Omega Products TQ504 Installation Manual

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User’s Guide

TQ504

Torque Transducer

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It is the policy of OMEGA to comply with all worldwide safety and EMC/EMI regulations that
apply. OMEGA is constantly pursuing certification of its products to the European New Approach
Directives. OMEGA will add the CE mark to every appropriate device upon certification.

The information contained in this document is believed to be correct, but OMEGA Engineering, Inc. accepts
no liability for any errors it contains, and reserves the right to alter specifications without notice.
WARNING: These products are not designed for use in, and should not be used for, patient-connected applications.

INDEX

1. Applications and typical attributes ............................................... Page 1

2. Description of the measurement system ...................................... Page 1

2.1 Mechanical design ................................................................. Page 1

2.2 Electrical design ..................................................................... Page 2

2.3 Angle-of-rotation transducer ............................................... Page 3

3. Electrical connection of the torque transducer ............................ Page 4

3.1 Connector pin assignments .................................................. Page 5

3.1.1 Signals, angle outputs ........................................................... Page 6

3.2 Laying of the output signal cables ...................................... Page 6

3.3 Placement of conductors in cable ........................................ Page 6

4. Mechanical installation of the torque transducer........................ Page 8

4.1 Suggestions for installation .................................................. Page 8

5. Mechanical calibration ..................................................................... Page 9

5.1 Assembly of a simple calibrating setup ............................ Page 10

5.2 Sample calculation of lever arm length............................. Page 10

5.3 Electrical calibration ............................................................. Page 11

6. Maintenance...................................................................................... Page 11

7. Troubleshooting guide for transducer shaft............................... Page 12

See Data Sheet for technical specifications

TQ504 Torque Transducer

i

1. Applications and typical attributes

• Torque transducer with inductive angular position measurement system.

• Measurement of constant and variable torques.

• Torque measurement on a rotating shaft.

• For laboratory, production and quality assurance applications.

• Built- in instrument amplifier.

• Built- in angle-of-rotation transducer.

2. Description of the measurement system

2.1 Mechanical design

• The transducer consists of a stator through which a bearing-mounted shaft
passes.

• A certain length of the shaft is utilized to convert the torque into a proportional
torsional angle.

• This torsional angle or angle of twist is measured between the two ends of this
shaft length by an inductive (wave-form) angular position measurement
system.

• The inductive angular position measurement system converts the angle of
twist into a proportional electrical signal.

TQ504 Torque Transducer

1

Bearing

Angular
Sensor

Pulsedisk Stator Inductive (wave-

Rotary

transformers

form) angular

position measure-

ment system

Bearing

Torsion

length

• The electrical power for operation of the inductive angular position
measurement system, which rotates along with the shaft, is provided by means
of a rotary transformer.

• The electrical output signal, which is proportional to the torque, is transferred
to the stator by a second rotary transformer.

• The connection box on the stator contains the electronics, the power supply
unit, and the instrument amplifier.

2.2 Electrical design

The built-in electronics comprise the following functional groups:

• Oscillator for generation of the AC input voltage

• Preamplifier for the output signal

• Phase-sensitive rectifier for conversion of the AC output signal into a DC
voltage

• Output amplifier

TQ504 Torque Transducer

2

Mechanical part
of transducer

Inductive (wave­form) angular

Oscillator

120kHz

position measure­ment system

Preamplifier

Output
amplifier

Rotary transformers Phase-sesitive

rectifier

2.3 Angle-of-rotation transducer

Schematic of angle-of-rotation measurement system

1. Rotating shaft

2. Encoder disk

3. Double-arm photoelectric barrier

4. Open-collector output (external pull-up resistor required)*

Features:

• 360 slots in the encoder disk

• Two double-arm photoelectric barriers 90° apart.

• Number of pulses generated proportional to angle of rotation.

* The ohmic value of the resistor depends on the maximum speed of rotation and
the cable length (e.g. 1500 rpm and a 4 m cable, R=3.3kΩ).

TQ504 Torque Transducer

3

+

+5

V

+5

V

1

3

E

3

B

4

0

V

5V

V

0

2

intern

+5

V

4

3. Electrical connection of the torque transducer

• Cable type: at least 12 conductors, e.g. LIYCY 12 x 0.14

• Max. cable length: 15 m

TQ504 Torque Transducer

4

Connector

Shielded
cable

To power supply

and to display

Transducer

3.1 Connector pin assignments

Description of interface for Type, art.-no.: 7203

Angle outputs: open collector outputs with internal 10kΩ pull-up to +Vop

Built in connector: Binder Series 680, type 09-0331-80-12 or equivalent

Cable diagram with plugs on both sides

TQ504 Torque Transducer

5

Top view of connector on
transducer

Function Pin Description

supply voltage A -U

B

-10.5..-16V, ≤ 30mA

angle output

B <1 360 impulse per revolution duty cycle

50/50 ±20%

moment output

CU

a

±5V bei ±Md

nenn

on ≥ 2k_

+5V at calibration

Ri=10_, output short circuit proof acc.

