers are potted with a plastic mater-
ial at an appropriate place. This procedure offers the SG high protection
against environmental influences. To retain the protective capacity and ensure
permanent functionality, the force transducer potting material must not
become damaged.
Potting material
Fig. 3.1: SG installation protection
3.3 Disturbance variables
Torsion, bending and lateral loads are disturbance variables and therefore to
be avoided.

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4 Conditions on site
Protect the transducer from weather conditions such as rain, snow, ice and
salt water.
4.1 Ambient temperature
The temperature effects on the zero signal and on the sensitivity are com-
pensated.
To obtain optimum measurement results, the nominal (rated) temperature
range must be observed. Constant, or very slowly changing temperatures are
optimal. Temperature‐related measurement errors are caused by heating on
one side (e.g. radiant heat) or by cooling. A radiation shield and all‐round
thermal insulation produce noticeable improvements, but must not be allowed
to set up a force shunt.
4.2 Moisture and humidity
Series S2M force transducers are protected against moisture. The trans-
ducers attain protection class IP67 per DIN EN60259. Despite this, force
transducers must be protected against permanent exposure to moisture.
The transducer must be protected against chemicals that could attack the alu-
minum, potting material or the cable.
The transducer can also malfunction due to corrosion. Implement some
means of protection if this danger exists.
NOTE
Moisture must not be allowed to penetrate the free end of the connection
cable. Otherwise the characteristic values of the transducer could vary, and
cause measurement errors.
4.3 Deposits
Dust, dirt and other foreign matter must not be allowed to accumulate suffi-
ciently to divert some of the force to be measured, thus invalidating the meas-
ured value (force shunt).

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NOTE
Measurement errors may be the result if dust or dirt is deposited inside the
load cells. The relevant areas are marked by arrows in Fig. 4.1.
The overload stop must remain free
Fig. 4.1: Deposits at the marked areas must be avoided

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5 Mechanical installation
5.1 Important precautions during installation
Handle the transducer with care.
Welding currents must not be allowed to flow over the transducer. If there is
a risk that this might happen, you must use a suitable low‐ohm connection
to electrically bypass the transducer. HBM, for example, provides the highly
flexible EEK ground cable, which can be screwed on above and below the
transducer.
Make sure that the transducer cannot be overloaded.
WARNING
There is a danger of the transducer breaking if it is overloaded. This can
cause danger for the operating personnel of the system in which the
transducer is installed.
Implement appropriate safety measures to avoid overloads or to protect
against the resulting dangers.
5.2 General installation guidelines
The forces to be measured must act on the transducer as accurately as pos-
sible in the direction of measurement. Torsional and bending moments,
eccentric loadings and lateral forces can produce measurement errors and
can destroy the transducer if limit values are exceeded. Interference effects
must be absorbed by suitable construction elements, whereby these elements
must not absorb any forces in the measuring direction of the transducer.
Screws, knuckle eyes and other customer‐side construction elements must be
screwed into the S2M in such a way that the construction element does not
touch the measuring body (potting material) even at full displacement.
NOTE
Do not loosen the hexagon socket screws (Allen screws) that connect the
force applications and the overload stop with the measuring body, as other-
wise the force transducer calibration could become invalid.

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Rigid force transferRigid force transfer
correct incorrect
Fig. 5.1 Transducer orientation during installation
Important
The cable fastening side of the transducer should always be connected dir-
ectly with the rigid customer‐side force transfer areas. Ensure that the cable is
laid so that, where possible, no force shunt is caused by the cable (e.g.
through the weight or stiffness of the cable), see Fig. 5.1.
NOTE
Please note the maximum permissible load-carrying capacity of the loading
fittings and of the tension/compression bars, screws and knuckle eyes.

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5.3 Mounting the S2M
5.3.1 Mounting with tension/compression bars
In this mounting variant, the transducer is mounted with tension/compression
bars on a construction element and can then be measured in the tensile and
compressive directions. Alternating loads are also correctly recorded if the
transducer is mounted without axial play. For dynamic alternating loads, the
upper and lower threaded connectors must be pre‐stressed to above the
maximum operating load and then locked in place.
1. Installation and locking with initial stress:
Screw in the threaded connector
Pre‐stress transducer to 110% operating load in tensile direction
Hand‐tighten locknut
Relieve load on transducer
The transducer itself can be used to measure the initial stress.
2. Installation and locking with torque
Screw in the threaded connector
Tighten locknut with a torque of 15Nm.
NOTE
When locking, the tightening torque must not be shunted through the trans-
ducer.
5.3.2 Mounting with direct connection
In this mounting variant, the transducer is mounted directly on an existing con-
struction element and can then measure in the tensile and compressive direc-
tions. Alternating loads are also correctly recorded if the transducer is moun-
ted without axial play. For dynamic alternating loads, the screw connected to
the rigid force transfer must be tightened with a torque of 15Nm.
5.3.3 Mounting with knuckle eyes
Knuckle eyes prevent the application of torsional moments on the transducer
and also, when 2 knuckle eyes are used, bending moments, together with
lateral and oblique loadings. Although if two knuckle eyes are used, only
tensile forces can be measured. Knuckle eyes are suitable for use with
quasi‐static loading (load cycles v10 Hz). Pliable tension/compression bars

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should be used for dynamic loads with higher frequencies (see Section
5.3.1 ).
1. Installation of knuckle eyes and locking with initial stress:
Rotate the locknut back to the eye.
Screw the knuckle eye completely into the transducer.
Unscrew the knuckle eye 1 to 2 threads and align.
Load the transducer with 110% of the force that will occur during sub-
sequent operation in the tensile direction.
Tighten the locknut by hand.
Relieve the load on the transducer.
2. Installation of knuckle eye and locking with torque:
Rotate the locknut back to the eye.
Screw the knuckle eye completely into the transducer.
Align the knuckle eye.
Tighten the locknut with a torque of 15 Nm.
NOTE
When locking, the tightening torque must not be shunted through the trans-
ducer.

