Torq-Tronics - TestMart® Digital Torque Testersare designed and constructed to provide the user ......

Torq-Tronics®

Digital TorqueTester

Owners ManualVersion 2.1A 5/2001 P/N: 857432

For Models: 10I (10191), 50I (10192), 100I (10193), 300I (10194), 80 (10195,150 (10196), 150 (10197), 250 (10197), 600 (10198)

Sturtevant RIchmontDivision of Ryeson Corporation

3203 N. Wolf Road Franklin Park, IL 60131Phones: 800/877-1347 847/455-8677 Fax: 847/455-0347

E-mail: [email protected] Web: www.srtorque.comAn ISO 9001 Company

Table of Contents

Section Page

Safety Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Meet Your Torq-Tronics® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Chapter 1 - Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Chapter 2 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Chapter 3 - Testing Torque Wrenches and Torque Screwdrivers . . . . . . . . . . . . . . . . . . . . .15Chapter 4 - Power Tool Testing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Chapter 5 - Joint Simulators and Power Tool Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Chapter 6 - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Chapter 7 - Testing Power Tools Under 10 Inch-Pound Capacity . . . . . . . . . . . . . . . . . . . .29Chapter 8 - Testing Non-Shutoff Pulse Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33Chapter 9 - Testing Power Tools of Over 10 Inch-Pound Capacity . . . . . . . . . . . . . . . . . . .35Chapter 10 - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Chapter 11 - Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Safety Recommendations

For your safety and the safety of others, read and understand the safety recommendationsbefore installing or operating the Torq-TronicsÒ.

Torq-Tronics® Digital Torque Testers are designed and constructed to provide the userwith a safe and reliable means of calibrating torque wrenches and power tools. Should afault occur which impairs its function and/or compromises its safe use, immediately dis-connect the unit from its power source and secure against unitended operation. Under nocircumstances should repair be attempted by persons not qualified in the service of elec-tronic instrumentation.

When testing tool torque, always wear protective equipment:

For additional information on eye and face protection, refer to Federal OSHARegulations, 29CFR § 1910.133, Eye and Face Protection, and American NationalStandards Institute, ANSI Z87.1, Occupational and Educational Eye and Face Protection.Z87.1 is available from the American National Standards Institute, Inc., 11 West 42ndStreet, New York, NY 10036.

Hearing protection is recommended in high noise areas of 85 dBA or greater. The opera-tion of other tools and equipment in the area, reflective surfaces, process noises and reso-nant structures can substantially contribute to, and increase the noise level in the area.Excessive air pressure above 90 PSIG or worn motor components can also increase soundlevel emitted by the tool. Proper hearing conservation measures, including annual audio-grams and training in the use and fit of hearing protection devices may be necessary. Foradditional information on hearing protection, refer to CFR § 1910.95, Occupational NoiseExposure, and American National Standards Institute, ANSI S12.6, Hearing Protectors.

Torq-Tronics® Digital Torque Testers should be mounted and located such that inadver-tent movement will not allow the unit to be dislodged, possibly causing personal injury ordamage to the unit. Should the unit be dropped, it should be checked by someone qualifiedin the service of electronic instrumentation.

WARNING: Shock Hazard. Disconnect power to the unit before attemptingto service. Any internal adjustments should be carried out only by skilledpersons who are aware of the hazards of dealing with live circuitry. Thecabinet which houses the circuitry provides protection against dust andfalling dirt. This unit should be used only indoors. Do not use in explosiveatmospheres.

WARNING: Shock Hazard. Damaged cords or plugs are dangerous, andshould be repaired or replaced as necessary.

CAUTION: Tripping Hazard. Electrical cords and tool cables must beorganized and located in such a manner as to reduce the likelihood of theuser others of tripping or becoming entangled in electrical cords and cabledused with this product. Route electrical cord so that it is not subject to chaf-ing, crushing, or severing.

Meet Your Torq-Tronics®

1 Back Plate2 Mounting Hole (4 locations)3 Backlit LCD Display4 Keys

Zero KeyClear/Print KeyAuto KeyUnits KeyPeak Select KeyFilter Key

5 Transducer6 Battery Compartment Cover7 Power Switch8 Fuse9 Serial Port

10 Charger Receptacle

This page intentionally left blank.

Chapter 1 - Features

Back PlateThe Back Plate of your Torq-Tronics® unit provides primary structural strength for it and ameans by which the unit may be installed.

Mounting HolesThe Mounting Holes in the Back Plate provide a means of securing the unit in its' installedlocation. The holes are designed for use with 3/8" (or metric equivalent) bolts, and it isimportant to use bolts in all four holes when installing your Torq-Tronics®.

Backlit LCD DisplayThe 16-character, 3/8" high, Backlit LCD Display is your "information center" when operat-ing your Torq-Tronics® unit. It provides such information as software version, mode ofoperation, units of measure, direction of torque, automatic or manual printing/display clear-ing status, and warning of low battery power. Note: To conserve battery power, backlightoperates only when charger is connected.

Zero KeyThe Zero Key is used to return the unit to zero when changing torque test direction, or tozero when drift occurs. It is also used during the calibration process. It is important not topress the Zero key when torque is applied to the transducer.

Clear/Print KeyThe Clear/Print key performs two functions. When pressed, it sends the torque measure-ment on the display to the serial port for communication to a computer or printer, then itclears the display for the next torque measurement.

Auto KeyThe Auto key is a toggle switch which activates and deactivates the automatic status of theClear/Print function. When the automatic print/automatic clear function is active, an "A"will appear behind the measurement units on the LCD display. When the automaticprint/automatic clear function is deactivated, the displayed measurement must be printedand cleared manually by pressing the Print/Clear key, and no "A" will be displayed.

Units KeyThe Units key is used to page through the measurement units the tester offers. The meas-urement units available on each tester are given in the Specifications chapter of this manual.Each time this key is pressed, it pages to the next measurement unit available in the series.

Peak Select KeyThe Peak Select key is used to select from among the three modes of operation: Track,Peak, and Initial Peak. When turned on, your Torq-Tronics® always boots into Trackmode. Each time this key is pressed, it pages to the next mode of operation.

Track mode is used for calibration of the Torq-Tronics® unit. When the tester is in Trackmode, "Tk" will be displayed at the far right of the LCD.

Peak mode is used for testing all non-impacting power tools. This includes clutch, stall, andpulse-type tools. Your Torq-Tronics® cannot be used to test impact wrenches. When thetester is in this mode, "PK" will be displayed at the far right side of the LCD.

Initial Peak mode is used for testing clicker-type torque wrenches and torque screwdrivers.This mode captures the torque at which the torque stopped rising due to activation of thetorque-limiting mechanism inside. When the tester is in this mode, "IP" will be displayed atthe far right of the LCD.

Filter KeyFilters are electronic devices which "clean up" the analog electrical signal coming from thetorque transducer before the signal is measured and the measurement converted to torque.This filtering removes some of the top of the wave peak and the bottom of the wave troughin the signal from the transducer. There are five of these filters in the Torq-Tronics® tester,and they are numbered "0" through "4". The lower the filter number, the more of the peakand valley is discarded before the signal is sent on for processing. The Filter Key pagesthrough the four available filters in sequence. More about filters may be found in chapterson filters and power tool testing.

TransducerThe transducer is the device which uses Hooke's Law and Ohm's Law to convert appliedtorque into an electrical signal. The front of the transducer has either a male hex drive (onunits of 300 inch-pound capacity or less) or a female square drive (units of greater than 300inch-pounds capacity). It is the transducer to which the torque tool is connected for testing.

Battery Compartment CoverRetains the rechargeable AA nickel cadmium batteries. This cover should only be removedto replace batteries.

Power SwitchThe power switch is used to turn on the tester for use or turn it off when testing has beencompleted.

FuseYour Torq-Tronics® tester has a ½ ampere Buss fuse in the fuse holder.

