TABLE OF CONTENTS Safety Information I Introduction 1-1 Functional Description and Specifications Functional Descriptions SURETEST Torque Calibration System Roll cabinet Front Panel Rear Panel (Input/Output) Torque Transducers Specifications SURETEST Torque Calibration System Manual loader specifications 2-1 2-1 2-1 2-2 2-3 2-9 2-11 2-12 2-12 2-14 Setup and Programming SURETEST Torque Calibration System Setup Setting Up the Suretest System Suretest Controls Powering the Equipment 4-in-1 Transducer Sel
Suretest Indicator Torque Calibration Gravitational Effects Correction Factors on Test Weights Gravitational Charts 5-11 5-14 5-14 5-14 2000-600-02 Manual Loader Application Torque Tester/Calibrator 2000-600-02 Manual Loader Loader Rear Panel Controls Ball Handle Adaptor 4-in-1 Transducer (Accessory) Extension Arm (Accessory) Types of Loader Testing Torque Driver Testing Torque Multiplier Testing 6-1 6-1 6-2 6-3 6-5 6-6 6-7 6-8 6-9 6-9 6-9 Accessories SURETEST System Components and Inventory Control Opt
Using this Manual This manual contains instructions for use and setup of the Suretest Torque Calibration System. A table of contents and a table of illustrations are provided to make this manual easy to use. Some of the information shown in text or illustrations is obtained using optional equipment. Conventions This section contains a list of conventions used in text. Chapter References Additional information in text is referenced by chapter number and section name.
DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury to the operator or to bystanders. WARNING Indicates a potential hazard which, if not avoided, could result in death or serious injury to the operator or to bystanders. CAUTION Indicates a potential hazard which, if not avoided, may result in minor or moderate injury to the operator or to bystanders.
Safety Information Important Safety Instructions This manual contains important safety and operating instructions for CDI SURETEST Torque calibration system. Refer to the information in this manual often for safe operation. Read All Instructions Read, understand and follow all safety messages and instructions in this manual and on the test equipment. Safety messages in this section of the manual contain a signal word, a three-part message.
WARNING Risk of entanglement. • When starting power tools, check for obstacles near your hand and anticipate the reaction force by gripping the tool firmly. • Do not wear loose clothing and jewelry while operating a power tool. Loose clothes and jewelry can be caught in moving parts. • Keep body parts away from rotating parts. • Wear a protective hair covering to contain long hair and prevent contact with moving parts. • Do not overreach. Keep proper footing and balance at all times.
PRODUCT DESCRIPTION CDI-SURETEST MODEL 5000-ST The SURETEST is a laboratory grade instrument that provides TORQUE measurements. Although designed as an independent laboratory equipment, it can also be used in an integrated environment as the principal component of a Torque Calibration System. The SURETEST features versatile data acquisition capabilities including measurement storage, retrieval, statistical analysis and automatic downloading to an external printer/computer.
CHAPTER 1 Introduction The SURETEST is a laboratory grade instrument that provides TORQUE measurements. Although designed as an independent digital indicator, it can also be used in an integrated environment as the principal component of a Torque Calibration System. The SURETEST features versatile data acquisition capabilities including measurement storage, retrieval, statistical analysis and automatic downloading to an external printer/computer. A remote computer COM port is available for PC interfacing.
FUNCTIONAL DESCRIPTIONS AND SPECIFICATIONS CHAPTER 2 The SURETEST operates directly from any AC power line between 120VAC to 220 VAC, 50–60 Hz without the need for switch selection. A hard-wired lithium battery keeps the internal memory and date-time clock operating for up to 10 years. The real time clock is fully year 2000 compliant. The information in this manual is general. Operational features, procedures and specifications may change without notice.
FUNCTIONAL DESCRIPTIONS AND SPECIFICATIONS CHAPTER 2 CHAPTER 2 Functional Descriptions and Specifications The SURETEST is CDI’s next generation Torque Measurement System. It provides exceptional accuracy and ease of use. It is packaged in a compact, sturdy and attractive housing unit which requires little room on a laboratory bench. The SURETEST is typically used in conjunction with a Transducer and a Mechanical Loader. Fig 2-1 Base Unit The SURETEST monitors and displays the torque applied.
