Kistler 4502A Series User manual

Instruction
Manual
Mini-Smart Torque
Sensor
Type 4502A...
Version Q
(with standard square
connections)
Version H
(with standard hexagon
connections)
Version QA/HA
(with rotating angle
measuring system)
Version RA
(with round shaft and
rotation angle measure-
ment)
4502A_002-407e-02.22

Foreword
4502A_002-407e-02.22 Page 1
Foreword
This manual applies to the torque sensor Type 4502A… .
The instruction manual must be kept on hand for future
use, and must be available at the site of implementation of
the torque sensor, as needed.
The specifications in this manual can change at any time
without prior notification. Kistler reserves the right to im-
prove and to change the product for the purpose of tech-
nical progress without the obligation to inform persons and
organizations as the result of such changes.
Original language of these operating instructions: German
©2003 … 2022 Kistler Group. All rights reserved.
Kistler Group
Eulachstrasse 22
8408 Winterthur
Switzerland
Tel. [phone]
Fax [phone]
[e-mail]
www.kistler.com

Mini-Smart Torque Sensor, Type 4502A...
Page 2 4502A_002-407e-02.22
Content
1. Introduction ................................................................................................................................... 3
2. Important information.................................................................................................................... 4
2.1 Disposal instructions for electrical and electronic equipment ................................................ 4
3. Application and key features.......................................................................................................... 5
4. Description of the measuring system............................................................................................. 6
4.1 Mechanical design................................................................................................................ 6
4.2 Electrical block diagram ........................................................................................................ 7
4.2.1 Examples of application ........................................................................................... 8
4.3 Rotation angle measuring system (Version QA, HA and RA only) ........................................ 9
4.4 Adjustment for angle-pulse output (Version QA, HA, RA only).......................................... 10
5. Electrical connections................................................................................................................... 11
5.1 Plug connection (Tuchel, 12 pin) ........................................................................................ 12
5.1.1 Installing the signal lead ........................................................................................ 12
5.2 Instruction for electrical installation .................................................................................... 13
5.3 Connection cable ............................................................................................................... 14
6. Mechanical application ................................................................................................................ 16
6.1 Versions Q, QA, H and HA ................................................................................................ 16
6.2 Torque measuring shaft version RA .................................................................................... 17
6.3 Possible installation of version R/RA................................................................................... 17
6.4 Supply circuit and evaluation.............................................................................................. 18
7. Static calibration .......................................................................................................................... 19
7.1 Construction of a simple calibration device......................................................................... 19
7.2 Calculation example for lever arm length ........................................................................... 20
8. Maintenance ................................................................................................................................ 21
9. Repairs ......................................................................................................................................... 22
10. Ordering key ................................................................................................................................ 23
11. Index ............................................................................................................................................ 24
Total Pages 26

Introduction
4502A_002-407e-02.22 Seite 3
1. Introduction
Please take the time to thoroughly read this instruction
manual. It will help you with the installation, maintenance,
and use of this product.
Kistler offers a wide range of products for use in measuring
technology:
Piezoelectric sensors for measuring force, torque, strain,
pressure, acceleration, shock, vibration and acoustic-
emission
Strain gage sensor systems for measuring force and
torque
Piezoresistive pressure sensors and transmitters
Signal conditioners, indicators and calibrators
Electronic control and monitoring systems as well as
software for specific measurement applications
Data transmission modules (telemetry)
Electromechanical NC joining modules and force-
displacement monitors
Test stand systems for electric motors and gear units for
laboratory, manufacturing, and quality assurance
Kistler also develops and produces measuring solutions for
the application fields engines, vehicles, manufacturing,
plastics and biomechanics sectors.
Our product and application brochures will provide you
with an overview of our product range. Detailed data
sheets are available for almost all products.
If you need additional help beyond what can be found
either on-line or in this manual, please contact Kistler's ex-
tensive support organization.

Mini-Smart Torque Sensor, Type 4502A...
Seite 4 4502A_002-407e-02.22
2. Important information
2.1 Disposal instructions for electrical and electronic equipment
Do not discard old electronic instruments in municipal
trash. For disposal at e
nd of life, please return this
product to an authorized local electronic waste disposal
service or contact the nearest Kistler Instrument sales
office for return instructions.

Application and key features
4502A_002-407e-02.22 Seite 5
3. Application and key features
Torque sensor with strain gages measuring system
Wear-resistant transmission of the measuring signal,
integrated amplifier
Measurement of constant and variable torques
Torque measurement on the rotating shaft
Integrated system for rotation angle measurement (only
version QA/HA)
Application in the laboratory, manufacture and quality
control
Ideal for use with power tools (version QA/HA) and
test stand construction (version RA)
Suitable for low and high speed ranges
Fig. 1: Mini-Smart torque sensor Type 4502A…
Torque
Rotation angle
Measuring electronics
Strain gage
measuring shaft
11 ... 26 VDC

