HBM T10FS User manual

A078514.0 en
Torque Flange
T10FS
Mounting instructions

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HBMA078514.0en
Contents Page
Safety instructions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1Torque flange versions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Application 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Structure and mode of operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Mechanical installation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Conditionson site 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Mounting position 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Installation possibilities15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Installation without undoing the antenna ring
(without speed measuring system) 15. . . . . . . . . . . . . . . . .
4.3.2 Installation with subsequent stator mounting
(without speed measuring system) 16. . . . . . . . . . . . . . . . .
4.3.3 Installation example with couplings17. . . . . . . . . . . . . . . . .
4.3.4 Installation example with joint shaft 17. . . . . . . . . . . . . . . . .
4.4 Mounting the rotor 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Installing the stator 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Mounting of the clamp fixture 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7 Installing the slotted disc (speed measuring system) 23. . . . . . . . . .
4.8 Fitting the mounting elements(speed measuring system) 24. . . . .
4.8.1 Fixing the mounting elements25. . . . . . . . . . . . . . . . . . . . . .
4.8.2 Installing the torque flange with the speed
measuring system 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9 Aligning the stator (speed measuring system) 27. . . . . . . . . . . . . . .
4.9.1 Magneticspeed measuring system 27. . . . . . . . . . . . . . . . .
4.9.2 Optical speed measuring system 31. . . . . . . . . . . . . . . . . . .

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5 Electrical connection 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 General instructions33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Shielding design 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Option 2, code KF1 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.1 Adaptation to the cable length 34. . . . . . . . . . . . . . . . . . . . .
5.4 Option 2, code SF1/SU2 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Supply voltage 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Calibration 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Calibration Option 2, code KF1 40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Calibration Option 2, code SF1/SU2 41. . . . . . . . . . . . . . . . . . . . . . . .
7 Settings 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Torque output signal, code KF1 43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Torque output signal, code SF1/SU2 43. . . . . . . . . . . . . . . . . . . . . . .
7.3 Setting up the zero point 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Functional testing 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.1 Power transmission 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.2 Testing the optical speed module 46. . . . . . . . . . . . . . . . . . .
7.5 Setting the pulse count 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5.1 Magneticspeed measuring system 47. . . . . . . . . . . . . . . . .
7.5.2 Optical speed measuring system 50. . . . . . . . . . . . . . . . . . .
7.6 Vibration suppression (hysteresis)51. . . . . . . . . . . . . . . . . . . . . . . . .
7.7 Form of the rotation speed output signal 52. . . . . . . . . . . . . . . . . . . .
7.8 Type of the rotation speed output signal 53. . . . . . . . . . . . . . . . . . . .
7.9 Optical speed measuring system with a reference pulse53. . . . . .
8 Loading capacity 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Measuring dynamictorque 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Maintenance 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 Torque flange maintenance57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Speed module maintenance57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.1 Magneticspeed measuring system 57. . . . . . . . . . . . . . . . .
9.2.2 Optical speed measuring system 57. . . . . . . . . . . . . . . . . . .

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10 Dimensions 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1 Rotor dimensions58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Rotor dimensionswith the magneticspeed system 59. . . . . . . . . . .
10.3 Stator dimensions60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 Stator dimensionswith the magneticspeed system 61. . . . . . . . . .
10.5 Mounting dimensions62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 Order numbers, accessories 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Specifications 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Supplementary technical information 71. . . . . . . . . . . . . . . . . . . . . . . . . .
13.1 Output signals71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.1.1 Output MD torque (plug 1) 71. . . . . . . . . . . . . . . . . . . . . . . . . .
13.1.2 Output N: Speed and speed with a
reference pulse (plug 2) 72. . . . . . . . . . . . . . . . . . . . . . . . . . .
13.1.3 Plug 2, double frequency, stat. direction of rotation signal 73
13.2 Circular runout values74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Safety instructions
Use inaccordance withthe regulations
T10FS torque flangesare used exclusively for torque and rotation speed
measurement tasksand control and adjustment tasksdirectly connected
thereto. Use for any additional purpose shall be deemed to be notin
accordance with the regulations.
In the interestsof safety, the transducersshould only be operated asdescribed
in the Operating Manual. It isalso essential to observe the appropriate legal
and safety regulationsfor the application concerned during use. The same
appliesto the use of accessories.
The transducersare not a safety element within the meaning of itsuse as
intended. Proper and safe operation of these transducersrequire proper
transportation, correct storage, assembly and mounting and careful operation.
General dangers of failing tofollow the safety instructions
The transducerscorrespond to the state of the art and isfailsafe. The
transducerscan give rise to remaining dangersif it isinappropriately installed
and operated by untrained personnel.
Everyone involved with the installation, commissioning, maintenance or repair
of the transducersmust have read and understood the Operating Manual and
in particular the technical safety instructions.
Remaining dangers
The scope of supply and performance of the transducerscoversonly a small
area of torque measurement technology. In addition, equipment planners,
installersand operatorsshould plan, implement and respond to the safety
engineering considerationsof torque measurement technology in such a way
asto minimize remaining dangers. Prevailing regulationsmust be complied
with at all times. Reference must be made to remaining dangersconnected
with torque measurement technology.

