Scaime D2452 User manual

Operation Manual
for Non Rotating Torque Sensors
For D2452

2
References in this Text
1.6 Warning Notes; Page 4
Attention must be paid to the accident prevention regulations of the trade associations.
During operation the safety precautions must be serviceable.
4 Mechanical Assembly; Page 6
Caution: Impermissible large torques, bending moments or axial forces may not act
on the sensor or the couplings.
During the assembly, the sensor must be supported to protect it from falling down.
At small torques (< 20 N·m) connect the sensor electrically during the assembly and watch
the signal; the measuring signal may not exceed the limit values.
Caution at permutation of drive side and measuring side
• The cable connection can influence the torque measurement.
• At dynamic measurements, the measured value can be influenced by the inert
masses of the housing.
6.1 Engaging; Page 11
The warming-up period of the torque sensor is approx. 5 min.
6.4.1 General; Page 11
Operation of the device in natural resonance can lead to permanent damages.

3
Contents
1Read First.............................................................................................................................................. 4
1.1 Safety and Caution Symbols.......................................................................................................... 4
1.2 Intended Use.................................................................................................................................. 4
1.3 Dangers.......................................................................................................................................... 4
1.3.1 Neglecting of Safety Notes..................................................................................................... 4
1.3.2 Remaining Dangers................................................................................................................ 4
1.4 Reconstructions and Modifications................................................................................................ 4
1.5 Personnel....................................................................................................................................... 4
1.6 Warning Notes ............................................................................................................................... 4
2Term Definitions.................................................................................................................................... 5
2.1 Terms............................................................................................................................................. 5
2.2 Definition of the Pictograms on the Torque Sensor....................................................................... 5
3Product Description............................................................................................................................... 5
3.1 Mechanical Setup ......................................................................................................................... 5
3.2 Electrical Setup.............................................................................................................................. 5
4Mechanical Assembly............................................................................................................................ 6
4.1 Couplings....................................................................................................................................... 6
4.1.1 Examples for Single-Jointed Couplings.................................................................................. 6
4.1.2 Misalignment Possibilities of Single-Jointed Couplings......................................................... 6
4.1.3 Double-Jointed Couplings....................................................................................................... 7
4.1.4 Alignment of the Measurement Arrangement......................................................................... 7
4.2 Shaft Connection............................................................................................................................ 7
4.2.1 General................................................................................................................................... 7
4.2.2 Torque Sensors of 0,005 N·m to 0,02 N·m............................................................................. 7
4.2.3 Torque Sensors of 0,03 N·m to 15 N·m.................................................................................. 8
4.2.4 Torque Sensor from 20 N·m................................................................................................... 9
5Electrical Connection........................................................................................................................... 10
5.1 Pin Connection............................................................................................................................. 10
5.2 Cable............................................................................................................................................ 10
5.3 Shielding Connection................................................................................................................... 10
5.4 Extension Cable........................................................................................................................... 10
5.5 Running of Measuring Cables...................................................................................................... 11
6Measuring............................................................................................................................................ 11
6.1 Engaging...................................................................................................................................... 11
6.2 Direction of Torque....................................................................................................................... 11
6.3 Static / Quasi-Static Torques....................................................................................................... 11
6.4 Dynamic Torques......................................................................................................................... 11
6.4.1 General................................................................................................................................. 11
6.4.2 Natural Resonances............................................................................................................ 11
6.5 Disturbance Variables.................................................................................................................. 12
6.6 Calibration Control (Option)........................................................................................................ 12
7Maintenance........................................................................................................................................ 13
7.1 Maintenance Schedule ................................................................................................................ 13
7.2 Trouble Shooting.......................................................................................................................... 13
8Decommission..................................................................................................................................... 13
9Transportation and Storage ................................................................................................................ 13
9.1 Transportation......................................................................................Erreur ! Signet non défini.
9.2 Storage......................................................................................................................................... 13
10 Disposal...................................................................................................Erreur ! Signet non défini.
11 Calibration................................................................................................Erreur ! Signet non défini.

4
1 Read First
1.1 Safety and Caution Symbols
Caution:
Injury Risk for Persons
Damage of the Device is possible.
Note:
Important points to be considered.
1.2 Intended Use
Torque sensors are intended for the measurement of torques. This measurand is further suitable for
control tasks. The valid safety regulations should be absolutely respected. The torque sensors are not
safety components in the sense of the intended use. The sensors need to be transported and stored
appropriately. The assembly, commissioning and disassembling must take place professionally.
1.3 Dangers
The torque sensor is fail-safe and corresponds to the state of technology.
1.3.1 Neglecting of Safety Notes
At inappropriate use, remaining dangers can emerge (e.g. by untrained personnel). The operation manual
must be read and understood by each person entrusted with the assembly, maintenance, repair,
operation and disassembly of the torque sensor.
1.3.2 Remaining Dangers
The plant designer, the supplier, as well as the operator must plan, realize and take responsibility for
safety-related interests for the sensor. Remaining dangers must be minimized. Remaining dangers of the
torque measurement technique must be pointed out.
1.4 Reconstructions and Modifications
Each modification of the sensors without our written approval excludes liability on our part.
1.5 Personnel
The installation, assembly, commissioning, operation and the disassembly must be carried out by
qualified personnel only. The personnel must have the knowledge and make use of the legal regulations
and safety instructions.
1.6 Warning Notes
Attention must be paid to the accident prevention regulations of the trade associations.
During operation the safety precautions must be serviceable.