FUNCTIONAL DESCRIPTIONS AND SPECIFICATIONS CHAPTER 2 The loader accepts all SURETEST series single transducers directly. Use a 2000-500-02 adapter kit to mount the optional 2000-400-02 4-in-1 transducer. For additional information refer to Appendix A–Accessories. Loader Use the 2000-600-02 Manual Loader for testing and calibrating all torque wrenches, drivers, torque multipliers, non-impact pneumatic and electric nut runners.
FUNCTIONAL DESCRIPTIONS AND SPECIFICATIONS CHAPTER 2 FRONT PANEL Figure 2-3: SURETEST Front Panel A- Membrane Function ( F1, F2, F3, F4, F5, F6 ), And Cursor/Selection (Up, Down, Left, Right and Enter ) Keys. B- Soft Key Menu: Zero, # Data Stored, Setup, Send, Store, Clear, Escape, Format. C- Real Time Clock. HH:MM:SS D- Modes: Track, Peak Hold, First Peak and Power tools. E- Maximum Range of Transducer. F- Engineering Units : Nm, dNm, Ncm, mkg, cmkg, ft.lb, in.lb, in.
FUNCTIONAL DESCRIPTIONS AND SPECIFICATIONS CHAPTER 2 SURETEST DISPLAY A 240 x 64 Full-featured Graphic LCD is used to provide versatile and clear displays of system menus as well as measurements. Characters and symbols are displayed in different fonts: • Maximum transducer range in the selected UNITS of measure. • Statistical mean of all measurements in memory. • The number of the present data memory location.
FUNCTIONAL DESCRIPTIONS AND SPECIFICATIONS CHAPTER 2 The SURETEST always returns to the default menu from the measurements mode in the event there is no selection / input by the User. This serves as a reminder for more (input) measurements. Setup Mode The following Selections are available: 1. SELECT MODE 2. SELECT UNIT 3. SELECT LANGUAGE 4. MANUFACTURER’S DEFAULTS 5. AUTO SETTINGS 6. EDIT LIMITS 7. CLOCK ADJUST 8. CALIBRATION 9. EDIT PARAMETERS 10. CDI INTERNAL 11. ABOUT 1.
FUNCTIONAL DESCRIPTIONS AND SPECIFICATIONS 3. CHAPTER 2 Select Language Selects either English, German (Deutsch), French (Francais), Spanish (Espanol), or Portuguese (Portugues). 4. Manufacturer’s Defaults: A warning message is first displayed. Upon confirmation by the User, the Default Settings will be loaded into the SURETEST. 5. Auto Settings Sets up CLEAR, STORE, and SEND functions. There are 2 options: Automatic or Manual.
FUNCTIONAL DESCRIPTIONS AND SPECIFICATIONS 6. CHAPTER 2 Edit Limits Sets up high torque limit preset. (->) to go Down 1 line. Sets up low torque limit preset. (<-) to go Up 1 line. Use Up or Down cursor key to increment or decrement the respective value. Use Left or Right cursor key to select digit. Press ‘Save’ to activate the change. Press ‘Clear” to Clear All Limit set-up. Press ‘Escape’ to Exit. Last setup is retained. 7. Clock Adjust Edits DATE/TIME programming function.
FUNCTIONAL DESCRIPTIONS AND SPECIFICATIONS CHAPTER 2 9. EDIT PARAMETERS Sets up serial protocol function. Sets delay (in ms) per character upon printing. Sets delay (in ms ) per Linefeed. Minimum block-out with zero at 0.1% F.S. in Tracking Mode. Minimum block-out with zero at 1.0% F.S. in Peak-Hold Mode. 10. CDI INTERNAL For Manufacturer’s use only. 11. About This provides relevant information regarding the CDI company, the software version, and the serial number of the SURETEST device. 12.
