HBM TOP Transfer User manual

B 20.TOPTRANS.10 en
Force transfer standard
TOP Transfer
Mounting Instructions

B 20.TOPTRANS.10 en HBM
Content page
Safety instructions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Scope of supply 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Applicationinformation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Structure and mode of operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 TOP–Z30 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 TOP–Z4A 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Conditionson site 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Ambient temperature 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Moisture 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Air pressure 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Chemical effects 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Loading disturbance variables 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Electromagneticcompatibility 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Mechanicalinstallation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Important measures for installation 13. . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Mounting accessories for compressive loading 14. . . . . . . . . . . . . . . . .
5.2.1 Installation drawing for compressive loading 14. . . . . . . . . . . . . .
5.3 Mounting accessories for tensile loading 15. . . . . . . . . . . . . . . . . . . . . . .
6 Electrical connection 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Instructions for cabling 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Wiring pin assignment 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Specifications 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 TOP Transfer dimensions 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Declaration of conformity 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Safety instructions
Use in accordance with the regulations
Force transducers of TOP Transfer types: TOP–Z30 and TOP–Z4A are used
to make comparative force measurements (force transfer). 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 TOP–Z30 and TOP–Z4A force transducer correspond 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 minimize remaining dangers. Prevailing regulations must be complied with
at all times. There must be reference to the remaining dangers connected with
force measurement technique.

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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: Possibly 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).
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

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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
Force transducers TOP–Z30 and TOP–Z4A are 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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1 Scope of supply
•Force transducer TOP–Z30, TOP–Z4A
•Operating Manual TOP Transfer
The TOP Transfer force transducers are only available in conjunction
with a DKD calibration certificate (not included in the scope of supply)
•DKD calibration certificate according to EN10002–3,
ISO 376 Order no. K–CAL–FD...
Accessories for TOP–Z30
•Knuckle eyes ZGW/ZGOW
for 100 N to 1000 N: Order no. 1–U1R/200kg/ZGW
for 2 kN to 10 kN: Order no. 1–U2A/1t/ZGUW
•Thrust piece according to EN 10002–3 or ISO376
for 100 N to 1000 N: Order no. EDO3/1kN
for 2 kN to 10 kN: Order no. EDO4/50kN
•Load button
for 100 N to 1000 N: Order no. 1–U1R/200kg/ZL
for 2 kN to 10 kN: Order no. 3–9202.0140
•Tensile force introduction according to EN10002–3 or ISO376
for 2 kN –10 kN Order no. 1–Z30/10kN/ZKM
•Cable/male connector
–Connection cable Kab 139–A–6, 6m,
with Binder cable socket and pigtails; Order no. 1–KAB139A–6
–Connector MS3106PEMV
fitted to Kab139A; Order no. D–MS/MONT
–15-pin D-Sub connector (male)
fitted to Kab139A; Order no. D–15D/MONT

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Accessories for TOP–Z4A
•ZKM tensile force introduction according to EN10002–3 or ISO376
for 20 kN: 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
•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
•Thrust piece EDO4 according to EN 10002–3 or ISO376
20kN Order no. 1–EDO4/20kN
50kN Order no. 1–EDO4/50kN
100kN Order no. 1–EDO4/100kN
200kN Order no. 1–EDO4/200kN
500kN Order no. 1–EDO4/500kN

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2 Application information
Force transducer TOP Transfer
High-precision force transducers of the TOP–Z30 and TOP–Z4A type series
measure compressive and tensile forces.
They measure static and quasi-static forces with great accuracy and
reproducibility and thus require extremely cautious handling. You must take
particular care when transporting and installing the devices. If you knock or
drop the transducers, this could permanently damage them. With TOP
Transfer, as you are dealing with a transducer of the utmost precision for
transfer measurements, it is advisable to keep a constant ambient
temperature in the nominal (rated) temperature range.
TOP–Z30 and TOP–Z4A transducers with DKD calibration certificate:
The standard is for transducers to be calibrated in the pressure direction. If
required, however, they can also be calibrated within the German calibration
service (DKD) in the tension direction. For high-precision measurements, the
transducer should only ever be loaded and used in one force direction.
The limits for the permissible mechanical, thermal and electrical stresses are
stated in the specifications. Be sure to allow for them when planning, installing
and operating the measurement configuration .
To obtain optimum measurement results, the transducer must be connected to
an amplifier of the greatest accuracy (for example, the DMP40 from HBM).

