USER'S MANUAL MOTORIZED CONTROL LOADER
Torque-Angle Tutorial Torque vs Load Today’s torque wrenches are very accurate. Unfortunately, torque can be a poor parameter to measure when you’re really interested in controlling load. As shown in the Torque vs Load graph at left, 120 Newton-meters of torque applied to a dry and corroded bolt only produces 7,000 pounds of clamping load in a sample joint. This same bolt, cleaned and lubricated, results in nearly 21,000 pounds of load for the same 120 Nm applied. That’s 14,000 lbs of uncertainty.
Front Panel Function Keys Toggles between TORQUE and FORCE measurement modes. Opens and terminates calibration mode. Selects TRACK, PEAK HOLD, POWER TOOL, FIRST PEAK and ANGLE modes. Edits DATE/TIME programming function. Selects following units on LCD display: Torque units in: Nm, dNm, cNm, mkg, cmkg, lb ft, in lb, in oz, or Force units in: N, dN, kp, gf,lbf, oz. Sets up high torque/force limit preset. Set up angle preset in torque-angle mode. Manually resets ANGLE display on LCD.
Table of Contents Safety Information ...................................................................................................................... I Introduction ............................................................................................................................ 1-1 Functional Description and Specifications ............................................................................ 2-1 Functional Descriptions .................................................................
Table of Contents Downloading Data List to Printer .................................................................................. 4-11 Downloading Data List to Personal Computer .............................................................. 4-12 How to Use Analog Output (Rear Panel BNC Connector) .............................................. 4-13 Measuring Torque and Angle .............................................................................................. 4-14 Torque Only ...................
Table of Illustrations Functional Description and Specifications ............................................................................ 2-1 Figure 2-1: Motorized Loader Control System ......................................................................2-1 Figure 2-2: Roll Cabinet Drawer Layout ..............................................................................2-2 Figure 2-3: 2000-810-01 Front Panel ..................................................................................
Using this Manual This manual contains instructions for use and setup of the Motorized Control Loader 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. Check Note A check note provides additional information about the subject in the preceding paragraph.
Using This Manual Safety Messages Safety messages are provided to help prevent personal injury and equipment damage. All safety messages are introduced by a signal word indicating the hazard level. The types of safety messages are: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury to the operator or to bystanders. Indicates a potential hazard which, if not avoided, could result in death or serious injury to the operator or to bystanders.
Safety Information IMPORTANT SAFETY INSTRUCTIONS This manual contains important safety and operating instructions for CDI Motorized Control Loader Torque 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, and, in some instances, an icon.
Safety Information WARNING Risk of electric shock and fire. • For indoor use only. Do not expose charger to rain or snow. Do not use in damp locations. • Replace defective cord immediately. Return to qualified service center for replacement. Electric shock or fire can cause injury. WARNING Flying particles can discharge when applying torque. • Users and bystanders must wear safety goggles. • Always wear safety goggles when applying torque. • Do not use this equipment with the power off.
Safety Information WARNING • Make sure all components, including, adaptors, extensions, drivers and sockets are rated to match or exceed the torque or load being applied. • Be sure the capacity of the Motorized Control Loader System matches or exceeds each application before performing a procedure. • Do not use the Mototrized Control Loader System if it makes unusual noises, has loose parts, or shows any other sign of damage. Have repairs performed at an Authorized Service Center before use.
Safety Information safety features LIMITING SWITCHES The limiting switches on the loading mechanism will automatically stop the motor before damage is done to the loading mechanism. To restart the motor reverse the direction of the load. “ OVER TORQUE ” PROTECTION FOR TRANSDUCER IN USE The motor will stop when the transducer in use has reached an “OVER RANGE” condition. This protects the transducer from permanent damage.
Introduction The 2000-810-01 Indicator is a laboratory grade instrument that provides TORQUE, FORCE and ANGLE of rotation measurements and set-able alert functions. Although designed as an integral component of the Motorize Torque Calibrator, it can also be used independently in many laboratory and industrial applications.