Serial PortThe serial port is a 9-pin port for serial communications with either a computer or serialprinter. Data is sent to the port for transmission when the display is cleared, whether auto-matically or manually.

Charger ReceptacleThe charger receptacle is provided for connection of the charger to the tester.

Chapter 2 - Installing Your Torq-Tronics®

Mounting To Wall or Bench - Location SelectionThere are several items that must be considered when selecting the location where yourTorq-Tronics® will be mounted. These are:

Tool proximity. Do you want to test tools at or near their use location or do you want tobring the tools to a central location? Will you be using a computer and Torque ToolManager (TTM) software with your Torq-Tronics®?

Solidity of mount. Your Torq-Tronics® unit must be secured to a solid support to functionproperly. If the tester can move when a torque tool is tested, the motion will degrade theaccuracy of the torque measurement, and over time the motion may damage the unit or thesupport the unit is attached to. The selected mounting location must also be equal to orlarger than the base plate of the tester - full support of the base plate is required to achievethe required rigidity. See the Safety Recommendations at the front of this manual.

Electricity source. Your Torq-Tronics® requires a source of electricity to power the unitand recharge the batteries. The backlight of the LCD will only work when the unit isplugged into the proper power source. If you will be using TTM with your unit, electricpower will be required for it as well. The installation must be close to an appropriate powersource. See the Safety Recommendations at the front of this manual.

Tester orientation. Your Torq-Tronics® unit will function properly in either the verticalor the horizontal plane. The primary consideration in selecting tester orientation isergonomic. If the tools to be tested are of low torque capacity, mounting the tester on aworkbench in the horizontal plane may be optimal. If the tools to be tested are of 50 foot-pounds capacity or higher, mounting the tester in the vertical plane at an appropriate heightis recommended. This will permit the user to utilize their body mass more efficiently incontrolling the tools being tested, thereby reducing the risk of injury. The reduced effortwill also encourage use of the proper tool handling procedure during testing.

Power/Communications access. Your Torq-Tronics® uses NiCd rechargeable batteriesand a battery charger as electric power sources. The batteries will need to be replaced peri-odically. This requires removal and reinstallation of the battery plate cover on the right sideof the Torq-Tronics® unit. This side also contains the charger receptacle and serial port. Itis important that sufficient clearance be maintained to the right of the unit that access andworkspace for battery replacement and power/communications connections be available.Note: Do not use other types of batteries.

Mounting to Selected SupportOnce the installation location has been determined, the actual installation process can begin.

1. Place your Torq-Tronics® in the selected mounting location, supported as necessary toassure stability of the location and safety.

2. Mark the location of the mounting holes on the surface to which the tester is to bemounted.

3. Remove the Torq-Tronics® from the installation location, and drill or drill and tapmounting holes.

4. Your Torq-Tronics® may be mounted with bolts and nuts or with bolts into a drilledand tapped hole. Regardless of method, the Torq-Tronics® is designed to be mountedwith 3/8" (or metric equivalent) diameter bolts. Bolts should be at least SAE Grade 5,with SAE Grade 8 preferred. Drill, and if necessary, tap the holes.

5. Place the Torq-Tronics® over the holes and install the bolts, and if necessary, nuts.Check to insure that the tester does not move after the fasteners have been installed.

Electrical Connection1. The first step in providing power is installation of the four (4) AA NiCd batteries.

a. Remove the two Phillips head screws holding the battery cover in place on the rightside of the Torq-Tronics® unit. Use a #1 Phillips screwdriver.

b. Gently remove the battery cover and attached battery pack from the Torq-Tronics®unit. Do not move the cover and battery pack any further from the unit than is nec-essary to install the batteries! The wires from the battery pack to the internal elec-tronics are small and soldered at each end. Placing excessive tension on them willbreak the wires and necessitate returning the unit for repair!

c. Open the package containing the supplied batteries.d. Following the battery orientation shown inside the battery pack, install all four bat-

teries into it. It is important that proper battery orientation be maintained!e. Gently push the wires connecting the battery pack to the internal electronics while

replacing the battery cover back in its' original position.f. Reinstall the two Phillips head screws used to retain the battery cover in place. The

screws should only be tightened snug.

2. The second step in providing power to your Torq-Tronics is connection to the AC powersource.a. Unwrap the trickle charger supplied with your Torq-Tronics®.b. Plug the charger pin into the charger pin receptacle on the right side of the unit.c. Plug the other end of the charger into a properly wired 120 VAC (240 VAC in

Europe) outlet.

Computer Communications (Optional)If you will be using your Torq-Tronics® with a computer and TTM software or a serialprinter, this is the time to establish communications.

1. Gently insert the male end of your 9-pin serial cable into the serial port on the right sideof your Torq-Tronics® unit.

2. Thread the externally-threaded fasteners on either side of the cable terminal into theinternally-threaded securing nuts on either side of the serial port. Tighten fasteners justenough to secure cable terminus in position.

3. Install the other end of the serial cable to the serial port on your computer or serial print-er.

4. Serial communications parameters are: 4800 baud, No parity, 8-bit, 1 stop bit.

Test InstallationThe last step in the installation process is checking to insure the unit works as installed.

1. Testing Electrical Power Supplya. Move the power switch to the on position. If the batteries are properly installed and

AC power is connected, the backlit LCD display will come on, a series of messageswill be displayed, and the unit will finish in Track mode at zero torque value inEnglish units of measurement. If the backlights on the LCD are not lit, it means theunit is not properly connected to an AC power source. Check power to the AC out-let, that the charger is firmly plugged into the outlet, and that the charger pin isfully-inserted into its' receptacle in the Torq-Tronics® unit.

b. Unplug the charger from the 120VAC outlet. If the backlight on the LCD goes outbut the characters remain displayed, the batteries have been properly installed. If thebacklight goes out and the characters do not remain displayed, the batteries haveeither not been installed or have been improperly installed. To correct this, move thepower switch to the off position, remove the battery pack cover, remove and proper-ly reinstall the batteries, then reinstall the battery pack. Move the power switch tothe on position and the characters will be displayed.

c. Move the power switch to the off position and reconnect the charger to the 120 VACpower outlet.

2. Testing communications (Optional)a. Computer Communications Test

i. Activate terminal software.ii. Move the power switch on the Torq-Tronics® to the on position.iii. The message "Sturtevant Richmont" then "System 7 Ver 1.1" then

"TORQTRONICS [Model]" will appear in the terminal software window if theTorq-Tronics is properly connected and the proper serial port is selected andproperly configured. If these letters do not appear, check for proper cable con-nection, proper port selection, and proper port configuration. Serial communica-tions specifications may be found in the Specifications section of this manual.

b. Serial Printer Testi. Move the power switch on the Torq-Tronics® unit to the on position.ii. Turn on the printer.iii. The message "Sturtevant Richmont" then "System 7 Ver 1.1" then

"TORQTRONICS [Model]" will print if the printer is properly connected and thepower is on. If this does not occur, check printer power, printer settings, andserial cable connections.

Chapter 3 - Testing Torque Wrenches & Manual TorqueScrewdrivers

This section covers the testing of clicker-type torque wrenches and manual torque screw-drivers using your Torq-Tronics®. These tool types have a specified accuracy of ± 4% to ±6% Indicated Value (I.V.) or less, and are suitable for testing on the Torq-Tronics®, whichhas an accuracy of ± 1% I.V. Tools of accuracy tighter than ± 4% I.V. should be tested on atorque tester of tighter accuracy. This includes most dial- and beam-type torque wrenches.If you have a need to calibrate such tools, contact Sturtevant Richmont for assistance inselecting an appropriate torque measurement system.

This section assumes yourTorq-Tronics® has been properly installed, and that any commu-nications connections have been made. If these steps have not been performed, please per-form them according to the instructions in the preceding chapter.

A clicker-type torque wrench will be used as an example in this chapter's photographs andtext. The procedure for testing a torque screwdriver is the same as that used for the torquewrench.