FUNCTIONAL DESCRIPTIONS AND SPECIFICATIONS CHAPTER 2 Rear Panel (Input/Output) Figure 2-5: SURETEST Rear Panel A- SOLENOID CONTROL (Hirose RM15TRD-12S) PIN 10 11 12 B FUNCTION Loader Relay Common Loader Relay CCW Limit Loader Relay CW Limit ANALOG OUTPUT (BNC) Analog output provides a voltage level output that is directly proportional to transducer input, from -1.8V (full scale counter clockwise) to +1.8V (full scale clockwise). Zero offset +/-100 mV. Linearity +/-1% of reading. Maximum load = 5 mA.
FUNCTIONAL DESCRIPTIONS AND SPECIFICATIONS F- PRINTER PORT (DB-9P) PIN 2 3 5 G- OPTIONAL (DB-9P) PIN 2 3 5 H- FUNCTION Receive Transmit Ground FUNCTION Receive Transmit Ground TRANSDUCER INPUT (DB-37S) PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 FUNCTION not used ground smart chip - bit 2 smart chip - bit 0 single xducer (-) signal single xducer (+) signal ground 4-in-1 xducer (-) signal 2 4-in-1 xducer (+) signal 2 ground 4-in-1 xducer (
FUNCTIONAL DESCRIPTIONS AND SPECIFICATIONS CHAPTER 2 SURETEST Transducers SURETEST transducers provide industry standard square drives. They feature a full bridge strain-gauge @ 350 Ohms nominal. Full range output is 1500 uE, 9mV (3mV/V @ 3.0V excitation). Torque transducers use a built-in EEPROM memory chip that stores range identification and calibration factors. Calibration of transducers is accomplished using precision torque bars and certified weights.
FUNCTIONAL DESCRIPTIONS AND SPECIFICATIONS CHAPTER 2 Specifications SURETEST Torque Calibration System System Accuracy ±0.25% of reading @ 25°C (Suretest and transducer calibrated together) SURETEST Transducers used with, but not calibrated to, another SURETEST provide a system accuracy of ±0.5% of reading @ 25°C. Temperature Drift +0.03%/°C (+0.017%/°F) Display Accuracy ±0.
FUNCTIONAL DESCRIPTIONS AND SPECIFICATIONS CHAPTER 2 Printer Serial Output Port Default: 9600 Baud Rate. Serial Communications RS-232 (true) 300—19.2K Baud 8 data bits 1 stop bit no parity Computer Serial COM Port (OPTIONAL) Default: 19,200 Baud Rate. RS-232 (True) Analog Output +(CW)/-(CCW) 1.8V at transducer full range linearity ±1% of reading Loader Control Relays Two, normally open, Form A, rated 12VDC @ 1/2A close contact at 110% CW or CCW of torque transducer range.
SETUP AND PROGRAMMING CHAPTER 3 Manual Loader Specifications Input Torque (Hand Crank) 8 ft lb maximum (without Motorized control). Output Torque 2000 ft-lb ±20 degrees rotation maximum Power Requirements (safety solenoids) switching From 100 to 230VAC ±10%, @ 50-60 Hz. Weight (including 2000-100-02 Roll Cab) 1500 lbs. Optional Calibration Fixturing (Load bars and Weights) ±0.05% accuracy.
SETUP AND PROGRAMMING CHAPTER 3 CHAPTER 3 SETUP AND PROGRAMMING SURETEST MANUAL LOADER 2000-600-02 TORQUE CALIBRATION SYSTEM SETUP G A MANUAL MECHANICAL LOADER REAR PANEL CONTROLS ANALOG OUTPUT H FOOT PEDAL SWITCH 950-87 I SOLENOID CONTROL CABLE 2000-117 SURETEST 9502-610-02 B C SO L E NO I D CO NT R OL AN A LOG OU TP UT POWER CABLES 110V/220 VAC PART NUMBER : 2000-114 ( U.S.A. ) 950-97 ( EUROPE ) 950-96 ( AUSTRALIA ) 950-95 ( U.K.
SETUP AND PROGRAMMING CHAPTER 3 Back panel connections A Manual Loader B Solenoid control cable C Suretest D Smart 4-in-1 transducer E Transducer cable F Smart single transducer G Analog Output H Foot cable switch I Power cables (110/220 VAC) J Printer cable K Personal computer cable Note: Cable (K) can be connected to Printer Port too. Setting Up the SURETEST Torque Calibration System 1. Position the roll cabinet on a level floor and lock the wheels. 2.
