HBM Z4A User manual

Force Transducer with
S.G Measurement System
Z4A, Z4A-G
Mounting Instructions
B 20.Z4A.20 en
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3
Z4A
HBM 20.11.00
Contents page
Safety instructions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Scope of supply 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Applicationinformation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Structure and mode of operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Measuring body 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Housing 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Disturbance variables 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Conditionson site 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Ambient temperature 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Moisture 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Air pressure 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Chemical effects 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Mechanicalinstallation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Important measures for installation 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 General installation guidelines 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Mounting accessories for tensile loading/compressive loading 12. . . .
6 Electrical connection 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Instructions for cabling 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Wiring pin assignment 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Specifications 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Dimensions Z4A, Z4A-G 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Declaration of conformity 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4Z4A
HBM 20.11.00
Safety instructions
Use in accordance with the regulations
Force transducers of types Z4A and Z4A-G are used for high-precision force
measurements and for force reference measurements (transfer standard).
Use for any additional purpose shall be deemed to be not in accordance with
the regulations.
In the interests of safety, the transducer should only be operated as described
in the Mounting Instructions. It is also essential to observe the appropriate
legal and safety regulations for the application concerned during use. The
same applies to the use of accessories.
The transducer is not a safety element within the meaning of its use as
intended. Proper and safe operation of this transducer requires proper
transportation, correct storage, assembly and mounting and careful operation
and maintenance.
General dangers due to non-observance of the safety instructions
The Z4A, Z4A-G force transducer corresponds to the state of the art and is
fail-safe. The transducers can give rise to residual dangers if they are
inappropriately installed and operated by untrained personnel.
Everyone involved with the installation, commissioning, maintenance or repair
of a force transducer must have read and understood the Mounting
Instructions and in particular the technical safety instructions.
Residual dangers
The scope of supply and performance of the transducer covers only a small
area of force measurement technique. In addition, equipment planners,
installers and operators should plan, implement and respond to the safety
engineering considerations of force measurement technique in such a way as
to minimise residual dangers. Prevailing regulations must be complied with at
all times. There must be reference to the residual dangers connected with
force measurement technique.
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5
Z4A
HBM 20.11.00
In these mounting instructions residual dangers are pointed out using the
following symbols:
Symbol: DANGER
Meaning: Highest level of danger
Warns of a directly dangerous situation in which failure to comply with safety
requirements will lead to death or serious physical injury.
Symbol: WARNING
Meaning: Dangerous situation
Warns of a potentially dangerous situation in which failure to comply with
safety requirements can lead to death or serious physical injury.
Symbol: ATTENTION
Meaning: Possibly dangerous situation
Warns of a potentially dangerous situation in which failure to comply with
safety requirements could lead to damage to property, slight or moderate
physical injury.
Symbol: NOTE
Refers to the fact that important information is being given about the product
or its use.
Symbol:
Meaning: CE mark
The CE mark signals a guarantee by the manufacturer that his product meets
the requirements of the relevant EC directives (see Declaration of conformity
at the end of this document).
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6Z4A
HBM 20.11.00
Prohibition of own 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.
Qualified personnel
These transducers are only to be installed by qualified personnel strictly in
accordance with the specifications and with the safety rules and regulations
which follow. It is also essential to observe the appropriate legal and safety
regulations for the application concerned. The same applies to the use of
accessories.
Qualified personnel means persons entrusted with the installation, fitting,
commissioning and operation of the product who possess the appropriate
qualifications for their function.
Conditions on site
Protect the transducer from damp and weather influences such as rain, snow,
etc.
Maintenance
The Z4A, Z4A-G force transducer is maintenance free.
Accident prevention
Although the specified nominal force in the destructive range is several times
the full scale value, the relevant accident prevention regulations from the
trade associations must be taken into consideration.
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7
Z4A
HBM 20.11.00
1 Scope of supply
•Z4A force transducer or
•Z4A-G force transducer1) including DKD certificate2) (class 00 / class 05 for
measuring range 500kN under DIN EN 10002-3 or ISO / FDIS 376)
•Z4A, Z4A-G Operating Manual
1) Z4A-G is only available from HBM in conjunction with a DKD calibration according to EN10002-3.