Starting the Torq-Tronics®1. Move the power switch to the ON position.2. Allow the Torq-Tronics® to boot up. During this process, two messages will be dis-

played on the LCD.a. "System 7 Ver 1.1"b. "TORQTRONICS [Model #}"

3. After these two messages have been displayed and cleared, the tester will display itsoperating status on the LCD. This will consist of:a. A plus (+) or minus (-) sign in front ofb. a torque value at or near zero, followed byc. the units of measure currently in use.d. There will then be one or two blanks, followed bye. "TK" to indicate the tester is in Track mode.

4. If the displayed torque value is not zero, press the Zero key to return the tester to zerovalue.

5. Press the Peak Select key twice to page from Track mode to Initial Peak mode. The lasttwo characters on the display will change to "IP" when the tester has entered this mode.

6. If you wish the test results to automatically print and clear from the LCD within a fewseconds of test completion, press the Auto key once. An "A" will be displayed immedi-ately behind the units of measure. If you wish the torque measurement to be displayeduntil you wish it cleared, you need do nothing. Clearing each measurement from thedisplay will require pressing the Clear/Print key after each display when in manualmode.

Preparing the Torque WrenchCheck that the torque wrench to be tested is of equal or lesser torque capacity than thetester. Under no circumstances should the Torq-Tronics® be used beyond its' rated capaci-ty! Adjust the torque wrench to the desired torque level for testing.

If your Torq-Tronics® has a male hex drive, put a socket of the same size on the front ofthe torque wrench, so the transducer drive can be engaged by the tool. If your Torq-Tronics® has a female square drive, a torque wrench square drive can be inserted directlyinto a transducer square drive. If the square drives are of different sizes, use a square driveadapter to mate the tool and transducer. Always use as few adapters as possible; the morethe torque wrench stands out from the transducer, the more likely error may be induced.

Testing the torque wrench.Grasp the torque wrench at its' load point, and apply slowly increasing force steadily until itclicks. Stop applying force immediately, and allow the torque wrench to reset. The meas-urement will be displayed on the LCD.

Chapter 4 - Power Tool Testing Overview

Types of Power ToolsPower tool types may be broken down by basic categories: the means by which they arepowered, the means by which they apply torque, and the means by which torque applicationstops. The breakdown of possible combinations appears as below:

Power Source Torque Sensing Shutoff TypePneumatic Clutch Clutch

Electric Switch SwitchHydraulic Pressure Valve

None None (Manual)

The miscellaneous combinations of these three characteristics is what creates the variety oftools offered on the market. The means by which they are combined, and the way thedesign is executed, determines the best means of calibrating the particular tool.

Tools Appropriate and Inappropriate for Testing on Torq-Tronics®Impact tools are not to be tested on the Torq-Tronics® family of testers. Doing so willinvalidate the tester warranty and probably damage the tester.

All other types of power tools may be tested on Torq-Tronics®. Stall, clutch, and valve,and pulse tools may be tested with good results. There will be differences among the typesin technique used to obtain accurate results, but accurate and repeatable results may beobtained with all of them.

Power Tool Testing ApproachesIn general, there are two basic approaches that can be employed in testing power tools: cor-relative, and tool or tool family specific. These techniques can also be combined to providethe most cost-effective result for your facility. Each approach has advantages and disadvan-tages, and the one best for you may not be the same as the best one for the next plant.

Correlative approaches are those that rely on the correlation of the test result (torque),obtained from a standardized method of testing the tools on the tester, with the actual torqueobtained in use on the joint.

ExamplePower tool brand X, serial number 1234, is producing a consistent and acceptable 42 - 48inch-pounds of torque on the hard joint on assembly Q. This is known from recent auditsand test results on the joint. The tool consistently produces test results of 50 - 56 inch-pounds on the tester when used with the joint simulator emulating a hard joint and usingFilter 4. Since it is known that a consistent offset of -8 inch-pounds (15% lower on joint

than tester), the offset can be used to avoid having to build an exact model of the joint(using the joint simulator and filter) to obtain identical results. As long as the actual jointremains the same (no new components or design changes to existing components) and thetest results are in the 50 - 56 inch-pound range, the tool is producing good assemblies.

The advantages of this approach include less test model design time up front, ease of use inpractice, and rapid test execution (effective zero time to configure joint simulator). If theoffset is known for each tool/joint configuration, testing is extremely rapid. This is of par-ticular importance when there are large quantities of tools to be tested.

The disadvantages of this approach are that one must be careful to assure the correct offsetis obtained for each joint/tool configuration, and recorded for use in determining whethertool performance has changed. Somewhere in the tool record the "Filter 4, Joint Q offset =-8 inch-pounds" must be recorded and used during torque testing. Also, if the tool is to beused on joint "R" instead of joint "Q", then testing will have to be performed to determinethe correct filter to be used (most consistent results) and the correct offset for that joint/toolcombination.

In many respects, the correlative approach is simplest to use.

The tool-specific approach is somewhat more cumbersome, but yields results which arevery closely aligned with the actual torque which will be experienced on the line. In thisapproach, each power tool/joint combination has an individual model of the joint built. Themodel consists of an almost exact replication of the specific joint built from two compo-nents: the joint simulator and a filter selected on the tester itself.

There are two advantages to this approach. The first advantage is that the numbers obtainedfrom joint audits closely match those obtained from the power tool testing. This is comfort-ing to those who are uncomfortable with the concept of offsets. The second advantage isthat there can be no arithmetic error in determining whether or not the tool is conforming torequirements. No calculation of offset means no arithmetic calculation, hence no possibilityof arithmetic error.

There are some significant disadvantages to this approach. The time investment required tobuild an exact simulator/filter model of every joint/tool combination in the facility can bequite large. This information must be recorded, then used for each test of each power tool.This means the person calibrating the tool must rebuild that exact model each and everytime the power tool is tested. This results in higher ongoing time and labor costs for cali-bration, and is still not 100% effective. Joint simulators using Belleville washers can bemade to closely emulate almost any joint in their usable range (capacity). But above a cer-tain torque level, it is necessary to use springs instead of Belleville washers because of heatbuildup in the washer stack during rapid torque application with the power tool. Since it isalmost impossible to obtain a spring for every joint rate experienced in a plant, those plantsusing higher torques (above about 300 inch-pounds) are forced to use a correlative approachabove the torque level where washer use is impracticable. If the plant is using torques

where both techniques (correlative and tool-specific) are employed, the possibility of confu-sion exists. This also adds to the cost of training new calibration personnel, as well asincreasing the probability of error.

The record keeping requirements for the tool-specific approach are slightly larger than thosefor the correlative approach. Each tool must have, in addition to the filter selection for eachtool, a record of the exact washer configuration for the tool/joint combination. Any devia-tion from the exact washer configuration will result in a differing joint rate, and on mosttools, show up as a shift in torque output.

ExamplePower tool brand D, serial number 2345, is used on joint "Y", which is a medium jointrequiring about 270 degrees of rotation to get from 10% of installation torque specificationto 100% of installation torque. Experimentation determines that to obtain results from test-ing the same as those on the line, it is necessary to use 12 washers in the joint simulator,stacked in a configuration where the direction of every third washer is reversed, and withfilter 3 selected.

For each calibration of that tool for use on that joint, the technician must (1) look up theproper washer configuration, (2) disassemble the joint simulator, (3) properly configure thewasher stack, (4) reassemble the joint simulator, (5) install the joint simulator on the tester,and finally (6) conduct the tests. At least three pitfalls exist (1, 3, and 1 and 3 together)which offer the possibility of error which will show up as discrepancy in power tool per-formance. When the power tool shows performance on the tester not consonant withrequirements, the technician must conduct a fairly detailed analysis to determine whetherthe problem is test error or a tool problem.

It is for the reasons given above that different plants arrive at different decisions on theapproach to be taken in power tool calibration. The small plant with four power tools of thesame make and model faces an entirely different situation from the very large plant with500 power tools of differing types, makes, and models.