GND

moment output D GND GND Reference for U

a

supply voltage

E GND GND Reference for Ub, R

kod

, Kal, <1),

<2

supply voltage F +U

b

+10,5V..+16V, ≤ 30mA

angle output

G <2 Signal 90°lagging to signal on Pin B

on rotation to the right

speed puls output H - 60-pulse / rotation

free J

calibration input

K Kal Off: 0V – 2V; On: 3,5V – 30V

Input impendence: > 100 k_

measuring range coding

LR

kod

free

shield M not used in the transducer

3.1.1 Signals, angle outputs

3.2 Laying of the output signal cables

-Note on safety-

• Do not lay together with control lines or lines carrying a high
current.

• Do not lay close to strong electromagnetic fields, e.g. those of transformers,
welding equipment, contactors, motors, etc.

• If the above is unavoidable, the cables must be laid in grounded heavygage
steel conduit.

• At the transducer, lay the cables in a sling in order to prevent vibration­induced damage to them.

3.3 Placement of conducters in cable

In order to prevent the measurement signal being distorted by the angle pulses,
the corresponding conductors should be separated within the cable.

TQ504 Torque Transducer

6

1

0V

t

2

0V

t

Positive pulse

Option

Pulse 90° phase-shifted with
respect to angle

Example application:
Detection of direction of

rotation (clockwise/counter­clockwise)

The cable length has virtually no influence on the measurement signal, but in the
case of the angle outputs the external pull-up resistances must be properly
adjusted.

TQ504 Torque Transducer

7

Example: 10-conductor cable

0V

0V

cal.

R

rod

–15V

+15V

V

out

+V

op

10k_

Connection cable
max. 15m

+V

op

Pull-up-resistanceR

R
(kΩ)

10

at n

= 1500 rpm

max

Resistance

1

2 10 1(m)

Cable length

4. Mechanical installation of the torque transducer

Transducer with fixed stator:

2 holes are provided in the transducer housing for this purpose.

• Use displaceable couplings as both shaft ends that are capable of
accommodating angular, radial and axial misalignment.

• Good results have been obtained with miniature couplings stiff against torsion
such as those described in data sheet 8303.

At torques of 50 Nm or greater, it is also possible to install the transducer
without fixed stator:

• In this case, use flexible couplings at both ends.

Caution: during installation no impermissibly high torques may be

allowed to arise between the two ends of the torque transducer shaft.

4.1 Suggestions for installation

Transducer with fixed stator and couplings able to accommodate angular, radial
and axial misalignment at both ends.

TQ504 Torque Transducer

8

Coupling able to accommo­date radial, angular and
axial misalignment

Shaft Shaft

Torque­transducer

Cable
connection

Attachment

angle

Coupling able to accommo­date radial, angular and
axial misalignment

BearingBearing

Transducer installed without fixed stator, with flexible coupling at each end.

This type of installation is possible at torques of 50 Nm and greater.

5. Mechanical calibration

To perform this, a calibration setup with lever arm and weights is needed to
create a torque.

Steps for calibration:

a) Apply the rated torque to the transducer, then remove the load again.

b) Precisely adjust the transducer to the zero point.

c) Apply a known torque to the transducer.

d) Set the indicator to the proper value.

Recording of a calibration curve:

a) Calibrate the transducer as described above.

b) Progressively apply greater torques to the transducer in steps of 1/10 up to

the full rated torque. Then gradually remove the torque in the same way. At
each step, wait at least 30 seconds for the torque reading to stabilize, and then
record.

TQ504 Torque Transducer

9

Torque­transducer

Bearing

Shaft Shaft

Flexible coupling

Cable
connection

Bearing

5.1 A simple calibrating setup

5.2 Sample calculation of lever arm length

TQ504 Torque Transducer

10

L=

Mt

m - g

eg. m = 1 kg. Mt = 10 Nm

L=

10Nm sec

2

1 kg _ 9.80665

= 1,0197 m

Lever arm

KK

Lever arm
bearing

K = coupling able to accommodate
axial and radial misalignments

Counter­support

Lever armTorque transducer

Bearing for lever
arm (double
bearing)

Weight
(calibrated)

Mt = torque
L = required lever arm length
m = required mass
g = 9.80665 m/sec2 - normal gravitational
acceleration (varies slightly from place to place)

Mt

M

L

5.3 Electrical calibration

A calibration control facility is integrated in the transducer to permit electrical
calibration.

Procedure for electrical calibration:

• Remove all mechanical loads from the transducer (no torque).

• Apply the calibration voltage Vc to pin K referenced to pin E.

• An output signal corresponding to the rated torque will be emitted.

6. Maintenance

• Type IE transducers require virtually no maintenance.

• The service life expectancy of the bearings within the rated temperature range
is approx. 20,000 hours.

• The service life expectancy of the bearing within the operating temperature
range is approx. 10,000 hours.

• The bearings can only be replaced in the factory.

• For high-precision applications: recalibrate the transducer once annually
(calibration at the factory or using an appropriate calibration setup).

• Once a month, check the cable connectors to make sure that they are securely
seated.

• Check the cables for damage once a month.

