HBM U10M User manual

A1385-6.2 en/de/fr
Force transducer
Kraftaufnehmer
Capteur de force
U10M/U10S
Montageanleitung
Mounting Instructions
Notice de montage

English Page 3 - 42.................................................
Deutsch Seite 43 - 83...............................................
Français Page 85 - 126..............................................

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Contents Page
Safety instructions 5..............................................
1Scope of supply and equipment variants 9.......................
2 General application instructions 11..............................
3 Structure and mode of operation 12..............................
3.1 Transducers 12............................................
3.2 SG cover 12...............................................
4 Conditions on site 13...........................................
4.1 Ambient temperature 13.....................................
4.2 Moisture and corrosion protection 13..........................
4.3 Deposits 13................................................
5 Mechanical installation 15.......................................
5.1 Important precautions during installation 15....................
5.2 General installation guidelines 15.............................
5.3 Assembly with adapter 16...................................
5.4 Mounting with knuckle eyes 18...............................
5.5 Assembly with adapter 19...................................
5.6 Mounting with mounted force application 21....................
6 Electrical connection 22.........................................
6.1 Connection with six‐wire configuration 22......................
6.2 Cable shortening or extension 23.............................
6.3 Connection with four‐wire configuration 23.....................
6.4 EMC protection 23..........................................
7 Electrical connection with TEDS 25..............................
7.1 TEDS transducer identification 25.............................
7.2 Hierarchy of rights for TEDS 25...............................
7.3 Content of the TEDS module as defined in IEEE 1451.4 26......
7.4 TEDS specifications 28......................................
7.5 Electrical connection with TEDS 28...........................
8 Versions and order numbers 29..................................
9 Specifications (VDI/VDE 2638) 31................................
9.1 U10M 31..................................................
9.2 U10S 33..................................................

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10 Dimensions 35.................................................
10.1 U10M/U10S with foot adapter 35.............................
10.2 U10M/U10S without foot adapter 38...........................
10.3 U10M with force application 39...............................
10.4 Accessories - Knuckle eyes 40...............................
10.5 Mounting dimensions of the connection variants 41.............

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Safety instructions
Designated use
The force transducers in the type series U10M/U10S are solely designed for
measuring static and dynamic tensile and/or compressive forces within the
load limits specified by the technical data for the respective maximum capacit
ies. Any other use is not the designated use.
To ensure safe operation, the regulations in the assembly and operating
instructions, together with the following safety rules and regulations, and the
data specified in the technical data sheets, must be complied with. It is also
essential to observe the applicable legal and safety regulations for the applic
ation concerned.
The force transducers are not intended for use as safety components. Please
also refer to the section: “Additional safety precautions". Proper and safe
operation of the force transducer requires proper transportation, correct stor
age, siting and mounting, and careful operation.
Loading capacity limits
The data in the technical data sheet must be complied with when using the
force transducer. In particular, the respective maximum loads specified must
never be exceeded. The following limits set out in the technical data sheets
must not be exceeded
Limit forces
Lateral limit forces
Breaking forces
Permissible dynamic loads
Temperature limits
Limits of electrical loading capacity
Please note that when several force transducers are interconnected, the load
/force distribution is not always uniform.
Use as a machine element
The force transducers can be used as machine elements. When used in this
manner, it must be noted that, to favor greater sensitivity, the force transducer
cannot be designed with the safety factors usual in mechanical engineering.
Please refer here to the section “Loading capacity limits" and to the specifica
tions.

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

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technology in such a way as to minimize residual dangers. Pertinent national
and local regulations must be complied with.
The markings used in this document
The marking below warns of a potentially dangerous situation in which failure
to comply with safety requirements can result in death or serious physical
injury.
WARNING
Description of a potentially dangerous situation
Measures to avoid/prevent the danger
The marking below warns of a potentially dangerous situation in which failure
to comply with safety requirements can result in slight or moderate physical
injury.
CAUTION
Description of a potentially dangerous situation
Measures to avoid/prevent the danger
The marking below warns of a situation in which failure to comply with safety
requirements could lead to damage to property.
NOTE
Description of a situation that could lead to damage to property
The marking below draws your attention to important information about the
product or about handling the product.
Important
Important information
The marking below contains application tips or other information that is useful
to you.