Information required for implementation of either approach is given in the following chap-ters in this manual.

Automatic Shutoff ToolsAll automatic shutoff tools use the joint for feedback to the shutoff mechanism. This meansthat the joint is part of the control loop which determines the shutoff point, and the finaltorque, achieved on the fastener by the tool. The tool affects the joint by tightening the fas-tener, which affects the tool by resisting further rotation, which affects the shutoff mecha-nism. This loop starts when the tool is activated while engaged with the fastener, and endsshortly after the shutoff mechanism activates.

The tool and joint do not stop interacting the instant the tool shuts off. All of the rotatingcomponents in the tool have momentum from the rotation. Once the power shuts off, thesecomponents (motor shaft, drivetrain components, chuck, and bit or socket) continue to inter-act with the fastener until all momentum is dissipated. This is discussed in more depth, andwith diagrams, in a later chapter. For now it is merely important to note that this is one ofthe primary reasons that filters and joint simulators are used.

Non-Shutoff Power Tools (Manual Shutoff)Non-shutoff or manual power tools continue to apply torque as long as power is present andthe tool is activated. The torque actually transmitted to the fastener will not perpetuallyincrease, even when the tool is activated for a long period of time. Once the fastener torquehas increased to the maximum output of the tool, either the tool will stall or the appliedtorque will simply stop moving the fastener because the torque is less than that already onit.

Pulse Tools - Special ConsiderationsA pulse tool is essentially an impact tool with a buffer between the hammer and the anvil.Due to the impacting pulses on the joint, these tools are typically joint sensitive. The actualtorque transmitted to the joint is a function of the peak output of the joint and the joint rate(hardness or softness). Within limits, the harder the joint, the higher will be the torque onthe fastener at the same torque setting on the tool.

The non-shutoff type of pulse tools has a different test method than automatic shutoff pulsetools. Both will be addressed later in the manual.

Chapter 5 - Joint Simulators and Power Tool Testing

Joint Hardness

Joint hardness is the rate at which a joint develops clamping force as torque is applied to thefastener. Any given joint may be "hard", "soft", or somewhere in between. Note: Jointhardness is classified in accordance with the ISO 5393 standard.

A "hard" joint is one which requires very little fastener rotation to develop the joint preload(clamping force) desired for the assembly. Stated another way, there are very few degreesof fastener rotation, and very little time, from the moment the fastener develops a small per-centage (10%) of the fastener preload desired to the moment the fastener develops 100% ofthe desired preload.

This is depicted in the first diagram. In this diagram,the horizontal axis is time or rotation angle, and thevertical axis is the torque which results in clampingforce. The very rapid rise in torque and clampingforce over very little time is what defines a hardjoint.

The next diagram is of a medium joint. Notice thatthe rise in torque and clamping force takes moretime - fastener rotation - than it did in a hard joint.The angle of rotation is between 30º and 270º.

TIME/ANGLE

TO

RQ

UE

TIME/ANGLE

TO

RQ

UE

The third diagram is of a soft joint. Notice the slowrise in torque; it takes more time - and fastener rota-tion - to reach the same installation torque. Theangle of fastener rotation is greater than 270º.

Joint Hardness and Power Tool CalibrationAlmost all non-impacting power tools rely on the reaction of the joint to determine when toshut off. The tool affects the joint by tightening the fastener. The joint affects the tool byvarying torque feedback. The feedback is as much a part of the torque control as is theclutch or valve that triggers the tool shutoff.

If a power tool is tested or calibrated on a joint that is feeding back information significant-ly different from the feedback the power tool will receive when used on the assembly line,the results may be markedly different from each other. The tester will show a torque outputof one level, but a test of the fastener torque on the assembly after the tool is used will showa different torque.

It is for this reason that joint simulators were developed, and are used in most power toolcalibrations.

Joint SimulatorsA joint simulator is a device intended for use in power tool torque testing on torque trans-ducers. It is designed to emulate the reaction of a wide range of joint hardnesses. By doingthis, it permits the user to obtain test results that are more predictive of actual tool perform-ance on the line.

Joint simulators are devices containing:

· A means of being attached to the torque transducer drive.· A set of Belleville washers (or springs) which can be configured to emulate the joint

response. Only joint simulators with Belleville washers are adjustable for joint rate sim-ulation. Joint simulators with springs have a joint rate fixed by the spring rate, and canonly be adjusted by spring replacement.

· A means of tightening the washers while transmitting the applied torque to the torquetransducer.

TIME/ANGLE

TOR

QU

E

The joint simulator may or may not contain additional elements such as multi-part housings.

Below are photographs of a Sturtevant Richmont joint simulator using Belleville washers.The joint simulators of 80 foot-pound capacity and above are the same, except that a springis substituted for the washer and no adjustment of the joint rate is made.

This is a joint simulator and its accessories asreceived. The large cylinder is the joint sim-ulator itself. The separate hex driver bit tothe front is placed in the chuck of the powertool to be tested, and used to engage the boltin the joint simulator. The small cylinder tothe left is the hard joint cylinder used in thejoint simulator when emulating a hard joint.

This is the joint simulator disassembled.From left to right, the components arethe base, the Belleville washers, thehousing, and the bolt. To use the jointsimulator, the washers are configured toemulate the joint, then stacked on thebolt. The bolt is then threaded about ¼"into the base. The housing is installedover the bolt and threaded onto the exter-nal threads on the base. The joint simu-lator is then ready for installation on thetester transducer.

To the left in this photograph is the hard jointcylinder, used in place of the washers when thesimulator is to emulate a hard joint. In the cen-ter, a stack of washers has been turned to faceall the same direction.

Stacked this way, the washers emulate a joint very close to a hard joint; there is very littletravel or time between when the bolt head contacts them and the time they are fully com-pressed. On the right, the same number of washers has been stacked in such a manner as toprovide more bolt rotation and time between bolt contact and full compression of the wash-ers. This will emulate a joint softer than the one emulated by the center configuration.

In these two photographs, two more washer configura-tions are displayed, each as stacked on the bolt. Thephotograph on the left depicts a stack that will emulatea joint slightly harder than the stack in the photo to theright.

There is a simple rule of thumb which can be used todetermine whether one stack of washers will emulate aharder or softer joint than another - the taller the stackof the same number of washers, the softer the joint itemulates. This is because it takes more bolt rotationand more time to compress the taller stack of washers.

In practice, the same amount of rotation it takes to tighten the actual joint should be emulat-ed on the joint simulator as closely as possible. This is the first and most basic step inmatching tool test performance to actual tool performance when individual joint/tool testingis performed. For correlative testing, it is merely important that the stack of washers (ifused) be consistent with each test.

Once the proper washer stackup has beendetermined and placed on the bolt, thebolt is loosely installed in the simulatorbase. Loose installation provides roomfor tool rundown prior to engaging thewashers, just as will occur in actual com-ponent assembly on the production line.

The next step is to thread the housing coveronto the simulator base. Thread the housingall the way down, and tighten just fingertight.

Once this is done, the simulator is ready forinstallation on the tester.

This photograph shows the rear of the joint simulator,with the base to the front. Two #8-32 setscrews arelocated in the small neck diameter of the base. Toinstall the joint simulator, use a hex key to back thesetscrews out of the female hex. The female hex isthen engaged to the male hex of the transducer (oradapter, on larger units), and the setscrews tightenedjust enough to hold the simulator on the tester.

Once the joint simulator is configured and in place on the tester, the tester itself may beconfigured for testing.

Rotation Measurement Procedure

This procedure is that used to measure the amount of rotationused to configure the joint simulator, and is to be conductedon the actual joint the power tool will assemble. A dial- orbeam-type torque wrench and a goniometer or other device tomeasure degrees of rotation will be needed. Even a piece ofcardboard and a marker can be used to record the start andfinish points for rotation measurement.