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3 Structure and mode of operation
3.1 TOP–Z30
Fig.3.1 TOP–Z30 (100 N...10 kN)
The measuring body comprises a system of measuring springs with strain
gauges. Two internal threads attached on both sides are used to introduce the
tensile forces. To introduce compressive forces, load buttons to screw into the
thread are available as accessories.
All the nominal (rated) forces of the TOP–Z30 have the same size.
The electrical connection is made via Binder male connectors. To reduce the
bending moment during tensile measurements, caused by the cable when the
outgoing cable is at the side, an additional male connector is provided on the
base of the housing.

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3.2 TOP–Z4A
1 = Measuring body
2 = Termination diaphragms
3=SG
4 = Threaded pin
5 = Cable box
6 = Tapped hole
423
1
6
2
5
Fig.3.2 TOP–Z4A (20 kN...500 kN)
The measuring body comprises a system of measuring springs with 8 applied
strain gauges (S.G.).
For the introduction of tensile forces, the TOP–Z4A transducer has a crowned
threaded pin at the top (also suitable for the introduction of compressive
forces) and a tapped hole at the bottom.
The housing with the integrated system of measuring springs is protected at
the top and bottom by thin metal diaphragms.

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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 uneven cooling or heating (for example by radiant
heat). A radiation shield and all-round heat insulation bring about marked
improvements. They must not form a force shunt.
4.2 Moisture
Extreme moisture or a tropical climate are to be avoided if they fall outside the
classified limits (TOP–Z4A degree of protection IP67 to DIN EN 60529;
TOP–Z30 degree of protection IP50).
4.3 Air pressure
Variations in air pressure do not affect the TOP–Z30 force transducer.
Variations in air pressure affect the TOP–Z4A force transducer in the same
way as force variations. With normal ambient pressure variations "20mbar,
however, the effect on the measurement signal is negligible (air pressure
variations of "10 mbar only have an effect on the zero signal of max. 6 N
with 20 kN and 50 kN transducers).
4.4 Chemical effects
The transducer housings are protected by a powder coating. They must not
be exposed to onerous environmental conditions (direct atmospheric
exposure, contact with media that encourage corrosion to develop).
The uncoated force introduction areas of the TOP–Z4A are greased to protect
them against corrosion.
4.5 Loading 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 ).

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4.6 Electromagnetic compatibility
The transducers have been tested for use in controlled electromagnetic envi-
ronments acc. to EN61326:2002;TabB.1.
5 Mechanical installation
5.1 Important measures for installation
–handle the transducer gently, it is essential not to apply mechanical stress
to the housing diaphragm
–when handling, always wear thermally insulated gloves
–before measuring, allow enough time for the force transducer to reach a
stable temperature with regard to its mounting parts and its environment.
For precision measurements, it is advisable to wait approx. 24 hours.
–connect the force transducer to the excitation voltage approx. 1 hour before
measurement
–when measuring compressive forces, make sure that the support structure
is rigid and level
–the force–introduction surfaces and the thread must be totally clean and
fully bearing
–keep to the engagement depths for the threaded rods or knuckle eyes. If
the engagement depths are changed, this may adversely affect
repeatability.
–do not overload the transducer, only load it up to its operating force
–forces must work as accurately as possible on the transducer in the
direction of measurement.
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.
WARNING
Torsion and bending moments, eccentric loading and
transverse forces result in measurement errors and if limit
values are exceeded, could destroy the transducer.