2) The calibration certificate must be ordered separately (see accessories).
Accessories (not included in the scope of supply)
•DKD calibration certificate according to EN10002-3 order no. K-CAL-FD
•ZKM tensile force introduction
for 20kN: Order no. 1-Z4/20kN/ZKM
50kN: Order no. 1-Z4/50kN/ZKM
100kN: Order no. 1-Z4/100kN/ZKM
200kN: Order no. 1-Z4/200kN/ZKM
500kN: Order no. 1-Z4/500kN/ZKM
•ZDK compressive force introduction
(recommended for standard measurements in industry)
for 20kN: Order no. 1-Z4/20kN/ZDK
50kN: Order no. 1-Z4/50kN/ZDK
100kN: Order no. 1-Z4/100kN/ZDK
200kN: Order no. 1-Z4/200kN/ZDK
500kN: Order no. 1-Z4/500kN/ZDK
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8Z4A
HBM 20.11.00
•ZGUW/ZGOW knuckle eye
for 20kN: Order no. 1-Z4/20kN/ZGOW
1-Z4/20kN/ZGUW
50kN: Order no. 1-U2A/2t/ZGOW
1-U2A/2t/ZGUW
100kN: Order no. 1-Z4/100kN/ZGOW
1-Z4/100kN/ZGUW
200kN: Order no. 1-U2A/10t/ZGOW
1-U2A/10t/ZGUW
500kN: Order no. 1-Z4/500kN/ZGOW
1-Z4/500kN/ZGUW
•EDO4 thrust piece
(recommended for precision measurements, for example EN10002-3
calibrations)
EDO4/20kN Order no. 3-9219.0718
EDO4/50kN Order no. 3-9219.0719
EDO4/100kN Order no. 3-9219.0720
EDO4/200kN Order no. 3-9219.0721
EDO4/500kN Order no. 3-9219.0722
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9
Z4A
HBM 20.11.00
2 Application information
Z4A force transducer:
Precision force transducers of the Z4A type series measure tensile forces and
compressive forces.
They measure static and quasi-static forces with great accuracy and
reproducibility and therefore require judicious handling. You must take
particular care when transporting and installing the devices. If you knock or
drop the transducers, this could permanently damage them.
Z4A-G force transducer with DKD certificate from HBM:
Force transducer calibrated with guaranteed class 00 (20kN – 200kN) and 05
(500kN) according to DIN EN10002-3 or ISO / FDIS 376.
The transducers are calibrated as standard in the tensile force direction. On
request, however, they can also be calibrated in the compressive force
direction, under the DKD.
The limits for the permissible mechanical, thermal and electrical stresses are
stated in the Specifications. Be sure to allow for them when planning the
measuring setup, when installing and lastly, when operating.
3 Structure and mode of operation
3.1 Measuring body
The measuring body comprises a system of measuring springs with 8 applied
strain gauges (S.G.). The strain gauges are arranged so that four of them are
extended and the other four are upset when a force acts on the transducer.
For the introduction of tensile forces, the Z4A and Z4A-G transducer has a
crowned threaded pin at the top (also suitable for the introduction of
compressive forces) and a tapped hole at the bottom.
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10 Z4A
HBM 20.11.00
3.2 Housing
The enclosure with the integrated system of measuring springs is hermetically
sealed at the top and at the bottom by metal membranes, so that moisture
cannot damage the sensitive application.
1 = Measuring body
2 = Sealing membranes
3=SG
4 = Threaded pin
5 = Cable box
6 = Tapped hole
423
1
6
2
5
Fig.3.1 Z4A, Z4A-G (20kN...500kN)
3.3 Disturbance variables
Torsion, bending and transverse load are disturbance variables and are
therefore to be avoided. If necessary they can be remedied with HBM
mounting accessories (section 5.3 ).
The effects of temperature on the zero signal (S/G bridge and housing) and
on the sensitivity are compensated.
Changes in the ambient pressure act as additive (subtractive) forces. These
are scarcely of importance when compared with large nominal loads.