1. Install the components of the joint and start the fastener.2. Run the fastener down to the point at which its' bearing

surface contacts the surface against which it will be seat-ed.

3. Use the torque wrench to tighten the fastener to between1% and 5% of its' final installation torque. This is thestart point for measuring rotation. See drawing.

4. If necessary, mark the start point.5. Use the torque wrench to tighten the fastener to the final

installation torque.6. If necessary, mark the finish point.7. Measure and record the number of degrees of rotation.

This is the amount of rotation the joint simulator shouldhave from the same start and finish torques to emulatethe actual production joint.

Start

Start

Finish

Rotation

Joint Simulator Washer Configuration Procedure

This procedure is used to obtain a washer stackup that will emulate the actual joint to betightened by the power tool. The goal is that the same number of degrees of rotation beobtained on the joint simulator as was measured in the prior procedure for the same torquevalues. A hex key of the same size as the female hex on the joint simulator, the dial- orbeam-type torque wrench, and a goniometer or other means of measuring the angle of rota-tion of the bolt in the joint simulator will be needed.

1. Evaluate the washers needed to emulate the assembly joint.a. If the degrees of rotation from Start to Finish from the prior procedure was < 10°,

use the hard joint cylinder in place of the washers for the balance of the procedure.Skip the next step.

b. If the degrees of rotation were > 10°, use the washers.

2. Select a washer stackup providing the desired rotation obtained in prior procedure.

3. Install the washers on the bolt.

4. Install the bolt, loosely, in the body of the joint simulator.

5. Install the housing cover on the joint simulator.

6. Attach the joint simulator to the transducer using the method described earlier in thischapter.

7. Use the methodology from the prior procedure to measure the degrees of rotationobtained on the joint simulator.

8. Evaluate the result.a. If the degrees of rotation are the same ± 10°, the joint has likely been suc-cessfully

emulated and can be used with this configuration. The joint simulator can beremoved from the hex key and is ready for use on the tester.

b. If the degrees of rotation are more than ± 10°, the joint has likely not been success-fully emulated and cannot be used with this configuration.i. If the rotation obtained in this procedure was greater than that sought, the wash-

ers stackup will have to be made shorter, emulating a harder joint.ii. If the rotation obtained in this procedure was less than that sought, the washer

stackup will have to be made taller, emulating a softer joint.iii. Remove the joint simulator from the transducer.iv. Adjust the washer stackup as indicated.v. Repeat steps 4 through 9 of this procedure.

Chapter 6 - Filters

PurposeThe electronic filters in the Torq-Tronics® Digital Torque Testers perform two key func-tions: preventing electronic noise from causing inaccurate torque readings, and assisting inthe discrimination of the true applied torque signal from the extraneous signals generated bypower tool mechanisms.

The first of these filtering functions is straightforward. These testers are used in electroni-cally "noisy" environments. Lights, electric motors, and power lines are just some of thesources of electronic noise present in factories and laboratories. The wires in the Torq-Tronics® can pick up this noise, and send it to the torque analysis circuitry. Part of the pur-pose of the filters is to eliminate this problem.

The second purpose of the filters is to enable the user to separate the mechanical actions ofthe power tool which perform the work of applying torque from those actions which resultin signals but which do not actually apply torque to the fastener.

Filtering ConceptIn Chapter 5, concept drawings were used to explain the relationship of time and degrees ofrotation to the applied torque and the clamping force it generates. For the sake of clarity,these drawings were simplified to straight lines. The next drawing is more typical of theactual performance of a power tool in use, as shown on an oscilloscope.

In this drawing, time is the horizontal axis, and voltage is the vertical axis. The horizontalline is the starting voltage from which torque is measured. The horizontal line = no torque.The erratic line is the voltage coming from torque transducer, unfiltered.

In this drawing, the power tool has been used torun down a single fastener. The tool shut offwhen it reached the shutoff torque.

The slope of the line (#1) during the rundown ofthe fastener is not a smooth line; the rundown isnot as smooth as it appears to the human eye.The acceleration and deceleration of the torqueapplication rate is the result of the inevitableimperfections in the fasteners, the power tool,the joint components, and how they interact dur-ing the rundown phase of the power tool use.

1

2

3

4

5

The tool actually shut off at the peak labeled point #2. Once the power driving the bit wasshut off, regardless of the means, the bit rebounded off the drive of the fastener, and createda backlash through the drive mechanism of the tool. This created torque in the oppositedirection, as displayed by the line running from point #2 to point #3. The components ofthe tool drive continued to rebound off each other, as shown in points #4, #5, and the rest ofthe line to the right of them, until it stabilized at zero.

The graph discloses a number of peaks during fastener rundown, as well as those occurringat and after tool shutoff. This type of action - not identical, but similar - occurs with allnon-impacting power tool types on all joints. There are many variables involved: the powertool type, the individual tool, the fasteners, the joint rate, the tool power supply, rundownspeed, the tool's shutoff mechanism, and the broad variety of the interactions between them.These sources of mechanical "noise" create the electronic noise that must be eliminated todetermine what will be the actual applied torque on the fastener.

It is the filter, augmenting the joint rate emulation of the joint simulator, which permitseffective off-line calibration with confidence the results on the tester will correlate with theresults in the assembly process.

There are five (5) filters provided on each Torq-Tronics®. The filters are numbered 0, 1, 2,3, and 4. Each filter provides a different amount of noise reduction, with Filter 0 having themost filtering and Filter 4 the least.

Since there are only five filters, and there is an extraordinary variety of joints and powertools on which the tester might be used (and more power tools and applications coming outevery year), learning to balance the joint simulator and the filters is a key to assuring a suc-cessful power tool testing program.

Chapter 7 - Testing Power Tools of Under 10 Inch-Pound Capacity

Power tools of less than 10 Inch-Pound capacity should be tested without the use of a jointsimulator. This includes clutch, stall, bypass, and pulse-type power tools. Tools of thiscapacity range are the only tools which should be tested without a joint simulator. Impactwrenches may not be tested on Torq-Tronics®.

This procedure assumes the tester has been installed per the instructions in Chapter 2.

Gathering Joint InformationThis section addresses obtaining the information necessary to select the correct filter for usein testing the power tool on your Torq-Tronics®. Use the tool to be tested to tighten theactual joint the tool will be used on. Insure the tool is used just as it will be once the test isfinished. Use a direct reading torque wrench to check the installation torque.* Mark the fastener location. The photographs which follow demonstrate one technique

for acquiring the joint information. In the first photograph in this demonstrationsequence, a 3" x 5" card has been cut to fit over the fastener, and a socket placed overthe fastener.

* Use a pen, marker, or other device to make a line on the fas-tener or socket and the surface against which it is tightened.In this first photograph , the mark for the starting point hasbeen made on the socket and card.

* Attach the torque wrench to the socket orbit In the second photograph, the torquewrench (dial) has been attached to thesocket without moving it. The torquemeasurement is ready to be made.

* Slowly and carefully apply steadily increasing force to the torque wrench until the fas-tener starts to move. It is important the torque applied be just enough to barely movethe fastener. If the fastener is rotated more than just a few degrees, the torque measure-ment will be higher than the applied torque by a significant percentage.

The third photograph depicts this portion ofthe process. The fourth photograph is acloseup of the socket and cardboard. In thisphotograph, the line on the socket has movedjust enough that it is no longer aligned withthe line on the cardboard. This is the point atwhich torque application stops and the torquereading is taken.

The importance of stopping the torque application at thispoint is difficult to over-emphasize. Stop torque applica-tion immediately when the two lines are no longer incomplete alignment with each other.

* Record the obtained torque.This number will be the oneused in selecting the correctfilter. You may wish torepeat the above steps sever-al times to assure you do nothave a "flier" as your datapoint.