Introduction Set-up and calibration programming is entered on front panel membrane keys. HIGH and LOW torque limits are adjustable to give an audible alert. The user selects TRACK mode to display torque values as they are applied, PEAK HOLD or POWER TOOL modes to display the highest torque value applied, or FIRST PEAK mode which captures the torque output at the “click” of a set-able wrench or driver. CLEAR, STORE and PRINT functions can be set up for automatic or manual operation.
Functional Description and Specifications The Motorized Control Loader System is comprised of the 2000-810-01 Indicator, one of the Multitest Torque/Force Transducers, a Motorized Loader, and a roll cabinet. System accuracy is achieved when the Indicator and Transducer are calibrated together.
Functional Description and Specifications A — Indicator The 2000-810-01 Indicator monitors and displays the torque applied. B — Transducer (Accessory) The loader accepts all MULTITEST series single transducers directly. Use a 2000-500-02 adaptor kit to mount the optional 2000-400-02 4-in-1 transducer. For additional information refer to Appendix A–Accessories.
Functional Description and Specifications 2000-810-01 Indicator This section describes the major hardware components of the MULTITEST Indicator, including: • Front Panel • Rear Panel (Input/Output) • MULTITEST Torque/Force Transducers NOTE: When used in conjunction with MCB, 2000-810-01 only makes torque measurements. Front Panel Figure 2-3: 2000-810-01 Front Panel A — MULTITEST Torque/Force Display TORQUE or FORCE displays on a bright red alphanumeric LED, with 0.
Functional Description and Specifications F — Maximum Range Display Figure 2-4: Maximum Range Display Two line by 16 character 5x8 dot-matrix LCD display that shows: • Maximum transducer range in the selected UNITS of measure on the upper line, • Statistical mean of all measurements in memory on the lower line, left, and • The number of the present data memory location on the lower line, right.
Functional Description and Specifications G — Front Panel Membrane Function Keys Toggles between TORQUE and FORCE measurement modes. Selects TRACK, PEAK HOLD, POWER TOOL, FIRST PEAK and ANGLE modes. Selects following units on LCD display: Torque units in: Nm, dNm, cNm, mkg, cmkg, lb ft, in lb, in oz, or Force units in: N, dN, kp, gf,lbf, oz Manually resets ANGLE display on LCD at any time. Manually resets ZERO TARE. Selects LED or LCD digit to right (blinking) for setup and programming.
Functional Description and Specifications Opens and terminates calibration mode. Edits DATE/TIME programming function. Sets up high torque/force limit preset. Set up angle preset in torque -angle mode. Sets up low torque/force limit preset. Set up clamping torque preset in torque-angle mode. Stores present measurement to memory. Recalls memory data to display. Sends all memory data, statistical analysis and histogram to printer/port.
Functional Description and Specifications Rear Panel (Input/Output) The 2000-810-01 Indicator rear panel is shown in Figure 2-5. A G F B C E D Figure 2-5: 2000-810-01 Rear Panel A — SOLENOID CONTROL (Hirose RM15TRD-12S) Not used (optional) B — 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.
Functional Description and Specifications D — PRINTER PORT (DB-9P) PIN 2 3 5 FUNCTION Receive Transmit Ground E — OPTIONAL (DB-9P) PIN 2 3 5 FUNCTION Receive Transmit Ground F — 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 Description and Specifications MULTITEST Torque/Force Transducers MULTITEST torque/force transducers provide industry standard internal square drives. They feature a full bridge strain-gauge @ 350 Ohms nominal. Full range output is 1500 µE, 9mV, (3mV/V @ 3.0V excitation). Torque/force 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 Description and Specifications Display Resolution for Transducers in Force Mode N dN lbf ozf kp gf 2000-7-02 03 .3 .007 .1 .003 3 2000-8-02 .08 .8 .02 .3 .008 8 2000-10-02 .1 1 .02 .4 .01 10 2000-11-02 .2 2 .05 .8 .02 n/a 2000-12-02 .5 5 .12 2 .05 n/a 2000-13-02 .9 9 .2 3 .1 n/a 2000-14-02 1.8 18 .4 6 .2 n/a Display Resolution for Transducers in Torque Mode mkg cmkg ft lb in lb in oz Nm 2000-5-02 .00003 .003 .0002 .002 .04 .0003 .
