HBM U93 User manual

A2081-2.2 en/de/fr
Kraftaufnehmer
U93
Montageanleitung
Mounting Instructions
Notice de montage
Force transducer
Capteur de force

English Seite 3 - 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutsch Page 23 - 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Français Page 43 - 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Contents Page
English
Safety Instructions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Scope of supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Application instructions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Structure and mode of operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Measuring body 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Strain gage covering 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Conditions on site 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Ambient temperature 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Moisture and humidity 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Deposits 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Mechanical installation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Important precautions during installation 12. . . . . . . . . . . . . . . . . . . .
5.2 General installation guidelines 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Mounting for tensile/compressive loading 13. . . . . . . . . . . . . . . . . . .
6 Electrical connection 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Notes on cabling 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Assignment of cable wires 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 Connecting to terminals 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.2 Connecting to a plug 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 TEDS transducer identification 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Specifications (VDI/VDE2638) 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Dimensions 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Options 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Safety Instructions
Designated use
The force transducers in the U93 type series are solely designed for measur
ing (static and dynamic) tensile and dynamic compressive forces within the
load limits specified by the technical data for the respective maximum capaci
ties. Any other use is not the designated use.
To ensure safe operation, the regulations in the mounting and operating in
structions, together with the following safety requirements, and the data speci
fied in the technical data sheets, must be complied with. It is also essential to
observe the applicable legal and safety regulations for the application con
cerned.
The force transducers are not intended for use as safety components. Please
also refer to the section: “Additional safety precautions”. Proper and safe op
eration of the force transducer requires proper transportation, correct storage,
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 loads
•Lateral load limits
•Breaking loads
•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 constructive mea
sures 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 applica
ble 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 in
volved 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 de
stroyed by non‐designated use of the force transducer or by non‐
compliance with the mounting and operating instructions, these safety instruc
tions or any other applicable safety regulations (BG safety and accident pre
vention regulations) when using the force transducers. Force transducers can
break, particularly in the case of overloading. The breakage of a force trans
ducer can also cause damage to property or injury to persons in the vicinity of
the force transducer.
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 gage 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. On‐site regulations
must be complied with at all times.
Warns of a potentially dangerous situation in which failure to comply with
safety requirements could result in death or serious physical injury.
WARNING
Description of a potentially dangerous situation
Measures to avoid/prevent the danger
The marking below draws your attention to a situation in which failure to com
ply 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.
Tip
Information/application instruction
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 ex
clude all liability on our part for any damage resulting therefrom.
Maintenance
The U93 force transducer is maintenance free.

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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 ap
plication concerned during use. The same applies to the use of accessories.
The force transducer must only be installed by qualified personnel, strictly in
accordance with the specifications and with the safety requirements and regu
lations listed below.

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1 Scope of supply
•U93 force transducer
•U93 operating manual
•Manufacturing certificate
2 Application instructions
The U93 type series transducers are suitable for measuring tensile and com
pressive forces. Because they provide highly accurate static and dynamic
force measurements, they must be handled very carefully. Particular care
must be taken when transporting and installing the devices. Dropping or
knocking the transducers may cause permanent damage.
It is essential to provide careful sealing so that the sensitive strain gage ap
plications are protected by the housing. Particular caution must be exercised
with the base of the housing, which is very thin.
The specifications on page 20 list the permissible limits for mechanical, ther
mal and electrical stress. It is essential that these are taken into account when
planning the measuring set‐up, during installation and, ultimately, during op
eration.

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3 Structure and mode of operation
3.1 Measuring body
The measuring element is a stainless steel, loaded member, to which strain
gages (SG) are applied. The SG are arranged so that two are stretched and
the other two compressed when a force acts on the transducer.
3.2 Strain gage covering
To protect the SG, the U93 force transducers are welded at an appropriate
place with a thin metal plate. This procedure offers the SG a high protection
against environmental influences. In order to retain the protective effect, this
plate must not be damaged in any way; see section 5.2 on page 12.