5
2 Term Definitions
2.1 Terms
Measuring Side:
Shaft connection in which the torque to be measured is applied. Usually this side has the smallest
moment of inertia.
Drive Side:
The shaft end on the opposite side of the measuring side with the larger moment of inertia.
At static torque sensors the housing is fastened on this side.
2.2 Definition of the Pictograms on the Torque Sensor
The measuring side of the torque sensor is designated as follows:
Measuring side:
or M
More information can be found on the data sheet if needed.
3 Product Description
The sensor measures static and dynamic torques. The mounting position of the torque sensor is
horizontally or vertically.
Caution: it is to be differentiated between measuring side and drive side.
3.1 Mechanical Setup
The sensors do not contain rotary parts.
They consist of a torsion body with shaft ends.
The torsion body, applied with strain gauges,
is protected by a housing. A plug or a cable connection
is fixed at the housing.
3.2 Electrical Setup
The strain gauge full bridge is directly connected at the
plug or at the cable.
Optionally a calibration control can be integrated. For
this, the SG full bridge gets detuned by an external
switch in such a way, that at the output the measuring
signal, which is corresponding to the positive nominal
torque, can be measured.
Torsion Body
Cable Connection
Housing
SG
M
R
k
R
1
R
2
R
4
R
3
Supply +
Control
Signal +
Signal -
Supply -
external switch
SG
Sensor External
Basic sketch of the strain gauge full bridge
with option calibration control

6
4 Mechanical Assembly
Caution: Impermissible large torques, bending moments or axial forces may not act on
the sensor or the couplings.
At small torques (< 20 N·m) connect the sensor electrically during the assembly and watch the
signal; the measuring signal may not exceed the limit values.
It is to be differentiated between measuring side and drive side of the sensor. The housing is fixed at the
drive side of the sensor.
Caution at permutation of drive side and measuring side
• The cable connection can influence the torque measurement.
• At dynamic measurements, the measured value can be influenced by the inert masses
of the housing.
4.1 Couplings
4.1.1 Examples for Single-Jointed
Couplings
For this torque sensor we recommend the
couplings intended by Scaime which must be
able to balance an axial, radial or angular offset
of the shafts and not allow large forces to act on
the sensor.
4.1.2 Misalignment Possibilities of Single-Jointed Couplings
Note: Radial misalignments are only possible in the combination of
single-jointed coupling – torque sensor (as adapter) – single-jointed coupling.
Thus, with both single-jointed couplings the torque sensor forms a double-jointed coupling.
During the assembly, the sensor must be supported to protect it from falling down.
Angular Misalignments Axial Misalignments
Single-jointed Coupling Sin
g
le-
j
ointed Cou
p
lin
g
Sensor
Radial Misalignments

7
4.1.3 Double-Jointed Couplings
Double-jointed couplings are used for the balance of inevitable angular, axial and radial misalignments.
4.1.4 Alignment of the Measurement Arrangement
Precisely alignment of the couplings reduces the reaction forces and increases the durability of the
couplings. Disturbance variables are minimized as well.
Due to the multitude of applications, an alignment of the coupling with a straight edge in two levels,
vertical to each other, is sufficient.
4.2 Shaft Connection
4.2.1 General
Before the assembly, shafts must be cleaned with dissolver (e.g. acetone), no foreign particles may
adhere to them. The hub must fit corresponding to the connection.
Connections with Clamping Piece:
The indications of the clamping piece manufacturer must be considered. The clamping piece must be
able to transfer the arising torques safely.
4.2.2 Torque Sensors of 0,005 N·m to 0,02 N·m
Sensors with small nominal torques are very sensitive to overload; therefore these sensors need to be
handled with greatest caution.
1. Connect the sensor electrically during the assembly and observe the measuring signal; the limit
values may not be exceeded in any case.
2. The coupling hub must easily shift onto the shaft
3. Assemble all parts, but do not fasten the shaft.
4. Clamp the coupling onto the shaft after all parts were aligned correctly.
ÆIf possible, start at the low torque resistance side,
ÆCounter-hold while tightening the screws.
Consider below described maximum forces:
Maximum force F on a lever in distance r from the axis Examples of
mass weight
Nominal Torque r = 5 mm r = 10 mm r = 20 mm
of the Sensor Fmax Fmax Fmax
0,005 N·m = 5 N·mm 1 N 0,5 N 0,25 N
0,01 N·m = 10 N·mm 2 N 1 N 0,5 N
0,02 N·m = 20 N·mm 4 N 2 N 1 N
0,25 N ↔ 25 g
0,5 N ↔ 50 g
1 N ↔ 100 g
2 N ↔ 200 g
4 N ↔ 400 g
F
r
Shaft
Axial Misalignments
Angular Misalignments