Functional Description and Specifications Specifications MOTORIZED CONTROL LOADER System System Accuracy ±0.25% of reading @ 25°C (Indicator and transducer calibrated together) MULTITEST Transducers used with, but not calibrated to, another MULTITEST Indicator provide a system accuracy of ±0.5% of reading @ 25°C. Temperature Drift +0.03%/°C (+0.017%/°F) Angle Precision Bi-directional rotary encoder pulses/revolution X4 2000-810-01 Indicator Display Accuracy ±0.
Functional Description and Specifications Data Storage/Recall w/Date Time Stamp 3,000 measurements Statistical Analysis Max, Min, Range, Mean, Sigma N, Sigma, Cp, Cpk %Error, -NoGo, +NoGo. Histogram: Lower Set Limit, Upper Set Limit, 10 Divisions Printer/Computer Serial Output Port Serial Communications RS-232 (true) 300—19.2K Baud 8 data bits 1 stop bit no parity Computer Serial COM Port RS-232 (True) 300—19.2K Baud NOTE OPTIONAL: This port will communicate with the Motorized Control Box at 19.2K Baud.
Functional Description and Specificatons Torque/Force Transducers Accuracy ±0.2% of reading @ 25°C, within specified range, when used as prescribed with the 2000-800-02 Loader. Range and Resolution Refer to transducer-indicator range and display resolution tables in Functional Description of this chapter. Temperature Operating Temperature 10 to 32°C (50 to 90°F) Storage -20 to 50°C (-2 to 122°F) Humidity Up to 90% non-condensing Temperature Drift +0.02%/°C (+.
Setup and Programming Motorized Control Loader System Setup Figure 3-1: Motorized Control Torque Tester/Calibrator/Loader Setup A B C D E F G H I J K L M N – – – – – – – – – – – – – – Internal printer Internal/External printer selector switch 2000-810-01 Indicator rear panel Power cables (110/220 VAC) Printer cable External printer Transducer cable Personal computer cable Smart 4-in-1 transducer Analog device Personal computer Smart single transducer Motorized Loader Indicator to Motor Control Box cable
Setup and Programming Setting Up the Motorized Control Loader System 1. Position the roll cabinet on a level floor and lock the wheels. 2. Mount the indicator stand, part number 2000-111-0, to the Loader. 3. Mount the 2000-810-01 Indicator to the stand. 4. Connect the cables between the Indicator, Motorized Control Box and Power Amplifier Box. (Refer to chapter 6) 5. Install the appropriate MULTITEST transducer to the Loader drive. 6. Install two (2) quick release pins, part number 2000-19512. 7.
Setup and Programming 2000-810-01 Indicator Controls Refer to the illustration below when performing the power-up and programming procedures.
Setup and Programming Powering the Equipment To power the equipment, press the power button on the front of the 2000-810-01 Indicator. • At POWER ON, the LED displays : UPDATE CDI SELFTEST... MEM O.K. EE O.K. SELFTEST O.K.
Setup and Programming Programming Setup Setting up Date and Time 1. Press DATE/TIME. The LCD display reads Date dd/month/yy - upper line Time hh:mm:ss - lower line, with the seconds flashing Figure 3-3: Date and Time Display 2. Push left or right DIGIT to select the date/time element being changed. 3. Increment or decrement the date/time element by repeatedly pushing up or down VALUE. Push and hold up or down VALUE to change the display quickly.
Setup and Programming Setting Up High and Low Limits Alert Torque/Force Mode Use SET HIGH and SET LOW to protect the tool under test or serve as a fastener installation torque or force preset alert. The 2000-810-01 produces a constant audible limits alert tone when the input torque/force exceeds the SET LOW limit. It then produces a pulsating limits alert tone when the input torque/force exceeds the SET HIGH limit.
