HBM T40 User manual

A24633.0en/de
Torque Flange
DrehmomentMessflansch
T40
Mounting instructions
Montageanleitung

English Page 3 − 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutsch Seite 35 − 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Contents Page
Safety instructions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Application 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Structure and mode of operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Mechanical installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Conditions on site 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Mounting position 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Installation options 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 Installation without dismantling the antenna ring 11. . . . . .
3.3.2 Installation with subsequent stator mounting 12. . . . . . . . .
3.4 Installing the rotor 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Installing the stator 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Electrical connection 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 General hints 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Shielding design 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Connector pin assignment 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Supply voltage 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Shunt signal 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Triggering the shunt signal 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Settings 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Output frequency settings 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Functional testing 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 Rotor status LED 1 (upper LED) 23. . . . . . . . . . . . . . . . . . .
6.2.2 Stator status LED 2 (lower LED) 23. . . . . . . . . . . . . . . . . . .
7 Loading capacity 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Measuring dynamic torque 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Specifications 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Dimensions 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 T40/500N@m and 1kN@m29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 T40/2kN@m and 3kN@m31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Supplementary technical information 33. . . . . . . . . . . . . . . . . . . . . . . . . .
10.1 Runout and concentric tolerances 33. . . . . . . . . . . . . . . . . . . . . . . . .
11 Order numbers 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Accessories 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Safety instructions
Appropriate use
T40 torque flanges are used exclusively for torque, rotation speed, angle of
rotation and power measurement tasks and control and adjustment tasks
directly connected thereto. Use for any additional purpose shall be deemed to
be not as intended.
Stator operation is only permitted with an installed rotor.
In the interests of safety, the transducer should only be operated as described
in the Operating Manual. 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 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.
General dangers of failing to follow the safety instructions
The transducer corresponds to the state of the art and is failsafe. The
transducer can give rise to remaining dangers if it is inappropriately installed
and operated by untrained personnel.
Everyone involved with siting, starting up, maintaining or repairing the
transducer must have read and understood the Operating Manual and in
particular the technical safety instructions.
Remaining dangers
The scope of supply and performance of the transducer covers only a small
area of torque measurement technology. In addition, equipment planners,
installers and operators should plan, implement and respond to the safety
engineering considerations of torque measurement technology in such a way
as to minimize remaining dangers. Prevailing regulations must be complied
with at all times. Reference must be made to remaining dangers connected
with torque measurement technology.

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In this Operating Manual, remaining dangers are pointed out using the
following symbols:
Symbol: DANGER
Meaning: Maximum danger level
Warns of an imminently dangerous situation in which failure to comply with
safety requirements will result in 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 result in death or serious physical injury.
Symbol: CAUTION
Meaning: Possibly dangerous situation
Warns of a potentially dangerous situation in which failure to comply with
safety requirements could result in damage to property or some form of
physical injury.
Symbols for application instructions and useful information:
Symbol: NOTE
Means that important information about the product or its handling is being
given.
Symbol:
Meaning: CE mark
The CE mark enables the manufacturer to guarantee that the product
complies with the requirements of the relevant EC directives (the Declaration
of Conformity can be found at http://www.hbm.com/HBMdoc).

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Symbol:
Meaning: Statutory waste disposal mark
In accordance with national and local environmental protection and material
recovery and recycling regulations, old devices that can no longer be used
must be disposed of separately and not with normal household garbage.
If you need more information about waste disposal, please contact your local
authorities or the dealer from whom you purchased the product.
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
The transducer must only be installed and used by qualified personnel, strictly
in accordance with the specifications and with safety requirements and
regulations. 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 accessories.
Qualified personnel means persons entrusted with siting, mounting, starting
up and operating the product who possess the appropriate qualifications for
their function.
Accident prevention
According to the prevailing accident prevention regulations, once the torque
transducers have been mounted, a covering agent or cladding has to be fitted
as follows:
•The cover or cladding must not be free to rotate.
•The cover or cladding should avoid squeezing or shearing and provide
protection against parts that might come loose.
•Covers and cladding must be positioned at a suitable distance or be so
arranged that there is no access to any moving parts within.
•Covering agents and cladding must also be attached if the moving parts of
the torque transducer are installed outside peoples’ movement and
operating range.

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The only permitted exceptions to the above requirements are if the various
parts and assemblies of the machine are already fully protected by the design
of the machine or by existing safety precautions.
Warranty
Where there are complaints, a warranty can only be given if the torque
transducer is returned in its original packaging.

