WIKA F5802 User manual

Operating instructions
Betriebsanleitung
EN
DE
Load pin, model F5802
Messachse, Typ F5802
Model F5802

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Operating instructions, model F5802
EN
DE
© 02/2024 WIKA Alexander Wiegand SE & Co. KG
All rights reserved. / Alle Rechte vorbehalten.
WIKA®is a registered trademark in various countries.
WIKA®ist eine geschützte Marke in verschiedenen Ländern.
Prior to starting any work, read the operating instructions and additional operating instructions!
Keep for later use!
Vor Beginn aller Arbeiten Betriebsanleitung lesen!
Zum späteren Gebrauch aufbewahren!
Operating instructions, model F5802 Page 3 - 26
Betriebsanleitung, Typ F5802 Seite 27 - 50

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Operating instructions, model F5802
Contents
1. General information 4
2. Safety 5
2.1 Explanation of symbols . . . . . . . . . . . . . . . . . . .5
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . .5
2.3 Improper use . . . . . . . . . . . . . . . . . . . . . .7
2.4 Responsibility of the operator . . . . . . . . . . . . . . . . .7
2.5 Personnel qualification . . . . . . . . . . . . . . . . . . .8
2.6 Personal protective equipment . . . . . . . . . . . . . . . .8
2.7 Labelling, safety marks . . . . . . . . . . . . . . . . . . .9
2.8 Signal jump electronics . . . . . . . . . . . . . . . . . . 10
3. Transport, packaging and storage 11
3.1 Transport. . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Packaging and storage . . . . . . . . . . . . . . . . . . 11
4. Design and function 12
4.1 Overview. . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Description . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . 12
5. Commissioning, operation 13
5.1 Precautions before commissioning . . . . . . . . . . . . . . 13
5.2 Mounting instructions . . . . . . . . . . . . . . . . . . 13
5.3 Mounting the load pin . . . . . . . . . . . . . . . . . . 14
5.4 Electrical connection. . . . . . . . . . . . . . . . . . . 15
6. Faults 20
7. Maintenance and cleaning 21
7.1 Maintenance . . . . . . . . . . . . . . . . . . . . . 21
7.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 21
7.3 Recalibration . . . . . . . . . . . . . . . . . . . . . 21
8. Dismounting, return and disposal 22
8.1 Dismounting . . . . . . . . . . . . . . . . . . . . . 22
8.2 Return. . . . . . . . . . . . . . . . . . . . . . . . 22
8.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . 22
9. Specifications 23
9.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . 24
9.2 Approvals . . . . . . . . . . . . . . . . . . . . . . 24
10. Accessories 25
10.1 Cable with connector, model EZE53. . . . . . . . . . . . . 25
Declarations of conformity can be found online at www.wika.com.
Contents

4Operating instructions, model F5802
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1. General information
1. General information

The load pin described in the operating instructions has been designed and
manufactured using state-of-the-art technology. All components are subject to
stringent quality and environmental criteria during production. Our management
systems are certified to ISO 9001.

These operating instructions contain important information on handling the
instrument. Working safely requires that all safety instructions and work instructions
are observed.

Observe the relevant local accident prevention regulations and general safety
regulations for the instrument's range of use.

The operating instructions are part of the product and must be kept in the immediate
vicinity of the instrument and readily accessible to skilled personnel at any time. Pass
the operating instructions on to the next operator or owner of the instrument.

Skilled personnel must have carefully read and understood the operating instructions
prior to beginning any work.

In case of a different interpretation of the translated and the English operation
instruction, the English wording shall prevail.

If available, the provided supplier documentation is also considered to be part of the
product in addition to these operating instructions.

The general terms and conditions contained in the sales documentation shall apply.

Subject to technical modifications.