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4 Conditions on site
Protect the transducer from extreme moisture and dampness, weather condi
tions such as rain, snow and ice, and salt water.
4.1 Ambient temperature
The temperature effects on the zero signal and on the sensitivity are compen
sated.
To obtain optimum measurement results, the nominal (rated) temperature
range must be observed. Constant, or very slowly changing temperatures are
optimal. Temperature‐related measurement errors are caused by heating on
one side (e.g. radiant heat) or by cooling. A radiation shield and all‐round ther
mal insulation produce noticeable improvements, but must not be allowed to
set up a force shunt.
4.2 Moisture and humidity
Series U93 force transducers are hermetically weld‐sealed, giving them de
gree of protection IP67 per DIN EN 60529 (test conditions: 100 hours under
1m water column). Nevertheless, the force transducers must be protected
against permanent moisture influence.
NOTE
Moisture must not be allowed to penetrate the free end of the connection
cable. Otherwise the characteristic values of the transducer could vary, and
cause measurement errors.
The transducer must be protected against chemicals that could attack the
transducer body steel or the cable. 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.

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4.3 Deposits
Dust, dirt and other foreign matter must not be allowed to accumulate suffi
ciently to divert some of the measuring force, thus invalidating the measured
value (force shunt).
NOTE
Measurement errors may be the result if dust or dirt is deposited inside the
force transducer. The relevant areas are marked by arrows in Fig. 4.1.
The gap below the flange face must
not become clogged with foreign
matter.
Fig. 4.1: Avoid deposits in the marked areas

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5 Mechanical installation
5.1 Important precautions during installation
•Handle the transducer with care.
•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, both 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 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. Torsional and bending moments, ec
centric loading and lateral forces may produce measurement errors and de
stroy the transducer, if limit values are exceeded.
NOTE
The transducer is hermetically sealed underneath by a welded base. This
base is very thin, and must not be subjected to mechanical stress (Fig. 5.1),
as otherwise the housing could be damaged. This would allow moisture to
penetrate and destroy the transducer.

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Load must not be applied
here!
Fig. 5.1: Avoid the application of load to the marked surface
Important
The cable fastening side of the transducer should always be connected dir
ectly with the rigid customer‐side force transfer areas. Ensure that the cable is
laid so that, where possible, no force shunt is caused by the cable (e.g.
through the weight or stiffness of the cable).
5.3 Mounting for tensile/compressive loading
The transducer is bolted directly (via the ring‐shaped flange faces) onto a
rigid, fully‐bearing structural element (such as a profile, a cover or a plate).
With this method of installation, transducers can measure axial forces in both
the tensile and pressure directions. Alternating loads can also be recorded
perfectly.
•For exact positioning, the transducer is fitted with centering aids on the
upper and lower mounting surfaces.
•The upper and lower bearing pads must be flat and even. The roughness of
the base bearing pad must not exceed Ra= 0.8μm.
•The component mounted on the U93 must be sufficiently hard and must not
deform when load is applied. We recommend a hardness of 43HRC.
•Thoroughly clean the bearing pads before assembly.
•For dynamic alternating loads, the tightening torque for the screws must be
selected so that the screws are pre‐stressed to above the operating load of
the transducer. The requisite data can be found in the table below.

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45°or 22.5°
offset in the drawing
MA
MA
customer
side
customer
side
Base
Flange
ØC
Center the U93 over diameter C!
admissible
centering depth
1 mm
admissible
centering depth 1.5 mm
ØC
F
Fig. 5.2: Force transducer installation
Nominal
(rated) force
(kN)
Centering
diameter CH8 Tightening torque MA(NVm) Screws for transducer
mounting
min. floor side
thread reach
(mm)
1kN …10kN 18 9 4 x M5; 12.9 5
20kN …50kN 32 16 8 x M6; 12.9 8
Important
When screwing through the upper tapped hole, make sure that a gap remains
between the screw and the transducer body, even when the nominal (rated)
force is applied. Otherwise there would be a force shunt, that could lead to
measurement errors.

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6 Electrical connection
The transducers are delivered with a 3 m cable with free ends as standard,
and the cable terminations are color‐coded. The cable shield is connected in
accordance with the Greenline concept. This encloses the measurement sys
tem in a Faraday cage. Electromagnetic interference cannot affect the mea
surement system.
Transducers with free ends must be fitted with CE‐norm connectors. The
shielding must be connected extensively.
With other connection techniques, an EMC‐proof shield should be applied in
the wire area and this shield should also be connected extensively (see also
HBM Greenline Information, brochure i1577).
6.1 Notes on cabling
•Use shielded, low‐capacitance HBM cables only.
•Do not route the measurement cables parallel to power lines or control
circuits. If this is not possible (in cable pits, for example), protect the
measurement cable with a rigid steel conduit, for example and keep it at
least 50 cms away from the other cables. The power lines or control circuits
should be twisted (15 twists per meter).
•Avoid stray fields from transformers, motors and contact switches.
•Do not ground the transducer, amplifier and indicator more than once, and
attach all the devices in the measuring chain to the same protective earth
conductor.
•The connection cable shielding is connected to the transducer housing.
•Follow the connection diagram and keep to the (Greenline) grounding
concept.
•To achieve full accuracy, a six‐wire configuration should be used for an
extension cable.
6.2 Assignment of cable wires
If the transducer is connected in accordance with the wiring diagram below
(Fig. 6.1), when the transducer is loaded in the pressure direction, the output
voltage at the amplifier is positive.