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1 Application
The T40 torque flange measures static and dynamic torques on stationary
and rotating shafts. Test beds can be extremely compact because of the short
construction of the measurement flange. They offer a very wide range of
applications.
The T40 torque flange is reliably protected against electromagnetic
interference. It has been tested with regard to EMC according to the relevant
European standards, and carries the CE mark.
2 Structure and mode of operation
The torque flange consist of two separate parts: the rotor and the stator. The
rotor comprises the measuring body and the signal transmission elements.
Strain gages (SGs) 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 coils for contactless
transmission of excitation voltage and measurement signal are located on the
measuring body’s outer circumference. The signals are sent and received by
a separable antenna ring. The antenna ring is mounted on a housing that
includes the electronic system for voltage adaptation and signal conditioning.
Connectors for the torque signal, the voltage supply and the digital output are
located on the stator. The antenna ring should be mounted concentrically
around the rotor (see Chapter 4).

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Stator housing
Rotor
Antenna segments
Type plate
Connector plugs
Connector plug
Fig.2.1: Mechanical construction
3 Mechanical installation
WARNING
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).
With alternating loads, you should cement the rotor connectionscrews
into the mating thread with a screw locking device (medium strength) to
exclude prestressing loss due to screw slackening.
An appropriate shaft flange enables the T40 torque flange to be mounted
directly. It is also possible to mount a joint shaft or relevant compensating
element directly on the rotor (using an intermediate flange when required).
Under no circumstances must the permissible limits specified for bending
moments, lateral and longitudinal forces be exceeded. Due to the T40
measurement flange’s high torsional stiffness, dynamic shaft train changes
are kept to a minimum.

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CAUTION
Check the effect on speeds and natural torsional oscillations critical to
bending, to prevent the transducer being overloaded by increases in
resonance.
NOTE
Even if the unit is installed correctly, the zero point adjustment made at
the factory can shift by up to approx.2 % of the characteristic value. If
this value is exceeded, we advise you to check the mounting conditions.
If the residual zero offset when the unit is removed is greater than 1 % of
the characteristic value, please send the transducer back to the
Darmstadt factory for testing.
For correct operation, do, in any case, comply with the mounting
dimensions.
3.1 Conditions on site
The T40 torque flange must be protected against coarse dirt particles, dust,
oil, solvents and humidity. During operation, the prevailing safety regulations
for the security of personnel must be observed (see "Safety instructions").
There is wide ranging compensation for the effects of temperature on the
output and zero signals of the T40 torque flange (see specifications).
If there are no static temperature ratios, for example, because of the
temperature differences between the measuring body and the flange, the
values given in the specifications can be exceeded. So for accurate
measurements, static temperature conditions must then be obtained by
cooling or heating depending on the application. As an alternative, check
thermal decoupling, by means of heat radiating elements such as multiple
disc couplings.
3.2 Mounting position
The transducer can be mounted in any position. With clockwise torque, the
output frequency is 60 to 90kHz (Option 5, Code SU2: 10 kHz to 15 kHz;
HU2: 240 kHz to 360 kHz). In conjunction with HBM amplifiers or when using
the voltage output, a positive output signal (0V to +10V) is present.

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3.3 Installation options
In principle, there are two possibilities for torque flange mounting: with the
antenna ring complete or dismantled. We recommend mounting in
accordance with Section 3.3.1. If mounting in accordance with Section 3.3.1 is
not possible, (e.g. in the case of subsequent stator replacement), you will
have to dismantle the antenna ring. It is essential in this case to comply with
the notes on assembling the antenna segments (see "Installing the stator").
3.3.1 Installation without dismantling the antenna ring
1.Installrotor 2.Installstator
Customer
mounting
3. Align stator and finish installation
Supportsuppliedbycustomer
4. Mount the support

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3.3.2 Installation with subsequent stator mounting
1.Installrotor 2.Installshaft
3.Dismantleantennasegment 4.Installantennasegment
Supportsuppliedbycustomer
5. Mount the support