Factory calibrations / DAkkS calibrations are carried out in accordance with
international standards.
Further information:
- Internet address: www.wika.com
- Relevant data sheet: FO 51.55
- Application consultant: Phone: [phone]
[e-mail] / info.wika.com
Abbreviations, definitions
2-wire
The two connection leads are used for the voltage supply
The measuring signal also provides the supply current
3-wire Two connection leads are used for the voltage supply
One connection lead is used for the measuring signal
UB+ Positive power supply terminal
UB- Negative power supply terminal
S+ Positive signal output
S- Negative signal output
UR+ Positive power supply terminal for relay (signal jump)
UR- Negative power supply terminal for relay (signal jump)
x-pin Pin assignment
Shield
Case

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Operating instructions, model F5802
2. Safety
Model Version Design
F5802 Basic version for measuring ranges
20 ... 10,000 kN [204 ... 101,972 tf]
2. Safety
2.1 Explanation of symbols
WARNING!
... indicates a potentially dangerous situation that can result in serious
injury or death, if not avoided.
CAUTION!
... indicates a potentially dangerous situation that can result in light injuries
or damage to property or the environment, if not avoided.
Information
... points out useful tips, recommendations and information for efficient
and trouble-free operation.
2.2 Intended use

6Operating instructions, model F5802
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2. Safety
Force transducer for measuring tension or compression forces, for example in cranes.
The product is designed for use both outside and inside buildings.
Load pins can measure forces in both directions.The measured force is output as an
electrical signal.These devices are designed for operation in industrial environment.
In other environments, e.g. residential or commerical, they may interfere with other
equipment. In this case, the operator may be required to implement appropriate
measures.
Only use the load pins in applications that are within the technical performance limits
(e.g. max. ambient temperature, material compatibility, etc.). For performance limits, see
chapter 9 “Specifications”.
The load pins of model F5802 are not approved for use in hazardous areas!
For this, see models F53C1 or F53C8.
These instruments have been designed and tested in accordance with the relevant
safety regulations for electronic measuring instruments. Any usage outside of this
is deemed to be improper.The perfect functioning and operational safety of the
transducers can only be guaranteed when complying with the instructions given in the
operating instructions. During its use, the legal and safety regulations (e.g.VDE 0100)
required for the particular application must additionally be observed.This also applies
accordingly when using accessories.Tension/compression force transducers are
RoHS-compliant in accordance with directive 2011/65/EU.
Faultless and safe operation of this transducer requires proper transport, professional
storage, installation and mounting as well as careful operation and corrective
maintenance.
The load pins are designed exclusively for the intended use which is described here and
may only be used accordingly. Claims of any kind due to improper use are excluded.
Handle electronic precision measuring instruments with the required care (protect from
humidity, impacts, strong magnetic fields, static electricity and extreme temperatures,
do not insert any objects into the instrument or its openings). Plugs and sockets must be
protected from contamination.
The technical specifications contained in these operating instructions must be
observed. Improper handling or operation of the instrument outside of its technical
specifications requires the instrument to be taken out of service immediately and
inspected by an authorised service engineer.
This instrument is intended for connection to an external PELV circuit that meets
the requirements of UL/IEC/EN 61010-1 Section 9.4 (limited-energy circuit).The
manufacturer shall not be liable for claims of any type based on operation contrary to
the intended use.The load pins are designed for indoor and outdoor use, at altitudes of
up to 2,500 m above sea level. The pollution degree in accordance with UL certification
is degree 4: “Electrical equipment for outdoor use”.

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Operating instructions, model F5802
2. Safety
The instrument is used in the industrial sector. The operator is therefore responsible for
legal obligations regarding safety at work.
The safety instructions within these operating instructions, as well as the safety, accident
prevention and environmental protection regulations for the application area must be
maintained.
The operator is obliged to maintain the product label (see chapter 3.7 “Labelling, safety
marks”) in a legible condition.
To ensure safe working on the instrument, the operating company must ensure

that suitable first-aid equipment is available and aid is provided whenever required.

that the skilled electrical personnel are regularly instructed in all topics regarding
safety at work, first aid and environmental protection and know the operating
instructions and in particular, the safety instructions contained therein.

that the instrument is suitable for the particular application in accordance with its
intended use.

that personal protective equipment is available.
2.3 Responsibility of the operator
WARNING!
Injuries through improper use
Improper use of the instrument can lead to hazardous situations and
injuries.