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When using a knuckle eye, the following mounting dimensions apply:
Rigid force transfer
Dimensions (in mm; 1 mm = 0.03937 inches)
2 min
MB = 15 Nm
MB = 15 Nm
83 min / 85 max
Fig. 5.2 Installation with a knuckle eye

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When using two knuckle eyes, the following mounting dimensions apply:
Dimensions (in mm; 1 mm = 0.03937 inches)
Rigid force transfer
2 min
2 min
105 min / 110 max
MB = 15 Nm
MB = 15 Nm
Fig. 5.3 Installation with two knuckle eyes

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6 Electrical connection
The following can be connected for measurement signal conditioning:
Carrier‐frequency amplifier
DC amplifier
designed for strain gauge measurement systems.
The S2M force transducer is delivered in a six‐wire configuration.
6.1 Connection in a six‐wire configuration
The transducer is delivered with a 6 m cable with free ends as standard.
(white)
(black)
(gray)
Excitation voltage ())
(green)
(red)
(Shield)
Excitation voltage (*)
Sense lead (*)
Measurement signal ())
(blue) Sense lead ())
Measurement signal (*)
Cable shield, connected to the housing
Fig. 6.1: Pin assignment in a six‐wire circuit
With this cable assignment, the output voltage at the measuring amplifier is
positive in the tensile direction when the transducer is loaded.
The connection cable shielding is connected to the transducer housing. Trans-
ducers with free cable ends must be fitted with connectors complying with
EMC guidelines. The shielding must be connected extensively. With other
connection techniques, an EMC‐proof shield should be applied in the wire
area and this shielding should also be connected extensively (also see HBM
Greenline Information, brochure i1577).
6.2 Connection in a four‐wire configuration
When transducers with a six‐wire configuration are connected to amplifiers
with a four‐wire configuration, the sense leads of the transducer must be con-
nected to the corresponding supply leads: marking (+) with (+) and marking
(-) with (-), see Fig. 6.1. This measure also reduces the cable resistance of
the excitation voltage leads. However, there will be a voltage loss on the sup-
ply leads due to the cable resistance that is still present and not compensated
for by the six‐wire configuration. A large part of this loss can be eliminated by

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a calibration, however, the temperature‐dependent part remains. The TKc
value given in the specifications for the transducer therefore does not apply
for the cable and transducer combination when connection is with four‐wire
configuration, the cable percentage must be added.
6.3 Shortening the cable
As the transducer connection uses a six‐wire configuration, you can shorten
the 6‐wire transducer cable without affecting the measurement accuracy.
6.4 Extension cable
The cable of a six‐wire force transducer can be extended with a cable of the
same type.
Only use shielded, low‐capacitance measurement cables for extension.
Ensure that connection is perfect, with a low contact resistance.
6.5 EMC protection
Electrical and magnetic fields often induce interference voltages in the meas-
uring circuit. Therefore:
Use shielded, low‐capacitance measurement cables only (HBM cables
fulfill both conditions).
Do not route the measurement cables parallel to power lines and control
circuits. If this is not possible, protect the measurement cable withsteel
conduits, for example.
Avoid stray fields from transformers, motors and contact switches.
Do not ground the transducer, amplifier and indicator more than once.
Connect all devices in the measuring chain to the same protective earth
conductor.

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7 Specifications (VDI/VDE/DKD 2638)
Type S2M
Nominal (rated) force Fnom N 10 20 50 100 200 500 1000
Accuracy
Accuracy class 0.02
Relative reproducibility and
repeatability errors without
rotation brg
%
0.02
Relative reversibility error v0.02
Non‐linearity dlin 0.02
Relative creep over 30 min. dcr, F+E 0.02
Effect of the bending moment
at 10% Fnom * 10mm dc0.02
Effect of lateral forces
(lateral force = 10% Fnom)dQ0.02
Effect of temperature on
sensitivity: TKC% /
10 K
0.02
Effect of temperature on zero
signal TK00.02
Electrical characteristic values
Nominal (rated) sensitivity Cnom mV/V 2
Relative zero signal error dS, 0
%
5
Relative sensitivity error dc0.25
Rel. tensile/compression
sensitivity variation dZD 0.1
Input resistance Ri u345
Output resistance Ro350 "50
Insulation resistance Ris Gu2
Operating range of the
excitation voltage BU, GV0.5  12
Reference excitation voltage Uref5
Connection Six‐wire circuit
Temperature
Nominal (rated) temperature
range BT, nom
C
-10  +45
Operating temperature range BT, G-10  +70
Storage temperature range BT, S-10  +85
Mechanical characteristic quantities
Max. operating force FG
%
150
Limit force FL1000
Breaking force FB1000
Limit torque MLNm 4 8 25 28
Limit bending moment Mb perm 6 25 34 50 71 95 125
Static lateral limit force FQ% of
Fnom 100
Nominal (rated) displacement snom mm 0.27 0.21 0.18 0.15 0.13 0.12 0.13