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In thisOperating Manual remaining dangersare pointed out using the following
symbols:
Symbol: DANGER
Meaning: Maximum danger level
Warnsof an imminently dangeroussituation in which failure to comply with
safety requirementswill result in death or seriousphysical injury.
Symbol: WARNING
Meaning: Potentially dangerous situation
Warnsof a potentially dangeroussituation in which failure to comply with
safety requirementscanresult in death or seriousphysical injury.
Symbol: CAUTION
Meaning: Dangerous situation
Warnsof a potentially dangeroussituation in which failure to comply with
safety requirementscouldresult in damage to property or some form of
physical injury.
Symbolspointing out noteson use and waste disposal aswell asuseful
information:
Symbol: NOTE
Meansthat important information about the product or itshandling isbeing
given.
Symbol:
Meaning: CE mark
The CE mark enablesthe manufacturer to guarantee that the product complies
with the requirementsof the relevant EC directives(the declaration of
conformity isavailable at http://www.hbm.com/HBMdoc).

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Symbol:
Meaning: Statutory marking requirements for waste disposal
National and local regulationsregarding the protection of the environment and
recycling of raw materialsrequire old equipment to be separated from regular
domesticwaste for disposal.
For more detailed information on disposal, please contact the local authorities
or the dealer from whom you purchased the product.
Conversions and modifications
The transducersmust 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.
Qualifiedpersonnel
The transducersmust only be installed and used by qualified personnel, strictly
in accordance with the specificationsand with safety requirementsand
regulations. It isalso essential to observe the appropriate legal and safety
regulationsfor the application concerned during use. The same appliesto the
use of accessories.
Qualified personnel meanspersonsentrusted with the installation, fitting,
commissioning and operation of the product who possess the appropriate
qualificationsfor their function.

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Prevention of accidents
According to the prevailing accident prevention regulations, once the T10F
torque transducershave been mounted, a cover or casing hasto be fitted as
follows:
•The cover or casing must not be free to rotate.
•The cover or casing should avoid squeezing or shearing and provide
protection against partsthat might come loose.
•Coversand casing must be positioned at a suitable distance or so arranged
that there isno access to any moving partswithin.
•Coversand casing must also be attached if the moving partsof the torque
flange are installed outside peoples’ movement and operating range.
The only permitted exceptionsto the above requirementsare if the various
partsand assembliesof the machine are already fully protected by the design
of the machine or by existing safety precautions.
Warranty
In the case of complaints, a warranty can only be given if the torque flange is
returned in the original packaging.

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1Torque flange versions
In the case of option 2 "electrical configuration", the T10FS torque flange exists
in versionsKF1, SF1 and SU2. The difference between these versionsliesin
the electrical inputsand outputson the stator, the rotorsare the same for all
the versionsof a measuring range. Alternatively, versionsSF1 and SU2 can be
equipped with a magneticor optical speed measuring system (in the case of
the optical system, with or without a reference pulse).
SF1
Measured
quantity
Version
Power supply
Output signal
Canbe
connectedto
HBM
measurement
electronics
Excitation voltage
54V PP/14 kHz;
squarewave
Torque
KF1
Connection
cable
FrequencyFrequency
V1 ... V4
Excitation voltage
generator in HBM
electronics
T10FS
Torque
Speed, magneticor optical (option)
Speed and reference pulse, optical (option)
SU2
Supply voltage 18V to 30V DC
Excitation voltage generator in the torque flange
V5, V6, W1, W2, W5, W6
Frequency
and
voltage
Fig.1.1: T10FS versions
You can find out which version you have from the stator identification plate.
The version isspecified in the "T10FS..." number there.
Example: T10FS001RSU2S0V1Y (see also Page 63).

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2Application
T10FS torque flangesrecord staticand dynamictorque on fixed or rotating
shaftsand also return RS422 signalswith direction of rotation information to
determine the speed. With an optical measuring system, a reference pulse can
also be output with the speed pulses. Test bedscan be extremely compact
because of the short construction of the measurement flanges. They offer a
very wide range of applications.
In addition to conventional testbench applications(motor, roller and gear test
benches) new solutionsare possible for torque measurementspartly integrated
into the machines. Here, you benefit from the T10FS torque flanges’ special
characteristics:
•low rotor weights
•low mass momentsof inertia
•small outside diameters
•no bearings, no slip rings
Thanksto the bearingfree design and the contactless transmission of
excitation voltage and measured values, there are no friction or bearing
heating effects.
Torque flangesare supplied for nominal (rated) torquesfrom 100N⋅m to
10kN⋅m. Depending on the nominal (rated) torque, maximum speedsof up to
24000 min1 are permissible.
T10FS torque flangesare reliably protected against electromagnetic
interference. They have been tested with regard to EMC according to the
relevant European standards, and carry the CE mark.