SETUP AND PROGRAMMING SURETEST CHAPTER 3 Base Unit Controls Refer to the illustration below when performing the power-up and programming procedures. Figure 3-2: SURETEST Controls – SURETEST Graphic LCD Display – Power Switch – Front Panel Membrane Function Keys Powering the Equipment To power the equipment, press the power button on the front of the SURETEST. • At POWER ON, the SURETEST performs self-test and momentarily displays the results on the display.
SETUP AND PROGRAMMING CHAPTER 3 4-in-1 Transducer Installation When a 4-in-1 transducer is installed, the following is displayed: All four transducers are scanned as indicated by their associated red LED indicators. To select one of the transducers, apply at least 5% of its full range torque. To return to the scan mode, press ENTER. Single Transducer Installation: When a single transducer is installed, the following is displayed: The user can enter Setup mode then proceed to make Torque measurements.
SETUP AND PROGRAMMING CHAPTER 3 Programming Setup Setting up Date and Time 1. Press (Setup). 2. Scroll down to select Clock Adjust. Press ‘Enter’. The display reads: 3. Use Left or Right Cursor to select the date/time element to be changed. 4. Increment or decrement the date/time element by repeatedly pushing Up or Down Cursor. Push and hold Up or Down Cursor to change the display quickly. 5. Press ENTER to update date and time and to return to measurements mode.
SETUP AND PROGRAMMING CHAPTER 3 3. Press ‘Enter’. The display reads: 4. Press -> or <- to select Hi or Lo limit. 5. Use Left or Right Cursor to select a digit to be changed. 6. Increment or decrement the selected digit by pushing Up or Down Cursor. Push and hold Up or Down Cursor to change the display quickly. 7. Select and change the next digit using left and right DIGIT and up and down Cursor. Continue until all digits are set. 8. Press (Save) to save and to return to measurements mode.
SETUP AND PROGRAMMING CHAPTER 3 To use the AUTO CLEAR, STORE, or SEND: 1. 2. Press (Setup). Scroll down to select Auto settings. The display reads: 3. Press ‘Enter’. The display reads: 4. Use Right and Left Cursor to position the reverse-video (*) character under the function being changed. To program: CLEAR, press Up or Down Cursor to select "man" (manual clear), "auto" (automatic), or (delayed automatic) from "1Sec" to "9Sec" seconds.
TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4 Clear Single Memory Location Use the procedure in this section to clear the a single memory location. 1. 2. Press (Data) to enter data list display. The display reads: Use the Up or Down Cursor to move to the current data. The units and present memory location are given on the top line. The total number of memory locations is to the right -- separated by a forward slash (/).
TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4 CHAPTER 4 SURETEST TORQUE CALIBRATION SYSTEM SETUP This chapter contains information on how to test, measure, and use the SURETEST Torque Calibration System. Testing Torque Wrenches and Drivers To use the SURETEST Torque Calibration System for torque wrench testing, a transducer of the appropriate range is fitted to the 2000-600-02 Manual Loader.
TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4 Dial and Bending Beam Torque Wrenches and Screwdrivers Be sure the SURETEST transducer is capable of handling the intended torque to avoid damaging the transducer. WARNING Do not use this equipment with the power off. Always turn on the Base Unit so the torque values are indicated on the display. 1. To program the SURETEST Base Unit refer to Chapter 3 Set Up and Programming.
TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4 Adjustable or Preset “Click” Wrenches and Screwdrivers Be sure the SURETEST transducer is capable of handling the intended torque to avoid damaging the transducer. Always operate the system with the power on. WARNING Do not use this equipment with the power off. Always turn on the Base Unit so the torque values are indicated on the display. 1. To program the SURETEST Base Unit refer to Chapter 3–Set Up and Programming.
TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4 Testing Power Tools The dynamic torque characteristic of a power tool and the static torque applied when using a wrench usually result in different torque readings. Spinning electric and pneumatic motor armatures contain inertia that produces a higher torque reading than what is actually absorbed by a practical fastener.
TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4 Figure 4-1: Power Tool Test Setup A B C – – – Power Tool Joint Rate Simulator Transducer 7. Couple the power tool to the joint rate simulator using the appropriate accessory adaptors and bit. 8. While holding the power tool drive perfectly in-line with the transducer drive, energize the tool until its motor stalls or, if featured, the tool clutch slips. 9. Remove the power tool. Loosen the joint rate simulator load screw. 10.
TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4 13. While holding the power tool drive perfectly in-line with the transducer drive, reinstall the tool onto the simulator and energize the tool until its motor stalls or, if featured, the tool clutch slips. Be careful not to add torque by turning the tool by hand. 14. Release the torque and note the Power tool reading on the display. 15. CLEAR the display. 16. Repeat steps 4 through 15 in the opposite direction, if required.
TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4 Displaying Statistical Analysis The SURETEST Base Unit accumulates torque measurements in a data list. The list is created with each AUTO or MANUAL data store entry. Statistical analysis is calculated on the list, and if SET HIGH and SET LOW limits are established, draws a simple histogram of the results. These features are very useful in statistical process control (SPC) management.
TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4 Printing Statistical Analysis 1. Press Data , then Press Format. 2. Press SEND to display the Print out menu. Use Down key to select Send Statistics then press Enter to Print. 3. Press Escape to return to measurements mode. SPC PRINT-OUT _____________________ SPC listing _____________________ PART NO. _____________________ NAME _____________________ STATISTICAL ANALYSIS Time : 16/Nov/1998 14:23 ** LIMIT DATA ** Set High: 254.85 in-lb Set Low : 251.
TORQUE CALIBRATION SYSTEM SETUP ** R Data Max Min Range Mean Sig.n Sigma Cp Cpk E : : : : : : : : : CHAPTER 4 S U L T ** 0010 254.89 in-lb 251.49 in-lb 3.4039 in-lb 253.19 in-lb 0.9755 in-lb 1.0283 in-lb 0.5348 0.5317 %Err. : 20.000% -NoGo : 0001 +NoGo : 0001 H I S T O G R A M LSL :251.55 in-lb USL :254.85 in-lb DIV : 10 -NG0001:X LSL ---------------A 0000: B 0000: C 0002:XX D 0001:X E 0001:X F 0002:XX G 0000: H 0001:X I 0001:X J 0000: USL ---------------+NG0001:X Scale: X =01 A 251.55 in-lb< B 251.
TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4 Displaying or Downloading Data List Torque measurements stored in the data list also include a date and time stamp. For additional information on setting up printer or PC ports, refer to Chapter 3—Set Up and Programming in this manual. Displaying Data List 1. Press DATA. The display reads: 2. Torque Units of measure are displayed at top of the display with present memory location/total memory locations to the right.
CALIBRATION CHAPTER 5 How to Use Analog Output (Rear Panel BNC Connector) Analog Output on the SURETEST provides a real time voltage level that is directly proportional to the torque applied to the transducer. It is useful for direct driving equipment such as analog plotters and chart recorders, or interfacing to a computer/controller with analog to digital (A/D) data acquisition capability. Maximum output loading must be less than 5 mA. The output varies between approximately +1.
CALIBRATION CHAPTER 5 Annual calibration is recommended. Calibration by the user is recorded in memory and voids factory certification. Contact your authorized CDI sales representative for calibration and repair services. If extreme calibration precision is required, refer to Correction Factors on Test Weights in this chapter. Mounting Details Single Transducer Mounting Detail for Calibration Single transducer calibration requires the use of a reaction stand and transducer calibration block.
CALIBRATION CHAPTER 5 Torque Under 250 ft lb Mount the calibration block at the center of the stand with two 1/2-13 socket head cap screws with test bars that are 10" or shorter. Install these screws using the supplied torque wrench and 3/8-3/8 socket driver adapter. Use this configuration for up to 250 ft lb of applied torque. A 1/2" to 3/8" reducer is required when mounting the 10" arm to transducers having 3/8" drives.
CALIBRATION CHAPTER 5 WARNING Always position the 40" arm over the front of the stand as shown. Never extend the test arm behind the stand because the stand will tip over when weights are applied. The 40" test arm is coupled to the 2000-13-02, 1000 ft lb, and 2000-14-02, 2000 ft lb transducers using a 1-1/4" drive adapter plate. 1. Remove the internal drive adapter plate and bottom plate from the transducer using the torque wrench, ratchet head and 3/8-3/8 hex bit or 3/4" open end adapter supplied. 2.