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3.4 Installing the rotor
NOTE
In general, the rotor identification plate is no longer visible after
installation. This is why we include with the rotor additional stickers
with the important ratings, which you can attach to the stator or any
other relevant testbench components. You can then refer to them
whenever there is anything you wish to know, such as the shunt signal.
To explicitly assign the data, the identification number and the
measuring range are engraved on the rotor flange, where they can be
seen from outside.
Transmitter winding (covered)
Flange plane face
Fig.3.1: Rotor of the T40 torque flange
1. Prior to installation, clean the measurement flange’s and counter flanges’
plane surfaces. For safe torque transfer, the surfaces must 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 winding.
2. For the bolted rotor connection, use eight DIN EN ISO 4762 property class
10.9 hexagon socket screws of a suitable length (dependent on the
connection geometry).
We recommend fillisterhead screws DIN EN ISO 4762 or similar,
blackened, smoothheaded, permitted size and shape variance in
accordance with DIN ISO 4759, Part 1, product class A.

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WARNING
With alternating load: Use a screw locking device
(e.g. LOCTITE)no. 242) to glue the screws into the counter thread to
exclude prestressing loss due to screw slackening.
3. Tighten all screws with the specified tightening torque (Tab. 4.1).
4. For further mounting of the shaft run, there are eight tapped holes on the
rotor. Also use screws of property class 10.9 or 12.9 and fasten with the
tightening torque specified in Table 4.1.
CAUTION
With alternating loads, use a screw locking device to cement the
connecting screws into place. Guard against contamination from
varnish fragments.
Measuring range
(NVm)
Fastening screws
(Z)1) Fastening screws Property class Prescribed tightening torque
(NVm)
500 M10
10.9
67
1 k M10 67
2 k M12 115
3 k M12 12.9 135
Table 3.1: Fastening screws
1) DIN EN ISO 4762; black/oiled/mtot = 0.125
3.5 Installing the stator
On delivery, the stator has already been installed and is ready for operation.
The upper antenna segment can be separated from the stator, for example,
for maintenance or to facilitate stator mounting.
If your application does not require the stator to be dismantled, proceed as
described in points 2., 5., and 6.

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Fan type lock washers
Hole ∅4.2 mm
for fixing the antenna
segment
Stator housing
upper
antenna segments
lower
Antenna segment bolts with
washers (M5)
Fig.3.2: Bolted antenna segment connections on the stator
Stator housing lower antenna segment Antenna wire
Fig.3.3: Stator housing and lower antenna segment with antenna wire
1. Undo and remove the bolted connections (M5) on the upper antenna
segment. There are fan type lock washers between the antenna
segments. Make sure that they do not get lost.
2. Use an appropriate base plate to install the stator housing in the shaft train
so that there is sufficient possibility for horizontal and vertical adjustments.
Do not yet fully tighten the bolts.
3. Now use two hexagon socket screws to mount the upper antenna segment
removed in 1. on the lower antenna segment. Make sure that the two fan type

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lock washers are inserted between the antenna segments (these ensure that
there is a defined contact resistance).
4. Now fasten all the bolted antennasegment connections with a tightening
torque of 5 N⋅m.
5. Then align the antenna to the rotor in such a way that the antenna
encloses the rotor more or less coaxially and the antenna wire in the axial
direction shows the position and the center of the transmitter winding on
the rotor. To make this alignment easier, the antenna segment and the
side of the rotor flange with the transmitter winding have the same width.
Please comply with the permissible alignment tolerances stated in the
specifications.
Fig.3.4: Alignment of the rotor with the stator
6. Now fully tighten the bolted stator housing connection.
CAUTION
To make sure that they function perfectly, the fan type lock washers
(A5.3FST DIN 6798 ZN/galvanized) must be replaced after the bolted
antenna connection has been loosened three times.
Depending on the operating conditions, oscillations may be induced in the
antenna ring. This effect is dependent on
•the speed
•the antenna diameter (depends in turn on the measuring range)
•the design of the machine base
To prevent this oscillation, it is essential that the customer supports the
antenna ring. There is a hole (∅4.2 mm) on the upper antenna segment,
which can be used to incorporate a clamping device (see 3.3.1, Figure 4).