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3 Structure and mode of operation
Torque flangesconsist of two separate parts: the rotor and the stator. The rotor
comprisesthe measuring body and the signal transmission elements.
Strain gages(S.G.) are mounted on the measuring body. The rotor electronics
for transmitting the bridge excitation voltage and the measurement signal are
located centrally in the flange. The transmitter coilsfor the noncontact
transmission of excitation voltage and measurement signal are located on the
measuring body’souter circumference. The signalsare sent and received by a
separable antenna ring. The antenna ring ismounted on a housing that
includesthe electronicsystem for voltage adaptation and signal conditioning.
The connector for the torque signal, the voltage supply and the speed signal
(option) are located on the stator. The antenna ring should be mounted more or
less concentrically around the rotor (see chapter 4).
A magneticor optical sensor performsthe speed measurement. With a
magneticmeasuring system, a magnetized rotor issampled by meansof a
magnetoresistive sensor (MR).
The optical sensor workson the infrared transmitted light barrier principle. The
reference pulse isgenerated by a magnet in the slotted disc and a
magnetoresistivesensor. In the case of option2 (speed measuring system),
code L, the speed sensor ismounted on the stator, the customer attachesthe
associated slotted disc on the rotor. In the case of code H, the slotted disc is
already mounted on the rotor.
Stator
Antenna segments
Rotor
(without slotted disc)
Fan type lock
washers
RF
enclosure
Optical speed sensor (option)
Fig.3.1: Mechanical structure, exploded view

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4Mechanical installation
Handle the torque flange carefully. The transducer might suffer
permanent damage from mechanical shock (dropping), chemical effects
(e.g. acids, solvents) or thermal effects (hot air, steam).
Withalternating loads, you shouldglue the rotor connectionscrews into
the counter threadwitha screw locking device (medium strength) to
exclude prestressing loss due toscrew slackening.
An appropriate shaft flange enablesthe T10FS torque flangesto be mounted
directly. It isalso possible to mount a joint shaft or relevant compensating
element directly on the rotor (using an intermediate flange when required).
Under no circumstancesmust the permissible limitsspecified for bending
moments, transverse and longitudinal forcesbe exceeded. Due to the T10FS
torque flanges’ high torsional stiffness, dynamicchangeson the shaft run are
minimized.
Doinany case check the effect on critical speeds and natural torsional
vibrations toavoidoverloading the measurement flanges due tothe
resonance stepup.
NOTE
Evenif the unit is installedcorrectly, the zeropoint adjustment made at
the factory canshift by approx."150 Hz. If this value is exceeded, we
advise you tocheck the mounting conditions. If the residual zerooffset
whenthe unit is removedis greater than"50 Hz, please send the
transducer back tothe Darmstadt factory for testing.
For correct operation, do inany case observe the mounting dimensions
(see page 62).

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HBM A078514.0en
4.1 Conditions on site
T10FS torque flangesare protected to IP54 according to EN60529. They
must be protected against coarse dirt particles, dust, oil, solventsand humidity.
During operation, the prevailing safety regulationsfor the security of personnel
must be observed (see "Safety instructions").
There iswide ranging compensation for the effectsof temperature on the
output and zero signalsof the T10FS torque flange (see specificationson page
64). Thiscompensation iscarried out at statictemperatures. Thisguarantees
that the circumstancescan be reproduced and the propertiesof the transducer
can be reconstructed at any time.
If there are no statictemperature ratios, for example, because of the
temperature differencesbetween the measuring body and the flange, the
valuesgiven in the specificationscan be exceeded. Then for accurate
measurements, statictemperature ratiosmust be obtained by cooling or
heating depending on the application. Asan alternative, check thermal
decoupling, by meansof heat radiating elementssuch asmultiple disc
couplings.
4.2 Mounting position
The measurement flange can be mounted in any position. With clockwise
torque, the output frequency is10 kHz to 15 kHz. With HBM amplifiersor with
the "voltage output" option, a positive output signal (0 V to +10 V) ispresent.
In the case of the speed measuring system, an arrow isattached to the head of
the sensor to clearly define the direction of rotation. If the measurement flange
movesin the direction of the arrow, the connected HBM measuring amplifiers
give off a positive output signal (0 V...+10 V).