CALIBRATION CHAPTER 5 The 4-in-1 transducer may also be mounted to the calibration stand, shown in Figure 5-2, using the standoff fixture and bracket assembly. For this mounting configuration the two slide knobs must be loosened and four 5/16-18 bolts attached to secure the 4-in-1 transducer to the bracket assembly.
CALIBRATION CHAPTER 5 Suggested Transducer Calibration Check Points, Bars, Hangers and Weights (Sheet 1 of 2) Part No. Range Bar Hanger Length Weight Calibration Points Check Points Weights to Add (n) = more than 1 Total Weight 2000-5-02 15-200 in oz 2.5" 2.5" 2.5" 2.5" 2.5" 2.5" none 1/2 lb 1/2 lb 1/2 lb 1/2 lb 1/2 lb 1 2 3 4 5 20.0 in oz 40.0 in oz 80.0 in oz 120.0 in oz 200.0 in oz 15.0 in oz 20.0 in oz 40.0 in oz 80.0 in oz 120.0 in oz 200.
CALIBRATION CHAPTER 5 Suggested Transducer Calibration Check Points, Bars, Hangers and Weights (Sheet 2 of 2) Part No. Range Bar Hanger Length Weight Calibration Points Check Points Weights to Add (n) = more than 1 Total Weight 2000-12-02 60-600 ft lb 40" 40" 40" 40" 40" 15 lb 15 lb 15 lb 15 lb 15 lb 1 2 3 4 5 60.0 ft lb 120.0 ft lb 240.0 ft lb 360.0 ft lb 600.0 ft lb 60.0 ft lb 120.0 ft lb 240.0 ft lb 360.0 ft lb 600.
CALIBRATION CHAPTER 5 Torque Calibrations SURETEST New Transducer Calibration Improper calibration can result in torque measurement errors. Follow these procedures precisely. If an error is made in the procedure, turn the Suretest off and begin again. Users are responsible for the results of their transducer calibration. SURETEST series Torque transducers can only be calibrated using the SURETEST Base Unit.
CALIBRATION 6. Enter the following code into the display using the Cursor Keys: CHAPTER 5 5222 ( Left / Right to select digit ; Up / Down = Increment / Decrement value ; ‘Enter’ to accept) Calibration CW: 7. Select Calibrate CW. Press ‘ENTER’. A warning is displayed. Select ‘Yes’. Press ‘Enter’ . 8. Using the Up or Down Cursor keys, enter “1” for a single transducer . Using the Up or Down Cursor keys, enter “4” for the 4-in-1 transducer. 9. Press ENTER.
CALIBRATION 10. 11. CHAPTER 5 Press F2 key and select the desired torque unit. Using the Up and Down Cursor keys, enter the Full Scale value for the 4-in-1 transducer to calibrate. Possible values are: 1 = 50 in-lb 2 = 400 in-lb 3 = 1000 in-lb 4 = 250 ft-lb ( For 4 in 1 Transducers display shows : CHECKING TRANSDUCER.) Apply load until “ Full Scale [units] shows on display. Press ENTER. To accept 50 in.lb Transducer. Press any key to zerotare. 12. Press any key. The LCD displays: 13.
CALIBRATION 13. Press (Accept) to accept the calibration value (1st Cal point). Apply 20% Torque = 10 in.lb 14. Press (Accept) to accept the calibration value (2nd Cal point) . CHAPTER 5 Apply 40% Torque = 20 in.lb 16. Press (Accept) to accept the calibration value (3rd Cal point) . Apply 60% Torque = 30 in.lb 17. Press (Accept) to accept the calibration value (4th Cal point) . Apply 100% Torque = 50 in.lb 18. Press (Accept) to accept the calibration value (5th Cal point) .
CALIBRATION 22. CHAPTER 5 All readings show minus sign (-). Press F1 twice to return to measurement mode. SURETEST Indicator Calibration WARNING: Improper calibration can result in torque measurement errors. Follow these procedures precisely. If an error is made in the procedure, turn the Suretest off and begin again. Users are responsible for the results of their calibration. Equipment • Laboratory grade millivolt meter for calibration measurements capable of resolving 1/100 millivolts.