8
Setup-Example: the sensor is being supported at the housing and the torque is led in on the
measuring side through a double-jointed coupling.
4.2.3 Torque Sensors of 0,03 N·m to 15 N·m
Sensors with nominal torques below 50 N·m are very sensitive to overload, therefore these sensors need
to be handled with greatest caution.
1. Connect the sensor electrically during the assembly and observe the measuring signal; the limit
values may not be exceeded in any case.
2. Align the arrangement before the parts are connected firmly.
3. Assemble the sensor at the low torque resistance side first, then at the stationary side
(this avoids impermissibly large torques from acting on the sensor).
4. Counter-hold by hand, so that impermissibly large torques or disturbance variables can not act on
the torque sensor.
Setup-Example: the sensor is assembled free-floating between two single-jointed couplings
Setup-Example: the sensor is clamped on one side, on the opposite side it is connected with a shaft
through a double-jointed coupling.
Measuring Side
Single-Jointed
Coupling
Single-Jointed Coupling
M
M
Measuring Side
Double-Jointed
Coupling
Sensor firmly
clamped
Ball Bearing
Sensor firmly
clamped
M
Double-jointed coupling
The shaft is fixed
in the housing
Measuring
side

9
Maximum Forces
Maximum force F on a lever in distance r from the axis.
Nominal Torque
of the Sensor r = 10 mm Fmax r = 20 mm Fmax r = 50 mm Fmax
0,03 N·m 3 N 1,5 N 0,6 N
0,05 N·m 5 N 2,5 N 1 N
0,1 N·m 10 N 5 N 2 N
0,2 N·m 20 N 10 N 4 N
0,5 N·m 50 N 25 N 10 N
1 N·m 100 N 50 N 20 N
4.2.4 Torque Sensor from 20 N·m
Before the assembly, shafts must be cleaned with dissolver (e.g. acetone), no foreign particles may
adhere to them. The hub must fit corresponding to the connection.
Connections with Clamping Piece:
The indications of the clamping piece manufacturer must be considered. The clamping piece must be
able to transfer the arising torques safely.
Setup-Example: the sensor is assembled free-floating between two single-jointed couplings
Setup-Example: the sensor is clamped on one side, on the opposite side it is connected with a shaft
through a double-jointed coupling.
F
r
Shaft
Measuring Side
Single-Jointed CouplingSingle-Jointed Coupling
M
M Measuring Side
Double-Jointed Coupling Sensor firmly
clamped
Ball Bearing

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5 Electrical Connection
5.1 Pin Connection
6-pin Function
1 SG- excitation -
2 SG- excitation +
3 Shield
4 SG- signal +
5 SG- signal -
6 100% calibration
control
7-pin Function
1 SG- excitation -
2 SG- excitation +
3 Shield
4 SG- signal +
5 SG- signal -
6 100% calibration
control
7 -
View: socket on soldering side
5.2 Cable
Only use a shielded cable with preferably small capacity. We recommend measuring cables from our
product range. They have been tested in combination with our sensors and meet the metrological
requirements.
5.3 Shielding Connection
In combination with the sensor and the external electronics, the shield forms a Faraday Cage. By this,
electro-magnetic disturbances do not have any influence on the measurement signal.
At potential difference problems we recommend to ground the sensor.
5.4 Extension Cable
Caution: depending on bridge resistance and wire cross section, the measuring cable length enters into
the characteristic value of the sensor.
Dependence of the characteristic value on the cable length:
Wire-cross
section Cable resistance per m
Deviation per m
cable length at
bridge resistance
350 Ω
Deviation per m
cable length at
bridge resistance
700 Ω
Deviation per m
cable length at
bridge resistance
1000 Ω
0,14 mm² 0,28 Ω0,08% 0,04% 0,028%
0,25 mm² 0,16 Ω0,046% 0,023% 0,016%
0,34 mm² 0,12 Ω0,034% 0,017% 0,012%
Cable resistance = 2 x resistance of the cable length (both feed lines of the sensor).