Setup and Programming Setting High Torque/Force Limit 1. Press SET HIGH. — The LED display reads: last SET HIGH value , with one digit flashing — The LCD display reads: Edit high limit - upper line [units] - lower line Change units of measure by pushing UNITS. 2. Select an LED digit to change (flashing) by pushing left or right DIGIT. 3. Increment or decrement the selected digit by pushing up or down VALUE. Push and hold up or down VALUE to change the display quickly. A decimal point ".
Setup and Programming AUTO CLEAR can be programmed with a 1 to 9 second delay. Use this feature to visually note the reading before the display clears. AUTO CLEAR with no delay stores, prints and/or clears with no delay at the initiation of the next torque or force input. STORE DATA must be pressed to save the last reading that displays on the LCD after a test. AUTO CLEAR must be selected to use AUTO STORE and AUTO SEND. To use the AUTO CLEAR, STORE, or SEND: 1. Press AUTO CLEAR.
Setup and Programming DATA LIST Memory When changing transducers, or when creating a new statistical data list, the data list memory must be cleared. The entire memory list or any single memory location may be selectively cleared. Clearing from the top of the list decrements the total number of memory locations. Clearing from inside the list shifts all subsequently taken readings down from that location and decrements the total number of memory locations.
Setup and Programming 4. Press ENTER to clear the last memory location. The number of total memory locations decrements by one. Pushing ENTER repeatedly continues to clear readings from the top of the list down. 5. Press left DIGIT to select "None." 6. Press ENTER to return to RECALL mode. 7. Press ENTER again to return to measurements mode. Clear Single Memory Location Use the procedure in this section to clear a single memory location. 1. Press RECALL DATA. — The LCD display reads as shown in Figure 3-5.
Setup and Programming Clear All Memory Locations Use the procedure in this section to clear all memory locations. 1. Press RECALL DATA. — LCD displays as shown in Figure 3-5. The present memory location at the upper left, the total number of memory locations to the right and the time data was stored at far right. — LED display shows the measurement value of that memory location while the LCD displays its engineering units at the lower right. 2. Press MANUAL CLEAR.
Setup and Programming 3. Press ENTER. — The LED display reads: PRINTER or OPTIONAL — The LCD display reads: Download: - upper line Port - lower line 4. Press up VALUE to toggle between "PRINTER" port or “OPTIONAL” Port 5. Press ENTER to return to measurements mode. Setting Up Serial Communications 1. Press CAL to enter calibration mode. — LED display reads the following with the least significant digit (LSD) flashing: CODE0000 2.
Setup and Programming 8. Press right DIGIT. — LED display indicates: YES or NO — LCD display reads: Download: - upper line Send Init yes/no - lower line 9. Press up or down VALUE to select "YES" to initialize the ports for reverse characters (on some external printers) or "NO" for standard characters. 10. Press ENTER to return to measurements mode. Encoders The 2000-810-01 uses X4 quadrature logic for maximum resolution with any bi-directional incremental rotary encoder.
Setup and Programming B . Rotate the encoder shaft exactly one complete turn (360 degrees). The upper right LCD display reads the total number of counts for the encoder. C. Push ENTER then CAL to return to the previous mode. To enter the resolution of a known encoder: A . Press up VALUE to select "Encoder: Enter Resolution" on the LCD display. B . Press ENTER and, using up and down VALUE and left and right DIGIT, enter the counts resolution of the encoder. C. Push ENTER then CAL to return the previous mode.
Setup and Programming Setting Up Torque-Angle Measurement Modes In using the torque-angle or "turn-of-the-nut" algorithm, a fastener is run down to a specified clamping torque and then rotated an additional number of angular degrees regardless of the torque necessary to turn it. A typical fastener specification might read: "15 ft lb & 50° rotation." For additional information, refer to the Torque-Angle Tutorial Quick Reference card that accompanies this manual.