CALIBRATION CHAPTER 5 Use DOWN Cursor key to scroll down to Calibration Item. Press ‘ENTER’. The display reads: 4. Enter the following code into the display using the Cursor Keys: 5111 ( Left / Right to select digit ; Up / Down = Increment / Decrement value ; ‘Enter’ to accept) Calibrate tester Using a laboratory millivolt meter, measure the voltage across pin 2 (ground) and 19 (Gage Excitation) of the calibration fixture. The display reads: Example: 3.
CALIBRATION CHAPTER 5 Using a laboratory millivolt meter, measure the voltage across pins 5 and 6. Example: 08.0622 mV 7. Program the measured voltage into the SURETEST Indicator as demonstrated in the example, “+08.0622” by pushing and holding the Up or Down Cursor keys. 8. Press ENTER. The display momentarily reads: SAVING... 9. Turn the power to OFF. Remove the calibration fixture.
MANUAL LOADER CHAPTER 6 Gravitational Effects Correction Factors on Test Weights Weights used in torque calibration are affected by their acceleration due to: • Altitude above or below sea level, and • Latitude on earth between the equator and the poles. Test bars are not affected by these conditions. The accuracy of torque wrenches and testers does not change due to changes in geographic location. Only when using weights must correction factors be considered.
MANUAL LOADER 500 600 700 800 900 CHAPTER 6 -0.1543 -0.1852 -0.2160 -0.2469 -0.2777 Correction Factor for Check Point Readings 1. Determine latitude and altitude. Obtain information from local geological survey office or library. 2. Find the acceleration due to gravity for sea level from its chart. 3. Subtract the free air correction for altitude from its chart. 4. Divide the result calculated in step 3 by the standard gravitational factor 980.665cm/sec/sec. 5.
MANUAL LOADER CHAPTER 6 Application The loader is a laboratory grade instrument used for testing and calibrating all torque wrenches, drivers, torque multipliers, non-impact pneumatic and electric nut runners Power To activate the limit solenoids that protect the transducers from overload, the loader requires AC power, 115/230VAC, 50 to 60 Hz, 1.0 amps. WARNING Do not use this equipment with the power off.
MANUAL LOADER CHAPTER 6 Functional Description This section describes major hardware components of the torque tester, including the: • Torque tester calibrator, • 2000-600-02 Manual Loader, • Loader rear panel controls, • Ball handle adaptor, • 4-in-1 transducer (accessory), and • Extension arm (accessory). Torque Tester/Calibrator The 2000-600-02 Manual Loader mounts on a CDI roll cabinet, part number 2000-100-02. An indicator stand mounts onto the loader.
MANUAL LOADER CHAPTER 6 Use the 2000-600-02 Manual Loader to test torque wrenches. Refer to Figure 6-2 for an exploded view of the Loader and components. Figure 6-2: 2000-600-02 Manual Loader, Exploded View A- Transducer Mounting A transducer facilitates the low-to-high ranges of the wrench under test. The transducer must be installed into the loader by lining up the red mark with the "TORQUE" label on the loader and securing it using two quick release pins.
MANUAL LOADER CHAPTER 6 IMPORTANT The connector on single transducer cables contains the EEPROM calibration memory chip. Never attempt to remove the connector from the transducer. B- Hand Crank Turn hand crank on the loader to apply torque. 2000 ft lbs of torque are generated with only 8 ftlbs of manual torque applied. C- Reaction Block The reaction block is positioned so that the reaction pins straddle the wrench handle at the hand hold position specified on the wrench.
MANUAL LOADER CHAPTER 6 Loader Rear Panel Controls The 2000-600-02 Manual Loader rear panel is shown in Figure 6-3. Figure 6-3: 2000-600-02 Manual Loader Rear Panel Controls A- Fuse The loader power supply is protected with a 1 amp slo-blow fuse. B- Voltage Select A selector switch allows the loader to use both 110VAC or 220VAC. C- AC Power Input The loader uses either 110VAC or 220VAC power. The loader connects to the SURETEST Base Unit by the 2000-117 cable.