Refrain from unauthorised modifications to the instrument.

Do not use the load pin as a climbing aid, counterweight or other
inappropriate use (see chapter 5 “Commissioning, operation”).

Any use beyond or different to the intended use is considered as
improper use.
2.4 Improper use

8Operating instructions, model F5802
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2. Safety
WARNING!
Risk of injury should qualification be insufficient
Improper handling can result in considerable injury and damage to
property.

The activities described in these operating instructions may only be
carried out by skilled personnel who have the qualifications described
below.
2.5 Personnel qualification
Skilled electrical personnel
Skilled electrical personnel are understood to be personnel who, based on their
technical training, know-how and experience as well as their knowledge of country-
specific regulations, current standards and directives, are capable of carrying out work
on electrical systems and independently recognising and avoiding potential hazards.
The skilled electrical personnel have been specifically trained for the work environment
they are working in and know the relevant standards and regulations.The skilled
electrical personnel must comply with current legal accident prevention regulations.
The requirements for the required protective equipment result from the ambient
conditions at the place of use, other products or the connection to other products.
The requisite personal protective equipment must be provided by the operating
company. The operator is in no way relieved of his obligations under labour law for the
safety and the protection of workers' health.
The design of the personal protective equipment must take into account all operating
parameters of the place of use.
2.6 Personal protective equipment

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Operating instructions, model F5802
2. Safety
2.7 Labelling, safety marks
Product label
Manufacturer logo
Year and week of manufacture
Output signal
Measuring range
Pin assignment
Country of Manufacture
Manufacturing address
Importer UK address
Supply voltage
Force direction
Website
Serial number, TAG number
Product code
Ingress protection per DIN EN 60529
Model
Before mounting and commissioning the instrument, ensure you read the
operating instructions!
DC voltage / direct current
Type:
IP:
P#:
S#:
XX/XXXX Pinout
+
-







11
12
13
14
15
11
12
13
14
15

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2. Safety
2.8 Signal jump electronics
An external safety control system independent of the force transducer must monitor the
safe functioning of the force transducer. The functional test with a signal jump of 4 mA / 2 V
is executed at an interval of 24 hours. The safety control system activates the relay A, thus
changing the output signal of the force transducer in a defined manner.
If the expected change in the output signal occurs, it can be assumed that the entire
signal path from the Wheatstone bridge via the amplifier through to the output is
functioning correctly. If this does not occur, then it can be concluded that there is a error
in the signal path.
Moreover, the measuring signal should be checked by the safety control for the min.
(A) and max. (B) signal value to ensure that any cable break or short-circuit that has
occurred is detected.
The default setting of the force transducer with current output 4 ... 20 mA for overload
detection is, for example:
With a fixed signal jump of, for example, 4 mA, the test cycle can then be triggered, in any
operating state, by activating the test relay. The upper measuring range limit of 20 mA will
never be reached and thus the checking of the signal jump is enabled.
Short-circuit (B)Cable break (A)
[mA]4
3.8 16 20 21
Signals of the signal jump electronics
Overload point
(100 % rated load)

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Operating instructions, model F5802
3. Transport, packaging and storage
3. Transport, packaging and storage
3.1 Transport
Check the load pin for any damage that may have been caused by transport.
Obvious damage must be reported immediately.
CAUTION!
Damage through improper transport
With improper transport, a high level of damage to property can occur.

When unloading packed goods upon delivery as well as during
internal transport, proceed carefully and observe the symbols on the
packaging.