Setup and Programming 3. Using up and down VALUE and left and right DIGIT, enter the clamping torque from the fastener torque-angle specification onto the LED display. 4. Press ENTER. 5. Press SET HIGH. — LED display shows the previously programmed degrees of rotation preset value. — LCD display reads: Edit max. angle Figure 3-9: Edit Angle Display 6. Using up and down VALUE and left and right DIGIT, enter the degrees of rotation from the fastener torqueangle specification onto the LED display. 7.
Setup and Programming 5. Press SET HIGH. — The LED display shows the previously programmed degrees of rotation preset value. — The LCD display reads: Edit max. angle 6. Using up and down VALUE and left and right DIGIT, enter the degrees of rotation from the fastener torqueangle specification onto the LED display. 7. Press ENTER to return to measurements mode.
Using the Multitest Torque Calibration System The 2000-810-01 Indicator is designed to work specifically with the Multitest series of smart transducers for measuring torque. The Multitest series transducers contain a memory chip that identifies the transducer range and calibration parameters to the Indicator. This chapter contains information on how to test, measure, and use the Motorized Torque Tester in the manual loader mode. For Automated testing refer to Chapter 6 - 2000-800-02 Motorized Loader.
Using the Multitest Toque Calbration System Dial and Bending Beam Torque Wrenches and Screwdrivers Be sure the Multitest transducer is capable of handling the intended torque to avoid damaging the transducer. Always operate the system with the 2000-800-02 Loader power on. WARNING Do not use this equipment with the power off. Always turn on the indicator and loader so the torque and load values are indicated on the display. 1. To program the 2000-810-01 Indicator refer to Chapter 3–Set Up and Programming.
Using the Multitest Toque Calbration System Example: When tool accuracy is 4% and 2000-810-01 Indicator / Transducer System accuracy is 0.25%, readings should be within ±4.25%. 9. Release the torque, CLEAR the indicator display, and reapply torque for each of the remaining check points recommended by the tool manufacturer. If no recommendation is available, check at 20%, 40%, 60%, 80% and 100% of the tool full scale. 10. Repeat steps 4 through 9 in the counter clockwise (CCW) direction.
Using the Multitest Toque Calbration System 5. Remove the tool from the transducer-loader and press ZERO TARE. 6. Press MODE to select FIRST PEAK mode. The red FIRST PEAK lamp lights. When testing “click” screwdrivers, it may be easier to use the PEAK HOLD mode on the 2000-810-01 Indicator to capture the maximum applied torque reading. 7.
Using the Multitest Toque Calbration System 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.
Using the Multitest Toque Calbration System 3. Press MODE to select TRACK mode. The green TRACK lamp lights. 4. Adjust the power tool to the desired torque output, if possible. 5. Adjust the appropriate joint rate simulator assembly for the desired soft-hard configuration. 6. Install the joint rate simulator onto the MULTITEST transducer, as shown in Figure 4-1. Secure the transducer set screw, if provided. Loosen the simulator load screw using the appropriate hex or box wrench.
Using the Multitest Toque Calbration System 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 Indicator POWER TOOL reading. 15. CLEAR the display. 16. Repeat steps 4 through 15 in the opposite direction, if required.
Using the Multitest Toque Calbration System Use the following procedure to make force measurements. 1. To program the 2000-810-01 Indicator, refer to Chapter 3—Set Up and Programming in this manual. Use SET HIGH and SET LOW limit alert, data STORE, display CLEAR, printer SEND and STATistical analysis features. 2. Install the compression or tension fixture according to the manufacturer’s instructions. 3. Press SELECT to select FORCE measurement. 4. Press MODE to select TRACK mode.
Using the Multitest Toque Calbration System Displaying Statistical Analysis on LCD 1. Press STAT. — The LED display reads: ** STAT** — The LCD displays reads: HIT SEND = PRINT - upper line ↑↓ = LIST STAT - lower line Figure 4-2: Statistical Analysis Display 2. Repeatedly press up or down VALUE to scroll through the LCD display as shown in Figure 4-3. Figure 4-3: Value Display 3. Press ENTER to return to measurements mode.