Mini-Smart Torque Sensor, Type 4502A...
Seite 6 4502A_002-407e-02.22
4. Description of the measuring system
4.1 Mechanical design
Torque sensors model Mini Smart consist of a base body
which contains the measuring shaft. The shaft ends are
performed as standard square connections or standard
hexagon ends.
On the measuring shaft there is a torsion distance with
strain gages and electronics with signal amplifier and A/D
transformer.
The connection box of the base body contains the statio-
nary electronics for the signal formation.
The base body of the sensor offers different assembly pos-
sibilities (see chapter "Mechanical application").
Fig. 2: Mechanical design Mini-Smart torque sensor
Type 4502A...
Square socket
(version Q/
QA)
or hexagon socket
(version H/HA
/R/RA)
Square end
(version Q
/QA)
or hexagon end
(version H/HA/R/RA
)
Cable connector
Shaft
Bearing
Sensor
Strain gauges
Bearing
Rotation angle measuring system
(only version QA/HA)
Rotating electronics
External electronics

Description of the measuring system
4502A_002-407e-02.22 Seite 7
4.2 Electrical block diagram
Fig. 3: Electrical block diagram
Feed and inspection input of electronic
measuring equipment, electrically isolated
Stator
Rotor
Internal power supply
Opto-
coupler
Logic and
modulator
Fiber optic
rotary
joint
Control
DMS
Rotor
electronics
Output ±5 V
Feed
11 ... 26 VDC
Control
5 ... 30 VDC
F
K
C
E
A
D
Frequency/
potential
transformer
Strain gages
measuring
system
(DMS)

Mini-Smart Torque Sensor, Type 4502A...
Seite 8 4502A_002-407e-02.22
4.2.1 Examples of application
Exactly use of electrical isolation for feed and measuring
signal.
Fig. 4: Separate speed and measuring supply
Shared access measuring supply for feed and measuring
supply.
Interlink the feed and measuring supply, evaluation elec-
tronic is to be made.
Fig. 5: Feed and measuring supply in the evaluation
electronic combined
F
E
K
A
C
D
M
Feed
Control
Feed
output
Shield
Feed device
Evaluation
electronic
Type 4502A…
F
E
K
A
C
D
M
Type 4502A…
Feed
Control
Feed
output
Shield
Evaluation
electronic
Feed device

Description of the measuring system
4502A_002-407e-02.22 Seite 9
4.3 Rotation angle measuring system (Version QA, HA and RA only)
Fig. 6: Diagram showing the design of the rotation
angle measuring system
1. Rotating shaft
2. Pulse disk
3. Forked light barrier with LED and photo diode
4. Operation amplifier
Features
360 light-dark stripes on the pulse disk
Two forked light barriers shifted by phase angle 90 °
Pulse number proportional to the rotation angle
0 V +5 V
1.
2.
3.
3.
4.
E
H
G
B
0 V

Mini-Smart Torque Sensor, Type 4502A...
Seite 10 4502A_002-407e-02.22
4.4 Adjustment for angle-pulse output (Version QA, HA, RA only)
With drive on square socket or hexagon end sense of rota-
tion cw.
Fig. 7: Adjustment for angle-pulse output
Sense of
rotation
View A 1:
A 1
D
rive side
(
Version QA)
Sense of
rotation
A 2
D
rive side
(
Version HA)
View A 2:
A 3
D
rive side
(
Version RA)
Sense of
rotation
View A 3:
Output Pin G
Output Pin B

Electrical connections
4502A_002-407e-02.22 Seite 11
5. Electrical connections
Fig. 8: Electrical connections
Shielded lead of 0,14 mm² nominal cross section
Shielded lead
Lead connector
To power supply unit and display
Torque sensor (all versions)

Mini-Smart Torque Sensor, Type 4502A...
Seite 12 4502A_002-407e-02.22
5.1 Plug connection (Tuchel, 12 pin)
Function PIN
Description
Supply
F
+U
B
11 ... 26 VDC,
power consumption
<1 W
E
GND
Ground relating to U
B
and angle of rotation
pulses
Shield
M
In sensor connected to housing
Torque
output
C
U
A
±5 VDC bei M
nom
at >2 kΩ
5 VDC at control signal activation
Ri,C = 10 Ω, output short circuit proof
relating to AGND
D
AGND
Ground relating to U
A
Angle of rotation sensor
Supply Angle of rotation
pulses
H
+UB
5 VDC
B
Track
A
Open collector output
Internal 1 kΩ resistance to 5 VDC (pull up),
TTL-level
G
Track
B
As Track A, 90° displaced
100 % control input
K
Control
Off: 0 ... 2 VDC
On: 5 ... 30 VDC
A
KGND
Ground relating to control input
J
Not connected
5.1.1 Installing the signal lead
Do not run the lead parallel to power cables or control
circuits.
Do not place the lead close to equipment producing
strong electromagnetic fields, e.g. transformers, wel-
ders, contactors, electric motors, etc.
If such situations cannot be avoided, run the lead inside
earthed steel conduit.
Make a loop in the lead when fixing it at the torque
sensor so that it is not damaged by vibration.
If supply and evaluation unit are galvanically connected,
a differential input must be used for the torque singal to
prevent that the voltage drop on the 0 V-supply line af-
fects the measured signal.