With internal transport, observe the instructions in chapter 4.2
“Packaging and storage”.
As precision measuring instruments, transducers require careful handling during
transport and mounting. Load impacts during transport (e.g. hitting a hard surface) can
lead to permanent damage, resulting in measured errors in the subsequent measuring
operation.
3.2 Packaging and storage
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g. change
in installation site, sending for repair).
The material of the measuring spring and the ingress protection class can be found in
the data sheet FO 51.55.
Permissible conditions at the place of storage:

Storage temperature: -20 ... +80 °C [-4 ... +176 °F]

Humidity: 35 ... 85 % relative humidity (non-condensing)
Avoid exposure to the following factors:

Mechanical vibration, mechanical shock (putting it down hard)

Dust, dirt, and other objects may not be deposited in such a way that they form a
force shunt with the measuring spring, since this will falsify the measuring signal.

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4. Design and function


F
F1/2
4. Design and function
4.1 Overview
Exemplary illustration
Axle retainer groove
Measuring spring
Electrical connection
4.2 Description
The load pin is designed for measuring static and dynamic tension or compression
forces.The load pin consists of a measuring spring and bonded strain gauges.The
measuring body is made of stainless steel and is elastically deformed by a compression
force introduced in the force direction.The resulting mechanical tensions are measured
and output by an electrical output signal.
4.3 Scope of delivery

Load pin

Operating instructions
Cross-check scope of delivery with delivery note.


F1/2

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Operating instructions, model F5802
5. Commissioning, operation
5. Commissioning, operation
5.1 Precautions before commissioning

Load pins are sensitive measuring instruments and must be handled with appropriate
care.

Before installing the load pin, check whether the holes of the mounting position have
been executed dimensionally accurately, thus guaranteeing problem-free mechanical
installation of the load pin.

Make sure that no frictional connection is formed between fork bearing and force
introduction. A gap of at least 0.5 mm [0.02 in] must be provided.

Before installation, make sure that the drilling chips have been removed from the
holes.

Depending on the installation situation, lubricant may be required in the holes for
mounting the load pin.
5.2 Mounting instructions
CAUTION!
Damage to the instrument through improper installation
Improper mounting can lead to incorrect loads on the load pin due to
torsional
and transverse forces. These loads cause measured errors and can
permanently damage or destroy the load pins.

Improper loading can lead to permanent damage resulting in a zero point
offset in the unloaded state.

Carry out the mounting of the load pin without using strong force (e.g.
hammer).

During mounting of the load pin, the output signal (force value) must
always be monitored to avoid mechanical overloading.

Do not use the load pin as a climbing aid.

The force acting on the load pin must be applied at the designated point
in the correct load direction.

The output signal and the pin assignment are stated on the product label.

Avoid torsional torques, off-centre loading and transverse loading or
lateral forces.Transverse loading and lateral forces also include the
corresponding components of the measurands that may be introduced
at an angle.

The load pin may only be subjected to loads in the intended type of bearing.

The acting forces are introduced via the two bores/holes.

Make sure that the force is applied exclusively via the bolts and not via
the bearing.

The bolt diameter should always be selected to match the bolt diameter
of the load pin.

Force shunts of any kind, e.g. due to spacer rings, must be avoided.
These can also lead to measuring deviations.

14 Operating instructions, model F5802
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5. Commissioning, operation
5.3 Mounting the load pin

The axle retainer to DIN 15058 must
be fastened such that the load pin is
secured in the installation situation
against twisting and axial play.

The axle retainer must not be
subjected to loads (e.g. axial loads)
while mounted.

Use only captive fasteners for the axle
retainer .

The axle bracket must not hinder the
deflection in the load direction. Please
observe the information given in DIN
15058 for axle retainers.

Prior to installation, observe the force
direction arrows on the front face
of the load pin and the mounting
position.

It must be ensured that there are no
force shunts in the mounted condition.

Introduce the load pin carefully into
the mounting position (fork bearing),
using the axle retainer groove as
reference for aligning the load pin .

The force introduction in the centre
may not move and must be mounted
such that an axial shift is not possible.
No force shunt may be produced.