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11
Z4A
HBM 20.11.00
4 Conditions on site
4.1 Ambient temperature
The effects of temperature on the zero signal and on the sensitivity are
compensated. To achieve optimal measurement results the nominal
temperature range must be maintained. Temperature-induced measurement
errors can be caused by heating (for example radiant heat) or cooling on one
side. A radiation shield and all-round heat insulation bring about marked
improvements. They must not form a force shunt.
4.2 Moisture
Extreme humidity or a tropical climate should be avoided if this means that the
classified limit values are exceeded (degree of protection IP67 under DIN EN
60529).
4.3 Air pressure
Changes in air pressure affect the force transducer in the same way as a
change in force. In the case of normal changes in ambient pressure
"20mbar, however, the effect on the measurement signal is negligible
(changes in air pressure of "10mbar only have an effect on the zero signal of
6N for 20kN and 50kN transducers).
4.4 Chemical effects
The steel housing of the transducers is protected by a powder coating. If used
in difficult environmental conditions (direct weather effects, contact with media
which encourage corrosion) additional protective measures should be
employed by the user. The unit can be painted with commercial protective
paint or a tar-based coating (underseal). The sheath of the connection cable
is made of silicon rubber.
The uncoated force introduction areas are greased to provide protection
against corrosion.
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12 Z4A
HBM 20.11.00
5 Mechanical installation
5.1 Important measures for installation
–treat the transducer gently
–if measuring compressive forces, make sure there is a solid support
structure
–the force-introduction surfaces must be scrupulously clean and carry in full
–keep to the depths of engagement for threaded rods or knuckle eyes
–do not overload the transducer.
WARNING
If there is a risk of breakage through overload on the
transducer and thus a risk to persons, additional safety
measures are to be taken.
5.2 General installation guidelines
The measurement direction in which forces act on the transducer must be as
precise as possible.
WARNING
Torsion and bending moments, eccentric loading and
transverse forces result in measurement errors and if limit
values are exceeded, could destroy the transducer.
5.3 Mounting accessories for tensile loading/
compressive loading
Knuckle eyes are provided for Z4A installation. This mounting accessories
prevent the introduction of torsional moments and when 2 knuckle eyes are
used, stop bending moments and transverse and angular loading being
introduced in the transducers. The knuckle eyes are intended primarily for
static tensile and compressive loading of the transducer.
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13
Z4A
HBM 20.11.00
Installing knuckle eye, ZKM and threaded adapters:
•Screw the knuckle eye thread into the transducer’s inside thread until it
reaches the stop, then loosen it by one turn.
•With Z4A/500kN in addition: turn the knuckle eye to align the bushing holes
with the knuckle eye apertures.
af
∅B
W
MA
MA
ZGOW/ZGUW knuckle eye accessories
Bushing
Type upper knuckle eye
lower knuckle eye Weight (kg) a f W ∅B MA(Nm)
Z4A/20 kN Z4/20kN/ZGOW
Z4/20kN/ZGUW 0.2 158 198 21 16H7 120
Z4A/50 kN U2A/2t/ZGOW
U2A/2t/ZGUW 0.8 0.4 184 234 25 20H7 350
Z4A/100 kN Z4/100kN/ZGOW
Z4/100kN/ZGUW 1.1 251 322 37 30H7 950
Z4A/200 kN U2A/10t/ZGOW
U2A/10t/ZGUW 3.2 1.1 352 475 35 50+0.001
+0.014 2000
Z4A/500 kN Z4/500kN/ZGOW
Z4/500kN/ZGUW 17.3 12.0 570 764 44 60+0.003
+0.018 40001)
1) underside secured with 2 screws to prevent rotation; for pin end with outside thread only
For dynamic loading, Z4A transducers must be installed without play.
Knuckle eyes only have limited applicability for dynamic loading, as with
dynamic alternating stress, the pivoting bearings increase their bearing
clearance, thus falsifying the measured value. With the increased load cycle,
there is a risk that the knuckle eyes could be destroyed. For this type of
loading, we recommend using flexible tension bars or pressure bars.
To install the transducers without play, they must be sufficiently prestressed
and locked with the mounting accessories (knuckle eyes, tension bars or
pressure bars).