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4 Electrical connection
4.1 General hints
To make the electrical connection between the torque transducer and the
amplifier, we recommend using shielded, lowcapacitance measurement
cables from HBM.
With cable extensions, make sure that there is a proper connection with
minimum contact resistance and good insulation. All plug connections or
swivel nuts nuts must be fully tightened.
Do not route the measurement cables parallel to power lines and control
circuits. If this cannot be avoided (in cable pits, for example), maintain a
minimum distance of 50cm and also draw the measurement cable into a
steel tube.
Avoid transformers, motors, contactors, thyristor controls and similar
strayfield sources.
CAUTION
Transducer connection cables from HBM with plugs attached are
identified in accordance with their intended purpose (Md or n). When
cables are shortened, inserted into cable ducts or installed in control
cabinets, this identification can get lost or become concealed. If this is
the case, it is essential for the cables to be relabeled!
4.2 Shielding design
The cable shield is connected in accordance with the Greenline concept. This
encloses the measurement system (without a rotor) in a Faraday cage. It is
important that the shield is laid flat on the housing ground at both ends of the
cable. Any electromagnetic interference active here does not affect the
measurement signal. Special electronic coding methods are used to protect
the purely digital signal transmission between the transmitter head and the
rotor from electromagnetic interference.
In the case of interference due to potential differences (compensating
currents), supply voltage zero and housing ground must be disconnected on
the amplifier and a potential equalization line established between the stator
housing and the amplifier housing (copper conductor, 10mm2wire
crosssection).
If potential differences arise between the rotor and the stator on the machine,
perhaps due to unchecked leakage, and this causes interference, it can

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usually be overcome by connecting the rotor directly to ground, for instance
by a wire loop. The stator should be fully grounded in the same way.
4.3 Connector pin assignment
The stator housing has two 7pin device plugs (Binder 723) and one 8pin
device plug.
The supply voltage connections and shunt signal connections of plugs 1 and 3
are each electrically interconnected, but are protected against compensating
currents by diodes. There is also an automatically resetting fuse (multifuse) to
protect the supply connections against overload by the stator.
Assignment for plug 1:
Supply voltage and frequency output signal.
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Binder 723
Top view
Binder
pin
Assignment Color
code SubD con
nector
pin
1 Torque measurement signal (frequency output;
5V1) wh 13
2 Supply voltage 0V; bk 5
3 Supply voltage 18V to 30V bu 6
4 Torque measurement signal
(frequency output; 5V1)) rd 12
5Meas. signal 0V; symmetrical gy 8
6 Shunt signal trigger 5V to 30V gn 14
7Shunt signal 0V; gy 8
Shielding connected to enclosure ground
1) Complementary signals RS422; for cable lengths of 10 m and longer, we recommend to
use a termination resistor R=120 ohms between wires (wh) and (rd).
CAUTION
Torque flanges are only intended for operation with a DC supply voltage.
They must not be connected to older HBM amplifiers with squarewave
excitation. This could destroy the connection board resistances or
cause other faults in the amplifiers.

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Assignment for plug 2:
TMC − only for connection to the TIM 40 Torque Interface Module within HBM.
Assignment for plug 3:
Supply voltage and voltage output signal.
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Binder 723
Top view
Binder
plug
pin
Assignment
1 Torque measurement signal (voltage output; 0V )
2Supply voltage 0V;
3 Supply voltage 18V to 30V DC
4 Torque measurement signal (voltage output; "10V)
5 no function
6 Shunt signal trigger 5V to 30V
7Shunt signal 0V;
Shielding connected to enclosure ground

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4.4 Supply voltage
The transducer must be operated with a separated extralow voltage
(18 to 30 VDC nominal (rated) supply voltage), which usually supplies one or
more torque flanges within a test bench.
Should the equipment be operated on a dc voltage network1), additional
precautions must be taken to discharge excess voltages.
The notes in this chapter relate to the standalone operation of the T40,
without HBM system solutions.
The supply voltage is electrically isolated from signal outputs and shunt signal
inputs. Connect a separated extralow voltage of 18 V to 30 V to pin 3 (+) and
pin 2 ( ) of plug 1 or 3. We recommend that you use HBM cable
KAB 8/002/2/2 and relevant Binder sockets, that at nominal (rated) voltage
(24 V) can be up to 50 m long and in the nominal (rated) voltage range,
20 m long (see Accessories).
If the permissible cable length is exceeded, you can feed the supply voltage in
parallel over two connection cables (plugs 1 and 3). This enables you to
double the permissible length. Alternatively an onsite power pack should be
installed.
CAUTION
The instant you switch on, a current of up to 4A may flow and this may
switch off power packs with electronic current limiters.
1) Distribution system for electrical energy with greater physical dilatation (over several test benches, for
example) that may possibly also supply consumers with high nominal (rated) currents.