MANUAL LOADER CHAPTER 6 Ball Handle Adaptor Wrenches featuring a ball handle are fixtured using the ball handle reaction adaptor shown in Figure 6-4. Install the adaptor onto the reaction slide using both reaction pins. Fix the adaptor height with the threaded knob.
MANUAL LOADER CHAPTER 6 4-in-1 Transducer (Accessory) The 4-in-1 transducer is mounted to the loader using the standoff fixture and bracket assembly as shown in Figure 6-5. Figure 6-5: 4-in-1 Transducer on 2000-600-02 Manual Loader A- Quick Release Pins Four quick release pins must be installed. The first two secure the standoff fixture to the loader and the second two lock the adaptor to the transducer bracket.
MANUAL LOADER CHAPTER 6 E- 4-in-1 Adapter Bracket Holds the 4-in-1 transducer horizontal to the loader.
MANUAL LOADER CHAPTER 6 Extension Arm (Accessory) The 2000-600-02 Manual Loader accepts torque wrenches up to 80" in length. The extension arm is attached as shown in Figure 6-6. A quick release pin is used at the end of the arm to capture the reaction pin slide assembly.
ACCESSORIES APPENDIX A Types of Loader Testing Torque Driver Testing An accessory torque screwdriver testing kit, 2000-750-02, is available for use in testing or calibrating most torque screwdrivers and "T" handled drivers. In addition to providing perfect driver-transducer alignment, it allows the use of the 2000-600-02 loader crank for precision torque application. Certain torque screwdrivers, "T" handled drivers, electric or pneumatic nut runners, and nonimpact power tools must be tested by hand.
ACCESSORIES APPENDIX A Figure A-1: Roll Cabinet Drawer Arrangement A-68
ACCESSORIES APPENDIX A SURETEST Torque Calibration System Components and Inventory Control Component Description Drawer-Cutout 2000-100-02* Roll cabinet 2000-100-2 2000-100-3 2000-100-4 2000-100-5 2000-100-7 2000-100-8 Foam insert Foam insert Foam insert Foam insert Foam insert Foam insert 6 7 8 9 3 4 2000-600-02 Manual torque loader 2000-600-10 2000-560 2000-111-0 2000-173-1 2000-173-2 343-50-02 2000-173-11 2000-173-6 QC2I75** QJ024** QIJR50** FA12E** 2000-114 2000-118 2000-119 2000-120 2000-195-12
ACCESSORIES APPENDIX A Optional Transducers and Accessories Component Description Drawer-Cutout 2000-5-02 1/4" ext. drive 15-200 in oz transducer 342-40 1/4" internal adaptor 2000-6-02 1/4" ext. drive 4-50 in lb transducer 342-40 1/4" internal adaptor 2000-65-02 1/4" ext. drive 15-150 in lb transducer 342-40 1/4" internal adaptor 2000-7-02 3/8" ext. drive 30-400 in lb transducer 342-41-2 3/8" internal adaptor 2000-8-02 3/8" ext.
ACCESSORIES APPENDIX A Component Description Drawer-Cutout 2000-550-02 2000-550-108 2000-550-115 2000-195-1 Extension arm kit, for up to 80" wrenches Arm Reaction pin slide block assembly Retention pin 8-F 8-I 2000-50-1 Cable, Indicator to PC 3-C 2000-50-2 Cable, Indicator to serial printer 3-A 2000-900-121 Cable, smart cable replacement 2000-750-02 Torque screwdriver testing kit 900-0 Joint rate simulator; 50 in lb max, 1/4" internal square drive for use on 2000-6-02 transducer 900-2-0
ACCESSORIES APPENDIX A Calibration Accessories Calibration of the 2000-610-02 Indicator and SURETEST series transducers is recommended at least every 1 year.
ACCESSORIES Component APPENDIX A Description Drawer-Cutout Weights 2500-310-1 2500-310-2 2000-310-2 2000-310-3 2000-300-2 2000-300-3 2000-300-4 2000-300-5 2000-300-6 2000-300-7 2000-300-8 0.3 oz Hook (1) 0.