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5.5 Running of Measuring Cables
Do not run measuring cables together with control or heavy-current cables. Always assure that a large
distance is kept to engines, transformers and contactors, because their stray fields can lead to
interferences of the measuring signals.
If troubles occur through the measuring cable, we recommend to run the cable in a grounded steel
conduit.
6 Measuring
6.1 Engaging
The warming-up period of the torque sensor is approx. 5 min. Afterwards the measurement can be
started.
The warming-up period of the torque sensor is approx. 5 min.
6.2 Direction of Torque
Torque means clockwise or clockwise torque if the torque acts clockwise when facing the shaft end. In
this case a positive electrical signal is obtained at the output.
Torque sensors by Scaime can measure both, clockwise and counter-clockwise direction.
6.3 Static / Quasi-Static Torques
Static and/or quasi-static torque is a slowly changing torque.
The calibration of the sensors occurs statically on a calibration device.
The applied torque may accept any value up to the nominal torque.
6.4 Dynamic Torques
6.4.1 General
The static calibration procedure of torque sensors is also valid for dynamic applications.
Note: The frequency of torques must be smaller than the natural frequency of the mechanical
measurement setup.
Operation of the device in natural resonance can lead to permanent damages
The band width must be limited to 70 % of the nominal torque.
6.4.2 Natural Resonances
Estimate of the mechanical natural frequencies:
⎟
⎟
⎠
⎞
⎜
⎜
⎝
⎛+⋅⋅
⋅
=
21
011
21JJ
cf
π
f0
J1, J2
c
= Natural frequency in Hz
= Moment of inertia in kg*m²
= Torsional rigidity in Nm/rad
Further methods for the calculation of natural resonances are corresponding purchasable programs or
books (e.g. Holzer-Procedure, Dubbel, Taschenbuch für den Maschinenbau, Springer Verlag)
c
J1J2

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6.5 Disturbance Variables
By disturbances, measured value falsifications can occur by
• Vibrations,
• Air motions at small torques,
• Temperature gradients in the torque sensor,
• Temperature changes,
• Electrical disturbances,
• Magnetic disturbances,
• EMC (electromagnetic disturbances),
Therefore avoid these disturbance variables by decoupling of vibrations, covers, etc.
6.6 Calibration Control (Option)
By a control resistance, a signal is generated in the
sensor which corresponds to the nominal value of
the sensor.
Advantage:
Re-Calibrations are reduced. Before each
measurement the zero point and the nominal value
can be checked.
Function:
By applying positive SG supply, the measuring
bridge is electrically detuned, so that at the output a
measuring signal of 100% of the nominal value is
available.
Optionally 50%, 80% possible.
Use calibration control at unloaded torque sensor, only.
R
k
R
1
R
2
R
4
R
3
Supply +
Control
Signal +
Signal -
Supply -
external switch
SG
Sensor External

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7 Maintenance
7.1 Maintenance Schedule
Action Frequency Date Date Date
Control of cables and connectors 1x p.a.
Calibration < 24 months
Control of fixation (flanges, shafts) 1x p.a.
7.2 Trouble Shooting
This chart is used for searching for the most frequent errors and their elimination.
Problem Possible Cause Trouble Shooting
No signal No sensor excitation • Outside of permissible range
• Connect excitation
• Cable defect
• No mains supply
Signal output connected wrong • Connect output correctly
• Evaluation electronics defect
Sensor does not react to
torque Shaft not clamped • Clamp correctly
No power supply • Outside of permissible range
• Connect supply
• Cable defect
• No mains supply
Cable defect
• Repair cable
Connector connected wrong • Connect correctly
Signal has dropouts Cable defect • Repair cable
Zero point outside of tolerance Cable defect • Repair cable
Shaft mounted distorted • Mount correctly
Distorted shaft string • Release from distortion
Strong lateral forces • Reduce lateral forces
Shaft overloaded
• Send to manufacturer
Wrong torque indication Calibration not correct • Re-calibrate
Sensor defect
• Repair by manufacturer
Torque shunt
• Eliminate shunt
Torque fluctuations Vibrations • Decoupling of vibrations
Air motions
• Apply covers
8 Decommission
• All sensors must be dismantled professionally.
• Do not strike sensor housings with tools.
• Do not apply bending moments on the sensor, e.g. through levers.
• The torque sensor must be supported to avoid falling down during the dismantling.
9 Transportation and Storage
The transportation of the sensors must occur in suitable packing.
For smaller sensors, stable cartons which are well padded are sufficient (e.g., air cushion film, epoxy
crisps, paper shavings). The sensor should be tidily packed into film.
Larger sensors should be packed in cases.
9.1 Storage
The storage of the sensors must occur in dry, dust-free rooms, only.
Slightly lubricate shafts and flanges with oil before storing (rust). NU-D2452-E-1107