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wh (white)
bk (black)
rd (red)
bu (blue)
gn (green)
gy (gray)
ye (yellow)
Measurement signal (+) UA
Excitation voltage (+) UB
Sense lead (-) and TEDS
Sense lead (+)
Excitation voltage (-) UBand TEDS
Measurement signal (-) UA
Cable shield, connected to the housing
Fig. 6.1: U93 pin assignment (six‐wire configuration)
Tip
Swap the white and red cable wires over, if you need a negative output volt
age at the amplifier under compressive loading.
6.2.1 Connecting to terminals
1. Cut the cable sheath as shown in Fig. 6.2, to gain access to the shield.
2. Connect the shield extensively to the housing ground.
6.2.2 Connecting to a plug
Connect the cable shield extensively to the connector housing.
Cable sheath cut open around the
circumference and pushed forward by about
2 mm
100
10
10
2
Fig. 6.2: Cable sheath with incision

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6.3 TEDS transducer identification
TEDS stands for “Transducer Electronic Data Sheet”.
An electronic data sheet can be stored in the transducer as defined in the
IEEE1451.4 standard, making it possible for the amplifier to be set up auto
matically. A suitably equipped amplifier imports the transducer characteristics
(electronic data sheet), translates them into its own settings and measure
ment can then start.
At the gray connection (to ground at black), there is a digital identification sys
tem available. The basis for this is a DS2433 1‐wire EEPROM, made by Max
im/Dallas.
HBM provides you with the TEDS Editor program, for storing your data. This
is a component part of the MGCplus Assistant software, for example, or the
TEDS dongle module from HBM, that allows you to program TEDS, even
without an amplifier.
Hierarchy of rights for TEDS
The TEDS Editor uses a hierarchy of rights:
1. Standard rights (USR level)
This level concerns entries that can be modified by any user, and which are
changed subject to their application, for example: measuring point name,
zero value, filters.
2. Calibration rights (CAL level)
This level concerns entries that a calibration laboratory must be able to
change, if, for example, the sensitivity in a TEDS module has to be updated
after recalibration.
3. Administrator rights (ID level)
Administrator rights in relation to TEDS are needed by the sensor manufac
turer. In the case of a self‐built sensor or subsequent upgrading with TEDS,
HBM customers can of course also make use of these rights.
Different user rights are needed in order to amend the entries in the so‐called
“templates”, and these rights may differ from one entry to the next within a
template. However, when used later with other programs, the software must
also support rights management, otherwise all the entries would be accessible
(the hierarchy of rights specified in the TEDS standard is not monitored by the
TEDS module, and not every software package supports rights management).
Contents of the TEDS module, as defined in IEEE 1451.4:
The information in the TEDS module is organized into areas, which are pres
tructured to store defined groups of data in table form. Only the codes of the
different templates and their associated values are stored on the TEDS mod
ule itself.

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The amplifier firmware assigns which template is to contain which data, and
the interpretation of the respective numerical values. This means that the
memory requirement for the TEDS module is very low. All the TEDS tem
plates are in English.
The memory content is divided into three areas:
Area 1:
An internationally unique TEDS identification number (cannot be changed).
Area 2:
The base area (basic TEDS), to the configuration defined in standard IEEE
1451.4. The transducer type, the manufacturer and the transducer serial num
ber are contained here.
Area 3:
Data specified by the manufacturer and the user are contained in this area.
HBM has already written the Bridge Sensor template for U93 force transduc
ers. The physical measurand and the physical unit are also defined when the
template is created.
The available unit for the particular measurand is specified in the IEEE Stan
dard. For the measurand of force, this is the unit N.
The resolution of the characteristic values mapped in TEDS (characteristic
curve of the transducer) must also be selected when the template is created.
HBM always opts for “Full Precision” here, in order to be able to use maxi
mum digital resolution. This choice is also recommended to users who pro
gram the TEDS module themselves.
Example:
Template: Bridge Sensor
Parameters Value 1) Unit Rights
level Explanation
Transducer electrical
signal type Bridge sen sor ID
Minimum force/
weight 0.000 N CAL The physical measurand and unit are
defined when the template is created,
after which they cannot be changed.
Maximum force/
weight 2.000 k NCAL
Minimum electrical
value 0.00000 m V/V CAL The difference between these values
is the sensitivity according to the
HBM manufacturing certificate or
from calibration.
Maximum electrical
value 1.00078 m V/V CAL
Mapping method Linear This entry cannot be changed.
Bridge type Full bridge ID Bridge type.
For HBM's SG‐based transducers,
the bridge type is always full bridge.