Electrical connections
4502A_002-407e-02.22 Seite 13
5.2 Instruction for electrical installation
Fig. 9: Electrical installation
Load machine with in-
ventor or
alike device
F
E
M
D
C
Stator support unit
11 … 26 VDC
ripple max.
100 mV
anodic coating
contingent
to delete
Length max. 50 m 0,25
Type 4502A…
Type 4502A…
Stator
Plug
Connector housing
min. 16

Mini-Smart Torque Sensor, Type 4502A...
Seite 14 4502A_002-407e-02.22
5.3 Connection cable
Material No. 18008943 / 18008944 (free end)
Cable definition
A
violet
B
yellow
C
pink
D
grey
E
blue
F
red
G
green
H
black
J
white
K
grey/pink
L
brown
M
----
Type 5867…

Electrical connections
4502A_002-407e-02.22 Seite 15
Type 5877…

Mini-Smart Torque Sensor, Type 4502A...
Seite 16 4502A_002-407e-02.22
6. Mechanical application
6.1 Versions Q, QA, H and HA
Torque sensors of version Q and QA have square con-
nections for plug-in tools acc. to DIN 3121.
Torque sensors of version H and HA have hexagon con-
nections acc. to DIN 3126, form E/F.
The torque sensors are plugged on to the drive spindle
as shown below.
Application examples:
Fig. 10: Application examples versions Q/QA & H/HA
Version
Q/QA
Version
H/HA
Motor/el.
or pneum.
wrench
Torque sensor
Type SD
Lead
conne
ctor
Socket spanner/bit
Lead
connec
tor

Mechanical application
4502A_002-407e-02.22 Seite 17
6.2 Torque measuring shaft version RA
For the electric connection of measuring shaft and supply-
and evaluation unit we recommend to use the shielded
signal lead, Type KSM072030-5, Mat.-No.: 18008935 with
low capacity.
As supply and evaluation unit we suggest the Control
Monitor CoMo Torque Type 4700B... .
The matching connection cable is Type KSM018538-2,5,
Mat.-No.: 18008963.
The signal lead should not exceed a length of 30 meters.
Do not run the lead parallel to power cables or control
circuits.
The pin connection is explained in chapter "Plug
Connection" of this manual.
On each side of the torque measuring shaft there is a high
quality bearing installed. The installation can have any
position, however offset couplings must always be applied
to balance geometrical errors and keep false loads away
from the torque measuring shaft.
Radial, axial, diagonal and angular errors are compen-
sated by:
Multi-disk couplings, e.g. data sheet 000-672 Type
2303A…,
or diaphragma coupling,
or claw couplings.
6.3 Possible installation of version R/RA
Fig. 11: Application example version RA
Couplings compensate axial-radial and angular misalign-
ment.
Type 4700B…
Firm stator (Type 4502A… version RA)
Full coupling on both sides
Fixed bearing on both sides
Full coupling
Full coupling
Specimen with
fixed bearing
Specimen retaining angle
Drive brake with fixed bearing

Mini-Smart Torque Sensor, Type 4502A...
Seite 18 4502A_002-407e-02.22
The connection of shaft and coupling hub is effected by a
span device. The measuring shaft is fastened with balan-
cing class 6,5. The torque measuring shaft is only a part of
the shaft strang. Radial and torsional vibrations may have a
very bad impact on the performance of the torque shaft
and the measuring signal.
For that reason the operating speed must not be near the
critical speed, either it has to be far underneath or above it.
6.4 Supply circuit and evaluation
The sensor may only be operated using filtered
11 … 26 VDC voltage.
Recommended supply voltage:
Fig. 12: Supply circuit and evaluation
Type 4700B…
CoMo Torque
Type
(Data sheet 000-944)
(Data sheet 000-597)
L1
PE
N
~
=
0 V
+11 ... 26 V
Torque output ±5 VDC
Panel meter
Quadrature counter
PLC
PC, processing of measuring
data
Torque output 1 5 V, TTL
Torque output 2 5 V, TTL
Terminal box for 4502A… version R/RA
0 V
0 V

Static calibration
4502A_002-407e-02.22 Seite 19
7. Static calibration
This procedure requires the use of a calibration device with
a lever arm and weights for producing specific values of
torque.
The calibration procedure is as follows
Apply the rated value of torque to the torque sensor
and then remove it again
Adjust the zero reading accurately
Apply a known value of torque to the torque sensor
Adjust the displayed reading to the corresponding value
Plotting a calibration curve
Calibrate the torque sensor as described above.
Apply torque in 1/10 steps up to the full rated value
and then remove it again in the same way. A delay of
at least 30 seconds must be allowed between the
individual 1/10 steps so that each reading can stabilize
before it is recorded.
7.1 Construction of a simple calibration device
Fig. 13: Calibration device
Torque sensor
Lever arm
Lever arm
K = Loose half-couplings
K
K
Counter bearing
Lever arm bearing
(duplex)
Weight
(calibrated)
Lever arm
bearing