Preparing the Torq-Tronics® for Testing1) Use the power switch to turn on the tester.2) Allow the tester to boot up. 3) After the capacity and software messages have been displayed and cleared, the tester

will display it's operating status on the LCD. This will consist of:a) A plus (+) or minus (-) sign in front ofb) a torque value at or near zero, followed byc) the units of measure currently in use.d) There will then be one or two blanks, followed bye) "TK" to indicate the tester is in Track mode.4) If the displayed torque value is not zero, press the Zero key to return the tester to zero

value. Press the Peak Select key once to enter Peak mode. The tester will briefly dis-play the message "Filter 0", then will return to the normal display with "PK" on the farright. If the units of measure you wish to use are those displayed, go to next step.

5) If the units of measure displayed are not those desired, press the Units key to pagethrough the selections until the units desired are displayed.

6) If you want the test results cleared from the LCD after a few seconds, Press the Autokey once. Activating the Auto function will also send the data to the computer or print-er if you are using one. If you wish to hold the test results until you clear them, simplydo not press the Auto key.

Test the Tool1) Engage the hex drive with the power tool. Make certain the tool is held in-line with the

hex drive throughout the test.2) Trigger the tool until it clutches or stalls, then release the trigger. Since tools in this size

range do not use a joint simulator, the clutch slip or stall will occur very quickly. Thetrigger should be released immediately after this occurs. Disengage the tool from thetransducer.

3) Read the torque result on the LCD. The torque result will be displayed moments afterthe trigger is released.

4) Evaluate the test result If the test result closely mirrors the torque wrench result, the "0"filter is the correct one for this tool, and can be used for testing this tool from now on.If the test result does not closely mirror the torque wrench result, the correct filter mustbe found. a) Press the Peak Select once to page from filter "0" to filter "1". b) Repeat the first four steps of "Test the tool" above. c) Evaluate the test results for filter "1".d) Repeat test/evaluate cycle until the correct filter has been determined.e) If none of the four filters provides a result matching that of the torque wrench, there

is likely an error in the joint data. Return to this step and gather data for comparisonto measurements taken from each filter.

5) Once correct filter has been determined, record the filter number for future use with thistool.

Chapter 8 - Testing Non-Shutoff Pulse Tools

Testing non-shutoff pulse tools requires use of the filters on the Torq-Tronics® testers, butmay or may not require use of the joint simulator. Some pulse tools may be tested byengaging the drive of the Torq-Tronics® transducer directly. The only means of determin-ing whether or not any specific tool requires use of the joint simulator is experimentation.

The procedure for determining whether or not a joint simulator should be used with anyspecific tool is straightforward. Test the tool the first time without a joint simulator, andevaluate the results. If the results match the results obtained on the joint on which the spe-cific pulse tool is used (whether determined from prior joint audits or application of JointInformation Procedure in Chapter 7), then use of the joint simulator is not necessary. If theresults do not match, then use of a joint simulator is recommended.

Test Procedure - No Joint SimulatorThis procedure assumes the Torq-Tronics® tester has been properly mounted in accordancewith the procedures given in Chapter 2.

1) Use the power switch to turn on the tester.

2) Allow the tester to boot up.

3) After the capacity and software messages have been displayed and cleared, the testerwill display it's operating status on the LCD. This will consist of:a) A plus (+) or minus (-) sign in front ofb) a torque value at or near zero, followed byc) the units of measure currently in use.d) There will then be one or two blanks, followed bye) "TK" to indicate the tester is in Track mode.

4) If the displayed torque value is not zero, press the Zero key to return the tester to zerovalue. Press the Peak Select key once to enter Peak mode. The tester will brieflydisplay the message "Filter 0", then will return to the normal display with "PK" onthe far right. If the units of measure you wish to use are those displayed, go to nextstep.

5) If the units of measure displayed are not those desired, press the Units key to pagethrough the selections until the units desired are displayed.

6) If you want the test results cleared from the LCD after a few seconds, Press the Autokey once. Activating the Auto function will also send the data to the computer or print-er if you are using one. If you wish to hold the test results until you clear them, simply do not press the Auto key.

Test the Tool1) Engage the hex drive with the power tool. Make certain the tool is held in-line with the

hex drive throughout the test.

2) Trigger the tool until it clutches or stalls, then release the trigger. Since tools in this size range do not use a joint simulator, the clutch slip or stall will occur very quickly.The trigger should be released immediately after this occurs. Disengage the tool from the transducer.

3) Read the torque result on the LCD. The torque result will be displayed moments after the trigger is released.

4) Evaluate the test result. If the test result closely mirrors the torque wrench result, the "0" filter is the correct one for this tool, and can be used for testing this tool from now on. If the test result does not closely mirror the torque wrench result, the correct filter must be found. a) Press the Peak Select once to page from filter "0" to filter "1". b) Repeat the first four steps of "Test the tool" above. c) Evaluate the test results for filter "1". d) Repeat test/evaluate cycle until the correct filter has been determined.e) If none of the four filters provides a result matching that of the torque wrench, there

is likely an error in the joint data. Return to this step and gather data for comparisonto measurements taken from each filter.

5) Once correct filter has been determined, record the filter number for future use with this tool.

Chapter 9 - Testing Power Tools Over 10 Inch-PoundCapacity

This chapter covers testing power tools of over 10 inch-pound capacity. Tools in this rangerequire the use of a joint simulator as well as the filters on the Torq-Tronics®. This proce-dure assumes the tester has been installed per the instructions in Chapter 2 of this manual.The procedure given below assumes exact measurement of the individual joint/tool combi-nation is desired. This procedure may be modified as needed for a correlative approach.

Procedure1) Measure Joint

a) Use the "Rotation Measurement Procedure" given in Chapter 7 to obtain informa-tion on the actual rotation required to tighten the fastener on the joint.

b) Determine the actual torque output of the tool on the joint using the "Gathering JointInformation" procedure in Chapter 7 of this manual to determine the actualtorque output of the tool. This data will be that used for comparison of test resultswith applied results.

2) Use the instructions in Chapter 5 to configure the joint simulator to approximate theamount of rotation required to tighten the fastener from 10% of the installation torque to 100% of the installation torque.

3) Use the instructions in Chapter 5 to install the joint simulator on the Torq-Tronics®tester.

4) Start the Torq-Tronics® tester.a) Use the Power Switch to turn on the tester, and allow it to boot up.b) Use the Units key to select the units of measure to be used.

5) Use the Mode key to select the Peak mode (PK). The tester will automatically selectFilter 0.

6) Press the Zero key to assure the tester is zeroed prior to the test.

7) Test the tool.a) Test power tool; tighten the socket head cap screw of the joint simulator.b) Record the torque displayed on the LCD of the tester.c) Loosen the socket head cap screw back to its' original position.d) Press the Clear/Print key to clear the display.e) Repeat the above four steps two more times.

8) Compare the results to the actual applied torque obtained from the joint.a) If the results agree with the actual output of the tool on the joint, record the

information on the joint simulator washer configuration and filter used for this testfor future use with this tool. Testing complete.

b) If the results do not agree with the actual output of the tool on the joint, and all fil-ters have not yet been tried, another filter may be better to use with this combinationof tool and joint. Go to step 9.

c) If the results do not agree with the actual output of the tool on the joint, and all fivefilters have been tried, then an adjustment to the joint simulator will be needed.i) Use the Power Switch to turn off the tester.ii) Remove the joint simulator from the tester.iii) Use the instructions found in Chapter 4 to make the joint simulator emu

late a slightly harder or softer joint.iv) Return to Step 3 of this procedure.

9) If the test results do not match the tool output, and all four filters have not yet been tried, it may be that the joint simulator is correct but a different filter may be needed.a) Press the Filter button on the Torq-Tronics® tester to change to the next filter.b) Repeat steps 6, 7, and 8 of this procedure.

Measure Joint- Fastener Rotation- Installation Torque

Configure Simulator- Same rotation as

joint.

Install Simulator

Start Torq-Tronics- Power

- Mode- Units

Test Tool- 3 rundowns

Compare Results- Actual Joint Torque

DoResults

Compare?