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Tip
Information/Application instructions
Conversions and modifications
The transducer must not be modified from the design or safety engineering
point of view except with our express agreement. Any modification shall
exclude all liability on our part for any damage resulting therefrom.
Maintenance
The force transducers U10M/U10S are maintenance‐free.
Disposal
In accordance with national and local environmental protection and material
recovery and recycling regulations, old transducers that can no longer be
used must be disposed of separately and not with normal household waste.
If you need more information about waste disposal, please contact your local
authorities or the dealer from whom you purchased the product.
Qualified personnel
Qualified personnel means persons entrusted with siting, mounting, starting
up and operating the product, who possess the appropriate qualifications for
their function.
This includes people who meet at least one of the three following require
ments:
- Knowledge of the safety concepts of automation technology is a require
ment and as project personnel, you must be familiar with these concepts.
- As automation plant operating personnel, you have been instructed how to
handle the machinery. You are familiar with the operation of the equipment
and technologies described in this documentation.
- As commissioning engineers or service engineers, you have successfully
completed the training to qualify you to repair the automation systems. You
are also authorized to activate, ground and label circuits and equipment in
accordance with safety engineering standards.
It is also essential to comply with the legal and safety requirements for the
application concerned during use. The same applies to the use of accessor
ies.
The force transducer may only be installed by qualified personnel, strictly in
accordance with the specifications and with the safety requirements and regu
lations.

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1 Scope of supply and equipment variants
Force transducer U10M (metric internal thread) or
U10S (UN/UNF internal thread)
U10M/U10S mounting instructions
Test certificate
Machine handles for handling use on variants 225 kN to 500 kN
Accessories (not included among the items supplied):
Cables/plugs Order number
Connection cable KAB157-3; IP67 (with bayonet locking); 3 m long, TPE outer
sheath; 6 x 0.25 mm2; free ends, shielded, outside diameter 6.5 mm 1-KAB157-3
Connection cable KAB158-3; IP54 (with screw locking); 3 m long, TPE
outer sheath; 6 x 0.25 mm2; free ends, shielded, outside diameter 6.5 mm 1-KAB158-3
Loose connecting socket (bayonet locking) 3-3312.0382
Loose connecting socket (screw locking) 3-3312.0354
Ground cable (400 mm long) 1-EEK4
Ground cable (600 mm long) 1-EEK6
Ground cable (800 mm long) 1-EEK8
Knuckle eye, M16 external thread 1-Z4/20kN/ZGUW
Knuckle eye, M33x2 external thread 1-ZGAM33F
Knuckle eye, M42x2 external thread 1-ZGAM42F
Knuckle eye, M72x2 external thread 1-ZGAM72F
Knuckle eye, M16 internal thread 1-Z4/20kN/ZGOW
Knuckle eye, M33x2 internal thread 1-ZGIM33F
Knuckle eye, M42x2 internal thread 1-ZGIM42F
Knuckle eye, M72x2 internal thread 1-ZGIM72F
Equipment options
All force transducers are available in different versions. The following options
are available:
1. Without adapter
You can purchase the force transducer without adapter. The force trans
ducer can then be directly screwed onto a structural element using the
pitch circle, see Fig. 1.1 on Page 10.

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Fig. 1.1: U10M with adapter (left) and without adapter (right)
2. Double bridge design
The force transducer is also available with two electrically isolated meas
urement bridge circuits.
3. TEDS
You can purchase the force transducer with transducer identification
(“TEDS"). TEDS (Transducer Electronic Data Sheet) allows you to store the
transducer data (characteristic values) in a chip, that can be read out by a
connected measuring device. Each measuring bridge has a separate TEDS
in the double bridge variant. See also Page 25.
4. Threaded connector or fixed cable
The force transducer is usually delivered with a bayonet connector. A
threaded connector or fixed cable 6 m long is instead available if required.
5. Calibration:
On request, HBM can calibrate the force transducer to 200% nominal
(rated) force. The high mechanical reserves of the force transducer enable
this application in purely static measurement tasks. Please note however
that the output signal doubles.
6. Force application part
On request, we can deliver the U10M with a force application bolt mounted
in the central thread, see Fig. 1.2 on Page 11.

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Fig. 1.2: U10M without force application bolt (left) and with mounted force applic
ation bolt (right); both pictures with foot adapter
2 General application instructions
The force transducers are suitable for measuring tensile and compressive
forces. Because they provide highly accurate static and dynamic force meas
urements, they must be handled very carefully. Particular care must be taken
when transporting and installing the devices. Dropping or knocking the trans
ducer may cause permanent damage.
Force transducers U10M have a metric internal thread and force transducers
U10S have an internal thread to UN/UNF standard.
The specifications on Page 31 list the permissible limits for mechanical,
thermal and electrical stress. It is essential that these are taken into account
when planning the measuring set‐up, during installation and, ultimately, during
operation.