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5.2 Mounting accessories for compressive loading
Thrust pieces according to EN10002–3 or ISO376 are available for
introducing the compressive forces.
For the TOP–Z30, thrust pieces EDO3/1kN or EDO4/50kN (see Page 26) and
two load buttons (see page 25) are available.
With the TOP–Z4A, the thrust piece (see page 32) can be placed directly on
the crowned threaded pin.
5.2.1 Installation drawing for compressive loading
F
Thrust piece
Load button
Transducer
TOP–Z30 TOP–Z4A
F
Transducer Load button Thrust piece
TOP–Z30/ 100 N –1000 N 1–U1R/200kg/ZL EDO3/1kN
TOP–Z30 / 2 kN –10 kN 3–9202.0140 EDO4/50kN
TOP–Z4A / 20 kN –EDO4/20kN
TOP–Z4A / 50 kN –EDO4/50kN
TOP–Z4A / 100 kN –EDO4/100kN
TOP–Z4A / 200 kN –EDO4/200kN
TOP–Z4A / 500 kN –EDO4/500kN

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5.3 Mounting accessories for tensile loading
Knuckle eyes and tensile force introductions (ZKM) according to ISO376 are
available for installing the TOP–Z30 and the TOP–Z4A. These 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.
Installing the knuckle eyes
•Screw in the thread of the knuckle eye until it reaches the stop in the
transducer’s internal thread and then unscrew by a full revolution.
•Additionally, with the Z4A/500kN: by turning the knuckle eye, bring the
holes of the sleeve and the slots of the knuckle eye to the cover. Screws
can then be attached to form a twist-proof fixing.
Knuckle eye ZGOW/ZGUW for TOP–Z4A
W
MA
MASleeve
a
f
∅B
W
Knuckle eyes ZGW/ZGUW
for TOP–Z30
a
f
∅B
Upper/lower knuckle eye
j
Type Upper/lower knuckle eye
Order number a f W
j
B
TOP–Z30/100N
–1000N 1–U1R/200kg/ZGW 147.5 170 12 8H7
TOP–Z30/2kN –
10kN 1–U2A/1t/ZGUW 169 201 16 12H7

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Type
upper knuckle
eye Weight a
approx. f approx. W∅B MA
Type lower knuckle
eye (kg) min max min max W
∅
B (Nm)
TOP-Z4A/20 kN 1–Z4/20kN/
ZGOW
1–Z4/20kN/
ZGUW 0,2 158 170 198 210 21 16H7 120
TOP-Z4A/50 kN 1–U2A/2t/ZGOW
1–U2A/2t/ZGUW 0,8 0,4 190 199 245 254 25 20H7 350
TOP-Z4A/100 kN 1–Z4/100kN/
ZGOW
1–Z4/100kN/
ZGUW 1,1 261 269 331 339 37 30H7 950
TOP-Z4A/200 kN 1–U2A/10t/
ZGOW
1–U2A/10t/
ZGUW
3,2
1,1 352 357 475 480 35 50 +0,001
–0,014 20001)
TOP-Z4A/500 kN 1–Z4/500kN/
ZGOW
1–Z4/500kN/
ZGUW
17,3
12,0 570 590 764 784 44 60 +0,003
–0,018 40002)
1) Secure the underside with two screws to stop it twisting; for the side of the pin with the external thread
only
To install the transducers without play, they must be sufficiently prestressed
and locked with the mounting accessories (knuckle eyes, tension bars or
pressure bars).
The tightening torques MArecommended in the table for the TOP–Z4A, must
be conducted non-positively through the transducer and must not be
exceeded.
When locking, make sure that the transducer signal changes by no more than
0.1%.
For transducers with nominal (rated) forces 100 N..200 kN, tensile loading can
also be locked in the following way:
•screw in the thread of the knuckle eye until it reaches the stop in the
transducer’s internal thread and then unscrew by a full revolution.
•load transducer with 10..20% of the nominal force
•tighten the lock nut of the lower knuckle eye
NOTE
With the TOP–Z30, tighten first the nut on the base and then the
upper nut; hold the TOP–Z30 by the flat of the nut.