AllFiltersTested

?

Modify Simulator

Remove Simulator

- FilterChange Filter

Record- Simulator- Filter

FLOWCHART 1

YesNo

No

Yes

Chapter 10 - Calibration

The calibration procedure for each model differs primarily in the arm and weight combina-tion required to reach the calibration points for the model's torque capacity. Each procedurerequires the use of:

* A computer equipped with a serial port and terminal software.* A serial cable.* Calibration weights, drive squares, arms, and platforms for the model to be tested.* Refer to the "Calibration Table - Torq-Tronics® Models" at the end of this chapter.

Calibration Procedure1) Turn on the Torq-Tronics® unit. Allow it to warm up for one (1) hour in Track mode.

2) Connect Torq-Tronics® unit to computer via serial cable.

3) Start terminal software.

4) For a summary of the calibration commands, type :CM into the terminal software, thenpress the "Enter" key.

5) Press the ZERO key on the Torq-Tronics® unit, then type :CM2 into the terminal soft-ware and press the Enter key. Observe acknowledgement of calibration zero.

6) Obtain the proper calibration arm. The correct arm can be found in the "CalibrationTable -Torq-Tronics® Models" at the end of this chapter.

7) Make certain the calibration arm is properly counterbalanced.

8) Attach the drive square of the calibration arm to the drive of the tester in the clockwisedirection, and press the Zero key.

9) Hang the weight platform (hook) and the full-scale weights (100%) (found in the"Calibration Table - Torq-Tronics® Models") on the calibration arm - gently, andimparting as little motion to the weights as possible. Wait until the weights have com-pletely stopped moving, then remove the full-scale load.

10) Wait one minute, then press the ZERO key on the tester.

11) Repeat steps 9 and 10 two more times, then proceed to step 12.

12) Hang the 1st calibration point (10%) weights, as found in the "Calibration Table -Torq-Tronics® Models", on the arm, gently. Wait for the arm to completely stop mov-ing, then enter :CM1 into the terminal software and press the Enter key. Observeacknowledgement of the 10% clockwise calibration point.

13) Again hang the weight platform (hook) and the full-scale weights (100%) (found in the"Calibration Table - Torq-Tronics® Models") on the calibration arm - gently, andimparting as little motion to the weights as possible. Wait for the arm to completelystop moving, then enter :CM0 into the terminal software and press the Enter key.Observe acknowledgement of the 100% clockwise calibration point.

14) Remove weights and reverse calibration arm to the counter-clockwise direction, andpress the Zero key.

15) Hang weight platform and full-scale (100% load as found in the "Calibration Table -Torq-Tronics® Models") load on the arm, gently. Wait until the arm has completelystopped moving, then remove the weights and platform.

16) Wait one minute, then press the ZERO button on the tester.

17) Repeat steps 14, 15, and 16 two more times, then proceed to step 18.

18) Hang weight platform and 10% weights on the calibration arm, gently. Wait until thearm has completely stopped moving.

19) Type :CM3 into the terminal program and press the Enter key. Observe acknowledge-ment of calibration 10% counter-clockwise.


21) Type :CM4 into the terminal program and press the Enter key. Observe acknowledge-ment of calibration 100% counter-clockwise.

22) To save calibration, type :CM5 into the terminal program and press the Enter key.Observe acknowledgement of calibration save.

Calibration Verification Procedure1) Disconnect the RS-232 serial cable from the tester.

2) Reverse calibration arm from counter-clockwise direction to clockwise direction, andpress the Zero key.

3) Hang weight platform and full-scale (100% load as found in the "Calibration Table -Torq-Tronics® Models") load on the arm, gently. Wait until the arm has completelystopped moving, then remove the weights and platform.

4) Wait one minute, then press the ZERO button on the tester.


6) The torque displayed on the LCD's should be within the accuracy tolerance for the 10%calibration point for the unit.

7) Repeat steps 5 and 6 with the 20%, 50%, 80%, and 100% loads as specified in the"Calibration Table - Torq-Tronics® Models" at the end of this chapter.

8) Remove and reverse calibration arm to the counter-clockwise direction, and press theZero key.

9) Repeat steps 3, 4 and 5 in the counter-clockwise direction.

RANGE

CA

LIB

RA

TIO

N C

HA

RT

- T

orq-

Tron

ics

Mod

els

MODEL

CALIB.

CAL ARM

TYPE &

LENGTH

IN.LB.

IN.LBS.

IN.LBS.

IN.LBS.

IN.LBS.

IN.LBS.

IN.LBS.

1 2 5 8 10

4"10I

50I

300I

100I

IN.LBS.

IN.LBS.

IN.LBS.

40 50

&

1 - 10

5 - 50

10 - 100

30 - 300

[CW & CCW]

POINTS

INCH-

POUNDS

INCH-

POUNDS

INCH-

POUNDS

INCH-

POUNDS

20 80 100

IN.LBS.

IN.LBS.

IN.LBS.

IN.LBS.

IN.LBS.

120

240

300

IN.LBS.

IN.LBS.

IN.LBS.

IN.LBS.

IN.LBS.

10"

10"

10"

5 10 25 10 50 30

150

HOOK

TYPE &

WGT.

4 OZ

SIZE & NUMBER OF WEIGHTS

ALL WEIGHTS ARE SLOTTED ROUND

OUNCES

POUNDS

.81

24

81

25

1020

50

1

1

11

1

12

8 OZ

1

1

11

1

12

1 LB

1

2 1 2

1 1

1 LB

1

1

21

11

2

21

2

TOTAL

WEIGHT

[LBS]

% OF

CAPA-

CITY 10 20 50 80 100

10 20 50 80 100

10 20 50 80 100

10 20 50 80

100

.25

1.25

2.00.50

2.50

.50

1.00

2.50

4.00

5.00

1.00

2.00

5.00

8.00

10.00

3.00

6.00

24.00

30.00

15.00

WEIGHTS

REQUIRED

8 OZ / 0.50 LB - 1 each

16 OZ / 1 LB - 2 each

8 OZ / 0.50 LB - 1 each

1 LB - 1 each

2 LB - 2 each

1 LB - 1 each

2 LB - 2 each

5 LB - 1 each

1 LB - 1 each

2 LB - 2 each

5 LB - 1 each

10 LB - 2 each

Pag

e 1

of 2

(SIZE & QTY.)

4 OZ / 0.25 LB - 1 each

RA

NG

E

CA

LIB

RAT

ION

CH

AR

T -

Tor

q-Tr

onic

s M

odel

s

MO

DE

LC

ALI

B.

CA

L A

RM

TY

PE

&LE

NG

TH

&

[CW

& C

CW

]

PO

INT

SH

OO

KT

YP

E&

WG

T.

SIZ

E &

NO

. OF

WE

IGH

TS

ALL

WE

IGH

TS

AR

E S

LOT

TE

D R

OU

ND

OU

NC

ES

PO

UN

DS

12

48

12

510

2050

TO

TAL

WG

T.[L

BS

]

% O

FC

APA

-C

ITY

10 20 50 80 100

WE

IGH

TS

RE

QU

IRE

D

Pag

e 2

of 2

(SIZ

E &

QT

Y.)

80 80

FT.

-LB

S.

150

150

FT.

-LB

S.

250

250

FT.

-LB

S.

600

600

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

FT.

-LB

S.

60 120

300

480

60025 50 125

200

250

15 30 75 150

1208 16 40 64 80

10"

48"

5 LB

11

2

11

1 1

1

11

11 1

2

2 2

5 LB

7.5

lb1

11 1 1 1 1

1 1 1 1

1

1

1 1

1 2 22

1 O

Z /

.062

5 LB

- 1

eac

h2

OZ

/ .1

25 L

B -

1 e

ach

4 O

Z /

.25

LB -

1 e

ach

8 O

Z /

.5 L

B -

1 e

ach

1 LB

- 1

ea.