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Parameters ExplanationRights
level
UnitValue 1)
Impedance of each
bridge element 345.0 ohm ID Input resistance according to the HBM data sheet
Response time 1.0000000
usec ID Not relevant to HBM transducers.
Excitation level
(nominal) 5.0 V ID Nominal (rated) excitation voltage according to the HBM data sheet
Excitation level
(minimum) 0.5 V ID Lower limit for the operating range of the excitation voltage according to
the HBM data sheet.
Excitation level
(maximum) 12.0 V ID Upper limit for the operating range of the excitation voltage according to
the HBM data sheet.
Calibration date 1‐Jun‐2006 CAL Date the manufacturing certificate
was created at HBM (or date of last
calibration or entry of TEDS data).
Format: day‐month‐year.
Calibration initials HBM CAL Initials of the calibrator or calibration
laboratory concerned (max. three
characters).
Calibration period
(days) 730 days CAL Time before recalibration, calculated from the date specified under
Calibration Date.
Measurement location
ID 0USR Identification number for the measuring point (assigned by the
user). Possible values: 0 to 2047
(numbers only). The HBM Channel
Comment template is also available
as a supplement.
1) Typical values for an HBM U93/2kN type force transducer, manufactured on 1.6.2006
The user can also write other templates, such as the Signal Conditioning
template.

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7 Specifications (VDI/VDE2638)
Nominal (rated) force Fnom kN 1 2 5 10 20 50
Nominal (rated) sensitivity Cnom mV/V 0.5 1 0.5 1 0.5 1
Relative sensitivity error
(pressure) dC%<"0.5
Relative zero signal error ds.o mV/V <"0.075
Hysteresis error
(0.5Fnom to Fnom)ν0.5 %<"0.5
Relative non‐linearity (pressure) dlin %<"0.5
Effect of temperature on
sensitivity per 10 K
relative to nominal (rated) sensitivity TKc%<"0.5
Temperature effect on the zero
signal/10 K
relative to nominal (rated) sensitivity TK0%< 0.8 < 0.5 < 0.8 < 0.5 < 0.8 < 0.5
Effect of lateral forces 1)
(lateral force 10 % Fnom)dQ%< 0.2 < 0.5 < 0.4
Effect of eccentricity per mm dE%< 0.07 < 0.03 < 0.12
Relative creep over 30 min dcrF+E %<"0.2
Input resistance RiΩ> 295
Output resistance RoΩ230 …350
Insulation resistance Ris Ω>1x 109
Reference excitation voltage Uref V 5
Operating range of excitation
voltage BU.G V 0.5 …12
Nominal (rated) temp. range Bt.nom °C -10 …+70
Operating temperature range Bt.G °C -30 …+85
Storage temperature range Bt.S °C -50 …+85
Reference temperature tref °C +23
Max. operating force (FG) % 180
Breaking force (FB) % > 400 > 300 > 300
Lateral limit force1) (FQ) % 100 80 40
Permissible force application ec
centricity eGmm 1.5 3 6
Nominal (rated) displacement
("15%) Snom mm 0.01 0.02 0.02 0.04 0.01 0.03
Natural frequency fGkHz 7.9 11.7 10.3
Weight with cable (approx.) g 200 600
Rel. permissible vibrational
stress Frb % 150
Cable connection, six‐wire con
figuration 3m cable length; outside diameter 4mm; 6 x 0.08mm2; PU sheath;
min. bending radius R10
Degree of protection per DIN60529 IP67
Transducer identification TEDS, per IEEE 1451.4
1) relative to a force application point on the force application surface