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14 Z4A
HBM 20.11.00
Do not use less than the starting torques MArecommended in the table
overleaf, which should be routed through the transducer, in non-positive
contact.
When locking, make sure that the transducer signal changes by no more than
0.1%.
In the case of transducers with nominal forces 20kN..100kN, you can also
lock as follows for tensile loading:
•screw in knuckle eyes
•load transducer with 10..20% of the nominal force
•tighten the lock nut of the lower knuckle eye
Static loading can also –in addition to using knuckle eyes –be carried
axially to the transducer through hardened (40...44HRc) pressure plates that
have been given a plane-parallel surface. The transducer support structure
must also have an inflexible, hardened and plane-parallel surface. We
recommend ZDK compressive force introduction parts for standard
measurements in industry.
∅D
Bz
ZDK compressive force introduction accessories
Type ZDK accessories Weight [kg] BZ∅D–0.3
–0.1
Z4A/20kN Z4A/20kN/ZDK 0.10 99 20
Z4A/50kN Z4A/50kN/ZDK 0.18 111 25
Z4A/100kN Z4A/100kN/ZDK 0.40 140 36
Z4A/200kN Z4A/200kN/ZDK 1.26 200 50
Z4A/500kN Z4A/500kN/ZDK 5.80 365 80
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15
Z4A
HBM 20.11.00
ZKM force introduction part for precision measurement, for example DIN
EN10002-3-calibrations
For use as a transfer standard or control standard for the Z4A, Z4A-G force
transducer, we recommend using ZKM force introduction parts according to
DIN EN 10002-3 or ISO/FDIS376.
∅D
CB
ZKM tensile force introduction accessories
Dimensions apply to tensile force introduction
Type ZKM accessories Weight
(kg) Bmin Cmax ∅D
Z4A/20kN Z4A/20kN/ZKM 0.82 325 228 276 35–0.120
–0.280
Z4A/50kN Z4A/50kN/ZKM 1.45 350 248 299 45 –0.130
–0.290
Z4A/100kN Z4A/100kN/ZKM 2.32 395 277 334 50–0.130
–0.290
Z4A/200kN Z4A/200kN/ZKM 4.19 447 317 382 64 –0.170
–0.330
Z4A/500kN Z4A/500kN/ZKM 20.1 623 432 522 90 –0.170
–0.390
Installing:
•Screw the thread of the ZKM force introduction part into the transducer’s
inside thread until it reaches the stop, then loosen it by one turn.
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16 Z4A
HBM 20.11.00
EDO4 thrust piece for precision measurement, for example DIN EN10002-3
or ISO/FDIS 376 calibrations
ED
CA
F45o
∅
∅B–0.1
+0.05
0.8 cut according to hardness
groove
∅5 x 0.5 deep
α
Type Thrust piece Weight
(kg) ∅A ∅B CDEFa
Z4A/20kN EDO4/20kN 16.2 29 5
Z4A/50kN EDO4/50kN 0.34 20.2 48 29 8512 o
Z4A/100kN EDO4/100kN 30.2 18o
Z4A/200kN EDO4/200kN 1.58 39.2 80 45 10 5 23
Z4A/500kN EDO4/500kN 4.35 72.4 112 68 15 12 30 15o
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Z4A
HBM 20.11.00
6 Electrical connection
6.1 Instructions for cabling
•Always use shielded, low-capacity measurement cable (HBM cables meet
these requirements).
•Do not lay measurement cable parallel to high-voltage power lines or
control circuits. If this is not possible (e.g. in cable ducts) protect the
measurement cable, e.g. with armoured steel tube and maintain a minimum
distance of 50 cm from the other cables. High-voltage power lines and
control lines should be twisted (15 turns per metre).
•Avoid stray fields of transformers, motors and contactors.
•Do not earth transducer, amplifier and display device more than once. All
the devices in the measuring chain are to be connected to the same
earthed conductor.
•The screen of the connection cable is connected to the transducer housing.
6.2 Wiring pin assignment
The 3m long transducer connection cable has colour-coded free wire ends.
The cable shielding is connected in accordance with the Greenline concept.
This means that the measurement system is surrounded by a Faraday cage.
Electromagnetic interference will not affect the measurement system.