TQ504 Torque Transducer

11

5V

CAL

+Vs

GND

Transducer

+5V

7. Troubleshooting guide for transducer shaft

TQ504 Torque Transducer

12

Problem Probable causes Remedial action

Shaft does not rotate

Bearings are defective due to:

freely

a) Torsional or flexional vibrations
b) Excessive axial or radial loads Return to factory
c) Old or soiled bearings
d) Bent shaft

Zero point displacement Rotational vibration Readjust zero point on
≤ 2 % Shock forces instrument amplifier

Zero offset between 2%

Transducer has been overloaded The zero point can be

and 5% of range

Shock forces recalibrated once at
Rotational vibration the instrument amplifier

Transducer has

Transducer has been overloaded

hysteresis between

by changing loads or rotational Return to factory

clockwise and counter-

Rotation vibration

clockwise torque

NOTES:

TQ504 Torque Transducer

13

WARRANTY/DISCLAIMER

OMEGA ENGINEERING, INC. warrants this unit to be free of defects in materials and workmanship for a
period of 13 months from date of purchase. OMEGA’s WARRANTY adds an additional one (1) month
grace period to the normal one (1) year product warranty to cover handling and shipping time. This
ensures that OMEGA’s customers receive maximum coverage on each product.

If the unit malfunctions, it must be returned to the factory for evaluation. OMEGA’s Customer Service
Department will issue an Authorized Return (AR) number immediately upon phone or written request.
Upon examination by OMEGA, if the unit is found to be defective, it will be repaired or replaced at no
charge. OMEGA’s WARRANTY does not apply to defects resulting from any action of the purchaser,
including but not limited to mishandling, improper interfacing, operation outside of design limits,
improper repair, or unauthorized modification. This WARRANTY is VOID if the unit shows evidence of
having been tampered with or shows evidence of having been damaged as a result of excessive corrosion;
or current, heat, moisture or vibration; improper specification; misapplication; misuse or other operating
conditions outside of OMEGA’s control. Components which wear are not warranted, including but not
limited to contact points, fuses, and triacs.

OMEGA is pleased to offer suggestions on the use of its various products. However,
OMEGA neither assumes responsibility for any omissions or errors nor assumes liability for any
damages that result from the use of its products in accordance with information provided by
OMEGA, either verbal or written. OMEGA warrants only that the parts manufactured by it will be
as specified and free of defects. OMEGA MAKES NO OTHER WARRANTIES OR
REPRESENTATIONS OF ANY KIND WHATSOEVER, EXPRESS OR IMPLIED, EXCEPT THAT OF TITLE,
AND ALL IMPLIED WARRANTIES INCLUDING ANY WARRANTY OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. LIMITATION OF
LIABILITY: The remedies of purchaser set forth herein are exclusive, and the total liability of
OMEGA with respect to this order, whether based on contract, warranty, negligence,
indemnification, strict liability or otherwise, shall not exceed the purchase price of the
component upon which liability is based. In no event shall OMEGA be liable for
consequential, incidental or special damages.

CONDITIONS: Equipment sold by OMEGA is not intended to be used, nor shall it be used: (1) as a “Basic
Component” under 10 CFR 21 (NRC), used in or with any nuclear installation or activity; or (2) in medical
applications or used on humans. Should any Product(s) be used in or with any nuclear installation or
activity, medical application, used on humans, or misused in any way, OMEGA assumes no responsibility
as set forth in our basic WARRANTY/ DISCLAIMER language, and, additionally, purchaser will indemnify
OMEGA and hold OMEGA harmless from any liability or damage whatsoever arising out of the use of the
Product(s) in such a manner.

RETURN REQUESTS/INQUIRIES

Direct all warranty and repair requests/inquiries to the OMEGA Customer Service Department. BEFORE
RETURNING ANY PRODUCT(S) TO OMEGA, PURCHASER MUST OBTAIN AN AUTHORIZED RETURN
(AR) NUMBER FROM OMEGA’S CUSTOMER SERVICE DEPARTMENT (IN ORDER TO AVOID
PROCESSING DELAYS). The assigned AR number should then be marked on the outside of the return
package and on any correspondence.

The purchaser is responsible for shipping charges, freight, insurance and proper packaging to prevent
breakage in transit.

FOR W

ARRANTY RETURNS, please have the

following information available BEFORE
contacting OMEGA:

1. Purchase Order number under which the product
was PURCHASED,

2. Model and serial number of the product under
warranty, and

3. Repair instructions and/or specific problems
relative to the product.

FOR NON-WARRANTY REPAIRS,

consult OMEGA
for current repair charges. Have the following
information available BEFORE contacting OMEGA:

1. Purchase Order number to cover the COST

of the repair,

2. Model and serial number of the product, and

3. Repair instructions and/or specific problems

relative to the product.

OMEGA’s policy is to make running changes, not model changes, whenever an improvement is possible. This affords
our customers the latest in technology and engineering.

OMEGA is a registered trademark of OMEGA ENGINEERING, INC.
© Copyright 2002 OMEGA ENGINEERING, INC. All rights reserved. This document may not be copied, photocopied,

reproduced, translated, or reduced to any electronic medium or machine-readable form, in whole or in part, without the
prior written consent of OMEGA ENGINEERING, INC.

M2958/0602

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