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3 Structure and mode of operation
3.1 Transducers
The measuring element is a steel loaded member made of steel (for nominal
(rated) forces from 12.5 kN) or high‐strength aluminum (for nominal (rated)
forces up to 5 kN) to which strain gauges (SG) are applied. The SG are
arranged in each measuring circuit so that four are stretched and the other
four compressed when a force acts on the transducer. Each strain gauge
changes its ohmic resistance in proportion to its change in length and so mis
aligns the Wheatstone bridge. If there is an excitation voltage, the circuit pro
duces an output signal proportional to the change in resistance and thus also
proportional to the applied force. The arrangement of the SGs is selected so
that parasitic forces or torques and temperature influences are essentially
compensated for.
3.2 SG cover
To protect the SG, the force transducers have thin cover plates that are wel
ded (steel versions) or glued (aluminum versions) top and bottom. This pro
cedure offers the SG a high protection against environmental influences. In
order to retain the protective effect, these plates must not be damaged in any
way.

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4 Conditions on site
Protect the transducer from weather conditions such as rain, snow, ice and
salt water.
4.1 Ambient temperature
The temperature effects on the zero signal and on the sensitivity are com
pensated.
To obtain optimum measurement results, the nominal (rated) temperature
range must be complied with. The arrangement of the SG results in high
insensitivity to temperature gradients due to the construction. Nevertheless,
constant or very slowly changing temperatures are best. A radiation shield
and all‐round thermal insulation produce noticeable improvements, but must
not be allowed to set up a force shunt.
4.2 Moisture and corrosion protection
The force transducers are hermetically encapsulated and are therefore very
insensitive to moisture. The transducers reach the protection class IP67 per
DIN EN 60259 (test conditions: 0.5 hours under 1 m water column). Neverthe
less, the force transducers must be protected against permanent moisture
influence.
Optionally, the force transducers are also available fitted with a fixed cable. In
this version, all U10 achieve degree of protection IP68 with a nominal (rated)
force equal to or greater than 12.5 kN.
The transducer must be protected against chemicals that could attack the
steel (nominal (rated) forces from 12.5 kN) or aluminum (nominal (rated)
forces up to 5 kN).
With stainless steel force transducers, please note that acids and all materials
which release ions will also attack stainless steels and their welded seams.
Should there be any corrosion, this could cause the force transducer to fail. In
this case, appropriate protective measures must be implemented.
4.3 Deposits
Dust, dirt and other foreign matter must not be allowed to accumulate suffi
ciently to divert some of the measuring force onto the housing, thus invalidat
ing the measured value (force shunt). The relevant areas are marked in
Fig. 4.1.

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The gap must remain free
Fig. 4.1: Deposits at the marked areas must be avoided

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5 Mechanical installation
5.1 Important precautions during installation
Handle the transducer with care.
Comply with the requirements for the force application parts as specified in
Chapter 5.3 and Chapter 5.5.
Welding currents must not be allowed to flow over the transducer. If there is
a risk that this might happen, you must use a suitable low‐ohm connection
to electrically bypass the transducer. HBM, for example, provides the highly
flexible EEK ground cable, which can be screwed on above and below the
transducer.
Make sure that the transducer cannot be overloaded.
WARNING
There is a danger of the transducer breaking if it is overloaded. This can
cause danger for the operating personnel of the system in which the
transducer is installed.
Implement appropriate safety measures to avoid overloads (see Specifica
tions in Chapter 9, Page 31) or to protect against resulting dangers.
5.2 General installation guidelines
The forces to be measured must act on the transducer as accurately as pos
sible in the direction of measurement. Torques and bending moments, eccent
ric loading and lateral forces may produce measurement errors and destroy
the transducer, if limit values are exceeded.