Connectors to CE standard are to be fitted at the free end of the transducer.
The shielding is here to be laid over the whole area.
If a different connection technique is used then good EMC shielding is to be
provided in the wiring loom, the shielding again being laid over the full area
(see also HBM Greenline Information, document G36.35.0).
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18 Z4A
HBM 20.11.00
If the transducer is connected according to the following connection diagram
then when the transducer has compressive loading the output voltage at the
measuring amplifier is positive.
WH (white)
BK (black)
RD (red)
BU (blue)
GN (green)
GY (grey)
YE (yellow)
Measurement signal (+) UA
Excitation voltage (+) UB
Sensor circuit (–)
Sensor circuit (+)
Excitation voltage (–) UB
Measurement signal (–) UA
Cable shielding, connected to housing
Six-wire connection
Fig. 6.1: Z4A, Z4A-G pin assignment
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19
Z4A
HBM 20.11.00
7 Specifications
Force transducer type Z4A / Z4A-G
Data according to VDI standards 2638
Nominal force Fnom kN 20 50 100 200 500
Accuracy class 0.02 0.04
Nominal sensitivity Cnom mV/V 2
rel. sensitivity deviation dc% 0.1
rel. tensile/compressive force sensitivity
difference dzd % 0.2
Zero signal tolerance ds,o % 0.5
rel. zero point compensation (zero signal
return)1) fo%t"0.025
Rel. range (0.2Fnom to Fnom) at:1)
unchanged mounting position, typically brg % 0.02
different mounting positions, typically brv % 0.03
Rel. range of inversion (0.2Fnom to Fnom)u % 0.1 0.3
Linearity deviation dlin % 0.02 0.03
Effect of temperature on sensitivity/10K
by reference to sensitivity TKc%0.01
Effect of temperature on zero signal/10K
by reference to sensitivity TK0%0.015
Effect of transverse forces (transverse
force 10% Fnom)2) dQ% 0.03
Effect of eccentricity per mm dE% 0.01 0.005
Rel. creep over 15min dcrF+E % 0.02
Input resistance ReΩ>345
Output resistance RaΩ356"0.3
Isolation resistance Ris Ω>5⋅109
Reference excitation voltage Uref V 5
Operating range of the excitation voltage BU,G V0.5 ... 12
Nominal temperature range Bt,nom °C +10...+40
Operating temperature range Bt,G °C -30...+85
Storage temperature range Bt,S °C -50...+85
Reference temperature tref °C +23
Max. operational force (FG) % 150
Limit force (FL) % 150
Breaking force (FB) % 250
Static lateral limit force (FQ) % 30
Limit torque MGNm 120 350 950 2000 4000
Nominal displacement Snom mm 0.2 0.25 0.28 0.45
Fundamental resonance frequency fGkHz 4.1 4.5 3.4 3.6 2.5
Weight kg 1.8 2.4 5.5 11.2 42
Rel. permissible vibrational stress Frb % 70 50
Degree of protection to DIN EN 60529 IP 67
1) see supplementary information according to DIN EN 10002-3 for Z4A-G
2) half pivot height for Z4A, Z4A-G
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20 Z4A
HBM 20.11.00
Supplementary information according to EN 10002-3 for Z4A-G3)
Nominal force Fnom kN 20 50 100 200 500
Class according to EN 10002-3 (ISO /
FDIS 376) 00 05
rel. zero point compensation (zero signal
return) fo%t"0.008 (typically t0.003)
Rel. range (0.1Fnom to Fnom) at:
unchanged mounting position bi%t0.02 (typically t0.01)
different mounting positions b % t0.03 (typically t0.02)
Rel. range of inversion (0.1Fnom to Fnom)u % t0.07 (typically t0.03) 0.2*)
(typ.
0.1)
3) Z4A-G is only available from HBM in conjunction with a DKD calibration according to EN10002-3.
*) applicable for 0.2 Fnom to Fnom
SUNSTAR传感与控制 http://www.sensor-ic.com/ TEL:[phone] FAX:[phone] E-MAIL:[email protected]
SUNSTAR自动化 http://www.sensor-ic.com/ TEL: [phone] FAX:[phone] E-MAIL:[email protected]