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HBMA078514.0en
4.3 Installation possibilities
In principle, there are two possibilitiesfor torque flange mounting: with the
antenna ring complete or dismantled. We recommend proceeding asdescribed
in subsection 4.3.1. If installation in accordance with 4.3.1 isnot possible,
(e.g. in the case of subsequent stator replacement or mounting with a speed
measuring system), you will have to dismantle the antenna ring. It isessential
in thiscase to comply with the noteson assembling the antenna segments
(see "Installing the stator" and Installing the slotted disc").
4.3.1 Installation without undoing the antenna ring (without speed
measuring system)
1. Install rotor 2. Install stator
3. Finish installation of shaft run
Customer
mounting
Support supplied by
customer
Clamp fixture
4. Mount clamp fixture where required.

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4.3.2 Installation withsubsequent stator mounting (without speed
measuring system)
1. Install rotor 2. Install shaft run
3. Remove one antenna segment
5. Align stator and finish installation
4. Install antenna segment around shaft run
Support supplied by
customer
Clamp fixture
6. Mount clamp fixture where required
Customer mounting

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HBMA078514.0en
4.3.3 Installation example withcouplings
Fig.4.1: Installation example with coupling
4.3.4 Installation example withjoint shaft
Fig.4.2: Installation example with joint shaft

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HBM A078514.0en
4.4 Mounting the rotor
Additional installation notesfor the speed measuring system can be found in
Section4.7, Page 23.
NOTE
Ingeneral, the rotor identification plate is no longer visible after
mounting. This is why we include withthe rotor additional stickers with
the important ratings, whichyou canattachtothe stator or any other
relevant testbenchcomponents. You canthenrefer tothem whenever
there is anything you wishtoknow, suchas the calibration signal. To
explicitly assign the data, the identification number and the measuring
range are engravedon the rotor where they canbe seenfrom outside
(see Fig.4.3).
1. Prior to installation, clean the measurement flange’sand counter flanges’
plane surfaces. For safe torque transfer, the surfacesmust be clean and
free from grease. Use a piece of cloth or paper soaked in solvent. When
cleaning, make sure that you do not damage the transmitter coils.
6x or 8x fastening screw (10.9/12.9)
6x or 8x(Z) DINEN ISO 4762 hexagonsocket screw (10.9/12.9)
Rotor
Identification number/measuring range
Fig.4.3: Screwed joint of the rotor

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HBMA078514.0en
2. Use eight DIN EN ISO 4762 hexagonsocket screws of property class
10.9 (measuring range w3kNVm: 12.9), of the appropriate length
(depending on the connection geometry) to screwfasten the rotor.
We recommend fillisterhead screwsDIN EN ISO 4762 or similar,
blackened, smoothheaded, permitted size and shape variance in
accordance with DIN ISO 4759, Part 1, product class A.
Withalternating load: Use a screw locking device (e.g. LOCTITE no. 242)
togluethe screws intothe counter threadtoexclude prestressing loss
due toscrew slackening.
3. Fasten all screwswith the specified tightening torque (Table4.1).
4. For further mounting of the shaft run, there are eight tapped holeson the
rotor. Also use screwsof property class 10.9 (or 12.9) and fasten with the
tightening torque specified in Table4.1.
CAUTION
Withalternating loads, use a screw locking device toglue the connecting
screws intoplace. Guardagainst contamination from varnishfragments.
Nominal (rated)
torque
(NVm)
Fastening screws
(Z)1) Fastening screws
Property class
Specified
tightening torque
(NVm)
100 M8 10.9 34
200
500 M10
10.9
67
1k M10 67
2k M12 115
3k M12
12.9
135
5k M14 220
10k M16 340
Table4.1: Fastening screws
1) DIN EN ISO 4762; black/oiled/mtot=0.125

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HBM A078514.0en
4.5 Installing the stator
On delivery, the stator hasalready been installed and isready for operation.
The antenna segmentscan be separated from the stator, for example, for
maintenance or to facilitate stator mounting. To stop you modifying the center
alignment of the segment ringsopposite the base of the stator, we recommend
that you separate only one antenna segment from the stator.
If your application doesnot require the stator to be dismantled, proceed as
described in points2., 6., 7. and 8.
Version withspeedmeasuring system
Asthe optical speed sensor includesthe slotted disc, it isnot possible to move
the stator axially over the preassembled rotor. In thiscase, you should also
comply with Section 4.7.
Fantype lock washer
Fig.4.4: Screw fittingsof the antenna segments
1. Slacken and remove the screw fittings(M5) on one antenna segment. Make
sure that the fantype lock washersare not lost.
2. Use an appropriate base plate to install the stator housing in the shaft run
so that there issufficient possibility for horizontal and vertical adjustments.
Do not yet fasten the screws.
3. Now reinstall the antenna segment removed under point 1.on the stator
with two hexagonsocket screwsand the fantype lock washers. Make sure
that none of the fantype lock washersnecessary for a defined contact
resistance are missing (see Fig.4.4). Do not yet fasten the screws.