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The customers's own structural elements (threaded bolts) must meet the fol
lowing conditions:
The upper and lower force application components must be aligned in one
axis. Installation is facilitated by centering aids on the top and bottom sides.
The admissible centering diameter corresponds to dimension D, the
admissible centering depth is 3 mm (see Page 35ff).
The anti‐screw‐through device attached to the interior thread of the adapter
must not be removed.
The (customer‐side) external thread must comply with a thread tolerance of
6g for metric threads and 3A for UN/UNF threads.
The threads must be cleaned of any deposits and soaked with graphite‐free
grease before being screwed in.
The following applies for steel force transducers (nominal (rated) forces
from 12.5 kN): To achieve the full endurance strength, a material with
sufficient tensile strength (min. Rp,0.2 = 900 N/mm2) and hardness
(min. 40 HRC) must be used. We recommend the use of threads rolled
after heat treatment for measurement ranges between 225 kN and 500 kN.
The screwed‐in force application units must be sufficiently pre‐stressed to
meet the specified specifications and the full endurance strength of the
threads. This is implemented with a locknut screwed onto the customer‐side
structural element. We recommend using one of the methods described
below.
1. Pre‐stressing with defined tightening torque
Screw the force application part into the transducer or adapter as far as
the retainer.
Unscrew force application part two revolutions.
Pre‐stress force application part with defined tightening torque.
Nominal (rated)
force Tightening torque MAScrew‐in depth
in kN in N@min lb@inch in mm in inch
1.25 17 150 26.4 1.04
2.5 35 310 26.4 1.04
5 68 600 26.4 1.04
12.5 135 1195 26.4 1.04
25 135 1195 26.4 1.04
2. Pre‐stressing with tensile forces (for nominal (rated) forces from 50 kN)
Force transducers with any nominal (rated) force can be mounted using
this method. The procedure should always be used for for force trans

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ducers from 50 kN in dynamic sustained loading, as the torque moment
required for the locknut would be too high in Method 1.
Screw the force application part into the transducer or adapter as far as
the retainer.
Unscrew force application part two revolutions.
Load the force transducer in the tensile direction to 120% of the max
imum operating force. The following table shows the tensile forces to be
applied when the transducer is subsequently loaded with the nominal
(rated) force. Correspondingly smaller tensile forces can be used for
applications in small force ranges.
Nominal (rated) force
in kN
Tensile force to be applied
in kN
50 60
125 150
225 270
250 300
450 540
500 600
The pre‐stressing force increase correspondingly when transducers with
the option “200% calibration" are used. If, for example, a U10M/125KN is
delivered with 200% calibration, the maximum operating force is then
250 kN. The pre‐stressing force to be applied here is then 300 kN.
Tighten both locknuts (adapter and force transducer) by hand.
Relieve the force transducer.
Important
The adapter should not be removed from the transducer versions with
adapter. Otherwise this may result in a slight deviation of the transducer char
acteristic values from the given values.
5.4 Mounting with knuckle eyes
Knuckle eyes are used in this mounting variant. These installation aids pre
vent the application of torque moments and, where two knuckle eyes are
used, bending moments, together with lateral and oblique loads in the trans
ducer.
Pre‐stressing the knuckle eyes is not possible. Knuckle eyes do not have high
endurance when the full vibration bandwidth is used. They are therefore inten

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Installation is facilitated by centering aids on the top and bottom sides of the
transducer. The admissible centering depth on the bottom side is equivalent to
the dimension Z (see Page 38). In order to transfer the lateral forces specified
in the data sheet, we recommend using the centering aids.
The customers's own structural elements (contact surfaces) must meet the
following conditions:
They must be in parallel to each other.
They must be paint‐free.
They must be oil and grease‐free, cleaning can be implemented e.g. with
RMS-1 (HBM order number 1-RMS1).
They must be sufficiently hard (minimum HRC 40).
They must be sufficiently rigid so that they do not warp.
The flatness of the contact surface is ideal when a tolerance of 0.005 mm
is not exceeded under load.
The screws used must comply with the property class specified in the
following table and tightened with the specified tightening torque. The
strength of the threaded holes must be high enough so that screws of the
specified property class can be used.
Nominal
(rated)
force
in kN
Tightening torque
MB*)
in Nm
Screws for transducer mounting
Number Metric Property
class UNF Grade
1.25 - 5 9 8 M6 x 40 8.8 1/4"5
12.5 - 25 15 8 M6 x 40 10.9 1/4"8
50 - 125 76 12 M10 x 1.25 x 55 10.9 3/8"8
225 - 250 150 16 M12 x 1.25 x 80 12.9 1/2"9
450 - 500 380 16 M16 x 1.5 x 100 12.9 5/8"9
*) Screws lightly oiled
MBMB
Fig. 5.2: Installation without adapter
Mount the screws in diagonally opposite sequence: After tightening one
screw, continue with the screw opposite. Do not apply the specified torque
immediately, increase the tightening torque in several steps. Initially, the