Align the load pin and mount the
axle retainer .
Axle retainer
Force direction arrows
Load pin (exemplary illustration based on
model F5301)
Axle retainer groove
Force introduction
Load pin mounting position

Connection of the load pin (e.g. fork bearing)










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Operating instructions, model F5802
5. Commissioning, operation
5.4 Electrical connection
To prevent interferences from coupling into the system, observe the following
information:

Use only shielded and low-capacitance measuring cables (for cables, see chapter 10
“Accessories”).

The shield of the measuring cable must be factored into the equipotential bonding /
grounding of the system.

Connect the cable shield to the case of the load pin. In the cables of the accessories,
the cable shield is connected by means of the knurled nut, thus connecting it to the
case of the load pin (for cables, see chapter 10 “Accessories”).

Do not install measuring cables in parallel to 3-phase-current cables and control
lines.

Avoid stray fields of transformers, motors and contactors.

Transducers, amplifiers and processing or display units must not be grounded
several times. Connect all instruments to the same protective conductor.
The pin assignment of the connector or of the cable can be found on the product label.
For a cable extension, only shielded and low-capacitance cables should be used.The
permitted maximum and minimum lengths of cable are defined in ISO 11898-2. Care
should be taken also to ensure a high-quality connection of the shielding.
Mounting situation of the load pin
Exemplary illustration.
The customer-specific load pin drawing of the respective order number has priority.
Pin retainer
(in accordance with DIN 15058)
Ground connection
M6-12/8 deep
“Force direction” symbol applied
F1/2F1/2
F

16 Operating instructions, model F5802
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5. Commissioning, operation
Output signal 1 ... 2 mV/V
Connector M12 x 1, 4-pin or 5-pin
(Red)
(Green)
(Black)
(White)
(Yellow-green)
Exc+
Sig+
Exc-
Sig-
Electrical connection
Supply voltage + Exc+ Red
Supply voltage - Exc- Black
Signal + Sig+ Green
Signal - Sig- White
Shield Shield Yellow-green
5.4.1 Pin assignment cable
Shield
Cable colours only apply when using the WIKA standard cable, e.g. order number 14259454

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Operating instructions, model F5802
5. Commissioning, operation
Abbreviations, definitions
Signal Description
UB Voltage source for sensor
UB+ Sensor-supply voltage (+)
UB- Sensor-supply voltage (-)
S+ Output signal (+)
S- Output signal (-)
0V 0V-Potential
Signal Description
Ammeter
Voltmeter
Voltage source
Switch
Shield (grounding)
A
V
+
-
Output 4 ... 20 mA, 2-wire
Connector M12 x 1, 5-pin
+
-
A
UB
UB+/S+
UB-
0V/S-
12
43
5
Signal 4 ... 20 mA, 2-wire Cable
colour
UB+/S+ 1 Brown
0V/S- 3 Black
Shield Case / connector -
Cable colours only apply when using the WIKA standard cable, e.g. order number 14259454
Signal 4 ... 20 mA, 3-wire Cable
colour
UB+ 1 Brown
S+ 4 Black
0V/S- 3 Blue
Shield Case / connector -
Output 4 ... 20 mA, 3-wire
Connector M12 x 1, 5-pin
+
-
A
UB
UB+
0V/S-
12
43
S+ 5
Signal 0 ... 10 V, 3-wire Cable
colour
UB+ 1 Brown
S+ 4 Black
0V/S- 3 Blue
Shield Case / connector -
Output 0...10 V, 3-wire
Connector M12 x 1, 5-pin
+
-
V
UB
UB+
0V/S-
12
43
S+ 5
5.4.2 Pin assignment of analogue output