2 LB

- 2

ea.

10 L

B -

1 e

a.20

LB

- 2

ea.

50 L

B -

1 e

a.

8 O

Z /

.50

LB -

1 e

ach

5 LB

- 1

eac

h10

LB

- 1

eac

h20

LB

- 2

eac

h

50 L

B -

2 e

ach

48"

48"

1 LB

11

1

11

11

1

1 11

1

11

11

1

11

11

1

11

11

1 11

11

2 2

2

7.50

18.7

5

30.0

0

37.5

0

6.25

12.5

0

31.2

5

50.0

0

62.5

0

15.0

0

30.0

0

75.0

0

120.

00

150.

00

9.60

19.2

0

48.0

0

96.0

0

.25

LB -

1 e

a..5

0 LB

- 1

ea.

1 LB

- 1

ea.

2 LB

- 2

ea.

5 LB

- 1

ea.

10 L

B -

1 e

a.20

LB

- 1

ea.

.25

LB -

1 e

a..5

0 LB

- 1

ea.

1 LB

- 1

ea.

2 LB

- 1

ea.

5 LB

- 1

ea.

10 L

B -

1 e

a.20

LB

- 2

ea.

.8

2 4 1

.8 O

Z /

.05

LB -

4 e

ach

3.75

76.8

0

1

2 LB

- 1

eac

h

10 20 50 80 100

10 20 50 80 100

10 20 50 80 100

Chapter 11 - Frequently Asked Questions

Can Torq-Tronics® be used to test dial or beam-type torque wrenches?No. There is a critical 4:1 ratio that must be maintained or exceeded when testing torquewrenches and torque screwdrivers. The tester must be at least four times as accurate as thetorque wrench or torque screwdriver to be tested on it. Since Torq-Tronics® has an accura-cy of ± 1% Indicated Value, it should only be used to test tools of ± 4% I.V. accuracy orless.

If you have (or acquire) dial or beam-type torque wrenches, look at the S/R System 4/5Digital Torque Testers. They provide excellent platforms for testing all types of torquetools.

What is Torque Tool Manager?Torque Tool Manager is software designed by Sturtevant Richmont to enable owners of ourvarious digital torque testers to immediately and economically create a torque calibrationsystem meeting all ISO and QS-9000 requirements. This software runs on any PC runningWindows 3.1 or later, and with the addition of a serial cable:

* Create a database containing the make, model, serial number, test procedure, and cali-bration interval for each torque tool the user owns.

* Store the N.I.S.T. traceability numbers for the tester and each transducer used with thetester.

* Immediately access the record for each tool, start a new calibration, feed the data direct-ly from the tester to the software, record the name of the Inspector, and date of calibra-tion, then generate and ISO and QS-acceptable certification with one click of the mousebutton.

* Save the record of calibration electronically for proof of performance.

Those owners who seek to attain compliance with ISO or QS 9000 requirements in theircalibration of torque tools find this software quite worthwhile. It is fully Y2K compliant,and can be obtained through your local S/R distributor.

Is the backlight on the Torq-Tronics® display adjustable?There is no adjustment for brightness or contrast on the display. The display operates withno backlight when the unit is used without AC power supplied. The purpose of this is toconserve battery power for maximum utility when used as a portable tester. The backlightis accessible, at only one brightness level, when AC power is used.

Why do joint simulators 80 ft.-lbs. capacity and higher have springsinstead of washers?When the joint simulator is used with power tools, the washers wind up rotating around thebolt as well as being compressed by it. This generates a considerable amount of heat. Inthe washer sizes necessary for use in larger joint simulators, the heat generated by this fric-tion during rundown is so high that in one or two rundowns the simulator is too hot for safeuse. To avoid this risk of injury, springs are used in the larger joint simulators.

I've tried many washer stackups and all the filters in every different combination and I stillcan't get a perfect match between the torque reading on the Torq-Tronics® and the resultsof joint audits. Why and what do I do?

The many washers in the joint simulator are designed to permit great flexibility in jointemulation. Combined with the five filter rates, incredible flexibility in tool/joint emulationis possible. But the combination is finite - and the variety of joint/tool combinations to beemulated is almost infinite. It is possible that the joint you are trying to emulate has a jointrate between two of those attainable with the tester and simulator. Under these rare circum-stances, two courses of action present possible solutions. The first is to use the simulatorand filter combination that gave results closest to the results of the joint audits. This is typi-cally quite close - about 1%. The second possibility is not to use the joint simulator, anduse a correlative approach as described in the overview of power tool testing.

How often should Torq-Tronics® be calibrated?At least annually, more often if subjected to heavy use. Immediately if damaged or over-torqued.

Specifications

The specifications contained herein are applicable solely to the models listed on the frontcover and having Version 1.1 software. Software version is displayed on unit startup.

Specifications subject to change without notice.

GeneralCharacteristic SpecificationAccuracy +/- 1% Indicated ValueAccuracy Range 10% - 100% CapacityAccuracy Direction Bi-Directional, Clockwise and Counter-ClockwiseModes Track, Peak, Initial PeakDisplay 3/8" High, Backlit, 16-Character LCDControls Six (6) button keypad: Zero, Clear/Print, Auto, Units, Peak Select,FilterFilter Five (5) user-selectable cutoff frequencies in Peak mode.Communication RS-232C Serial Port, 9-Pin. Baud Rate 4800, Stop Bits 1, Parity

NoneVoltage 120 VACCharger Trickle charger, standard.Batteries Four (4) each NiCd, 1000mA (max.) 1.5 VDCBattery Life Five (5) hoursFull Charge Time Twenty (20) hours with supplied trickle charger.

Range and Drive SizesModel Range Drive Size

Model 10I 1-10 in.-lbs./1.13-11.3 dNm 1/4" Male HexModel 50I 5-50 in.-lbs./5.65-56.5 dNm 1/4" Male HexModel 100I 10-100 in.-lbs./1.13-11.3 Nm 3/8" Male HexModel 300I 30-300 in.-lbs./3.39-33.9 Nm 3/8" Male HexModel 80 8-80 ft.-lbs./10.8-108 Nm 1/2" Female Square*Model 150 15-150 ft.-lbs./20.3-203 Nm 1/2" Female Square*Model 250 25-250 ft.-lbs./33.9/338.9 Nm 3/4" Female Square**Model 600 60-600 ft.-lbs./81.3-813 Nm 3/4" Female Square**

* 3/8" Square Adapter Included **1/2" Female Square Adapter Included

Units of MeasureModel Units of Measure

Model 10I In-Oz, In-lb, cNm, dNm, NmModel 50I In-Oz, In-lb, dNm, NmModel 100I In-lb, Ft-lb, dNm, NmModel 300I In-lb, Ft-lb, NmModel 80 In-lb, Ft-lb, NmModel 150 In-lb, Ft-lb, NmModel 250 In-lb, Ft-lb, NmModel 600 In-lb, Ft-lb, Nm

Options/AccessoriesPart No. Model Description10151 JS50I Joint Simulator, 50 in.-lb. capacity10152 JS300I Joint Simulator, 300 in.-lb. capacity10199 JS80/150 Joint Simulator, 150 ft.-lb. capacity10225 JS150/250 Joint Simulator, 250 ft.-lb. capacity870776 Adapter 1/4"F Adapter, 1/4"F square to 3/8"M square870777 Adapter 3/8"F Adapter, 3/8"F square to 1/2"M square870778 Adapter 1/2"F Adapter, 1/2"F square to 3/4"M square21101 Batt AA Batteries, NiCD, "AA" size, 1000mA10171 TTM Torque Tool Manager software

Note: Quick battery chargers for the batteries used in Torq-Tronics® are available throughRadio Shack.

Torq-Tronics - TestMart® Digital Torque Testersare designed and constructed to provide the user ......

Documents

Transcript of Torq-Tronics - TestMart® Digital Torque Testersare designed and constructed to provide the user ......