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Installation with force introduction piece ZKM according to EN10002–3 or
ISO376
∅D
C
b
ZKM tensile force introduction for TOP–Z4A
∅D
C
b
Tensile force introduction ZKM for
TOP–Z30
ZKM C
j
Type ZKM
Order number bmin max
j
D
TOP–Z30/2kN–
10kN 1–Z30/10kN/ZKM 229 250 312 35 –0.120
–0.280
Type ZKM accessories Weight BC
∅
(kg) B
min max
∅
D
TOP–Z4A/20kN Z4A/20kN/ZKM 0.82 325 228 276 35–0.120
–0.280
TOP–Z4A/50kN Z4A/50kN/ZKM 1.45 350 248 299 45 –0.130
–0.290
TOP–Z4A/100kN Z4A/100kN/ZKM 2.32 395 277 334 50 –0.130
–0.290
TOP–Z4A/200kN Z4A/200kN/ZKM 4.19 447 317 382 64 –0.170
–0.330
TOP–Z4A/500kN Z4A/500kN/ZKM 20.1 623 432 522 90 –0.170
–0.390
Installation:
•Screw in the thread of force introduction piece ZKM until it reaches the stop
in the transducer’s internal thread and then unscrew by a full revolution.

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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 meter).
•Avoid stray fields of transformers, motors and contactors.
•Do not earth transducer, amplifier and display device more than once. All
the devices in the measurement 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
TOP–Z30
Two 7-pin male device connectors are located on the enclosure (male
connectors, Series 723). To avoid creating force bypasses through the cable,
you can use either the lower or the lateral connector, depending on the
configuration.
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.
Pin
Male connector Assignment Wire colour
1Measurement signal (+) WH
2Excitation voltage (–) BK
3Excitation voltage (+) BU
4Measurement signal (–) RD
5No function –
6Sensor circuit (+) GN
7Sensor circuit (–) GY
Fig. 6.1: Male connector, series 723 (screwed)
61
572
43
Male connector, series 723
Top view

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TOP–Z4A
The 3m long transducer connection cable has color-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.
If connectors are fitted, the shielding must have a plane contact 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).
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)
bl (blue)
gn (green)
gy (gray)
Shield
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. 6.2: Pin assignment of TOP–Z4A

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7 Specifications
Type TOP-Z30 TOP-Z4A
Data according to VDI standards
2638
Nominal force Fnom kN 0.1 –1 2 –
10 20 –50 100 – 500
Nominal sensitivity Cnom mV/V 2 2
rel. sensitivity deviation dc% 0.1 0.1
rel. tensile/compressive force
sensitivity difference dzd % 0.1 0.2
Zero signal tolerance
rel. zero point compensation (zero
signal return)1)
ds,o
fomV/V
%0.1 0.004 0.01 0.004
Rel. range (0.2Fnom to Fnom) at:1)
unchanged mounting position bi% 0.002 0.003
different mounting positions
Compressive force
Tensile force
b%
%0.005 0.01 0.008 0.016
Rel. range of inversion (0.2Fnom to
Fnom)1) u % 0.03 0.033)
Cubic interpolation error
(0.2Fnom to Fnom)1) fc% 0.002 0.002
Effect of temperature/10K
by reference to nominal sensitivity
on sensitivity
on zero signal TKc
TK0%
%0.015 0.015 0.01 0.01 0.01 0.015
Effect of transverse forces
(transverse forces 10% Fnom)2) dQ% 0.1 0.03
Effect of eccentricity per mm dE% 0.005 0.01 0.005
Rel. creep over 20 min dcrF+E % 0.01 0.01
Input resistance ReΩ>345 >690 >345
Output resistance RaΩ300–500 600–
800 356"0.3
Isolation resistance Ris Ω>5⋅109>5⋅109
Reference excitation voltage Uref V 5 5
Operating range of the excitation
voltage BU,G V0.5 ... 12 0.5 ... 12
Nominal temperature range Bt,nom °C +17...+27
Operating temperature range Bt,G °C 0...+40
Storage temperature range Bt,S °C -10...+70
Reference temperature tref °C +22
1) Specifications to EN10002–3 or ISO376
2) applies in the case of the TOP-Z4A half pin height
3) in the case of tensile force TOP–Z4A/500 kN: 0.07%