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5. Commissioning, operation
Cable colours only apply when using the WIKA standard cable, e.g. order number: 14259454
+
-
A
UB
UB+/S+
UB-
0V/S-
12
43
UR-
UR+
+
-
UR
Output 4 ... 20 mA, 2-wire
Circular connector M12 x 1, 4-pin
Abbreviations, definitions
Signal 4 ... 20 mA, 2-wire Cable colour
UB+/S+ 1 Brown
0V/S- 3 Blue
UR+ 2 White
UR- 4 Black
Shield Case / connector -
5.4.3 Pin assignment with signal jump
Signal Description
Ammeter
Voltmeter
Voltage source
Switch
Shield [grounding]
Signal Description
UB Voltage source for sensor
UB+ Sensor-supply voltage (+)
UB- Sensor-supply voltage (-)
UR Voltage source for den signal jump
UR+ Signal jump-supply voltage (+)
UR- Signal jump-supply voltage (-)
S+ Output signal (+)
S- Output signal (-)
0V 0V-Potential
+
-
UB
UB+
0V/S-
12
43
UR-
UR+
+
-
UR
A
S+
Signal 4 ... 20 mA, 3-wire Cable colour
UB+ 1 Brown
0V/S- 3 Blue
UR+ 2 White
UR- 3 Blue
S+ 4 Black
Shield Case / Connector -
+
-
UB
UB+
0V/S-
12
43
UR-
UR+
+
-
UR
V
S+
Output 4 ... 20 mA, 3-wire
Circular connector M12 x 1, 4-pin
Output 0...10 V, 3-wire
Circular connector M12 x 1, 4-pin
A
V
+
-
Signal 0 ... 10 V, 3-wire Cable colour
UB+ 1 Brown
0V/S- 3 Blue
UR+ 2 White
UR- 3 Blue
S+ 4 Black
Shield Case / Connector -

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Operating instructions, model F5802
5. Commissioning, operation
5.4.4 Pin assignment for CANopen®
Abbreviations, definitions
Signal Description
CAN-SHLD, Shield Shield
CAN-V+ External positive voltage supply for the supply of the sensor
CAN-GND External 0V Potential for the supply of the sensor
CAN-High CAN_H Bus line (dominant high)
CAN-Low CAN_L Bus line (dominant low)
Signal Pin Cable colour
CAN-SHLD,
Shield
1 / case /
connector Brown
CAN-V+ 2 Blue
CAN-GND 3 White
CAN-High 4 Blue
CAN-Low 5 Black
Connect the cable shield to the case of the force transducer.
In the cables of the accessories, the cable shield is connected by means of the knurled
nut, thus connecting it to the case of the force transducer.
When using extensions, only
shielded and low-capacitance cables should be used.
The permitted maximum and minimum lengths of cable are defined in ISO 11898-2.
Care should also be taken with the shielding to ensure a high-quality connection.
Output CANopen® in according to CiA®303-1
Circular connector M12 x 1, 5-pin
Cable colours only apply when using the WIKA
standard cable, e.g. order number 14259454

20 Operating instructions, model F5802
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6. Faults
DANGER!
Danger to life from explosion
Through working in flammable atmospheres, there is a risk of explosion
which can cause death.

Only rectify faults in non-flammable atmospheres!
CAUTION!
Physical injuries, damage to property
If faults cannot be eliminated by means of the listed measures, the load
pin must be taken out of operation immediately.

Contact the manufacturer.

If a return is needed, please follow the instructions given in chapter 8.2
“Return”.
For contact details, see chapter 1 “General information” or the back page
of the operating instructions.
Faults Causes Measures
No output signal No or wrong supply voltage,
current pulse
Correct the supply voltage
Cable break Check the continuity
No or wrong output signal Wrong pin assignment Check pin assignment
Deviating zero point signal 
connection
Consult the manufacturer
Constant output signal when
changing force
Mechanical overloading,
wrong pin assignment
Consult the manufacturer
Signal span varies EMC interference sources
in the environment, e.g.,
frequency converter
Shield the instrument; line
shielding; remove source of
interference
Signal span drops/too small Mechanical overloading Consult the manufacturer
6. Faults