Using the Multitest Toque Calbration System Printing Statistical Analysis 1. Press STAT. — The LED display reads: **STAT** — The LCD display reads: HIT SEND = PRINT - upper line ↑↓ = LIST STAT - lower line 2. Press SEND to print out the entire statistical analysis. LED display reads: SENDING Refer to the sample printout in Figure 4-4. As indicated on the LCD display, use MANUAL CLEAR to cancel printing. 3. Press ENTER to return to measurements mode.
Using the Multitest Toque Calbration System 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 on LCD 1 Press RECALL DATA.
Using the Multitest Toque Calbration System 5. Press ENTER to download the raw data list. The LED display reads: SENDING 6. Press ENTER again to return to measurements mode. Downloading Data List to Personal Computer 1. Connect the accessory 2000-50-1 cable between the 2000-810-01 PRINTER port and the computer COM port. For additional information on setting up printer or PC ports, refer to Chapter 3—Set Up and Programming . 2. Set up your computer to receive serial communication.
Using the Multitest Toque Calbration System How to Use Analog Output (Rear Panel BNC Connector) Analog Output on the 2000-810-01 provides a real time voltage level that is directly proportional to the torque/force measurement 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.
Using the Multitest Toque Calbration System Measuring Torque and Angle Although measuring torque and angle is not a torque testing feature, transducers and the 2000-810-01 Indicator may be used to monitor torque during fastener installation. The Indicator can also be set up to monitor "turn-of-the-nut" or angle of rotation using common bi-directional incremental rotary encoders for critical fastener installations. Typically, a torqueangle algorithm is used where the joint is clamped using a preload torque.
Using the Multitest Toque Calbration System Angle Only The 2000-810-01 accepts input from common bi-directional incremental rotary encoders. The Indicator interfaces to any encoder resolution (counts per revolution) and can be programmed to display angle in degrees of rotation. For additional information on setting up angle encoders and measurement modes, refer to Chapter 3—Set Up and Programming in this manual. 1. Press MODE to select ANGLE. — LED displays torque.
Using the Multitest Toque Calbration System Torque-Angle Algorithm In addition to MULTITEST series torque transducers, the 2000810-01 Indicator accepts input from common bi-directional incremental rotary encoders. The Indicator features a special Torque-Angle measurement mode where a clamping torque is first applied and measured, then at torque preset coincidence, (when the input torque matches the SET LOW limit), the Indicator automatically switches to measuring angle in degrees of rotation.
Calibration The MULTITEST Torque Calibration system is factory calibrated using precision torque test arms, certified weights and laboratory grade equipment. MULTITEST series transducers must be positioned horizontally, with torque applied within ±15 degrees of horizontal. This chapter contains calibration instructions and information for the MULTITEST Torque Calibration System. Annual calibration is recommended. Calibration by the user is recorded in memory and voids factory certification.
Calibration Mounting Details Single Transducer Mounting Detail for Calibration Single transducer calibration requires the use of a reaction stand and transducer calibration block. As shown in Figure 5-2, the transducer is secured to the calibration block with two quick release pins. • Both pins must be installed for safety and stability of the mount. • The white mark on the transducer is aligned in the up position.
Calibration Torque Over 250 ft lb For torque calibration above 250 ft lb, the calibration block is moved to the left for CCW loading and to the right for CW loading. The torque arm is always extended over the front of the reaction bracket for both CW and CCW torque applications. In this configuration, useful up to 2000 ft lb, the calibration block is secured to the stand using four 1/2-13 socket head cap screws, each torqued to 75 ft lb. For additional information refer to Figure 5-3 .
Calibration 2. Remove separated adaptor from calibration block. 3. Attach transducer to the calibration block so that red mark on transducer lines up with white dot in left bottom corner on calibration block. Tighten six 1/2"-13 hex head bolts to 75 ft lb torque. 4. Attach the 1-1/4" drive adaptor plate using six 1/2"x13 hex head bolts, each torqued to 75 ft lb using the torque wrench, and 3/4” open end adaptor, supplied. 5.
Calibration Quick Check WARNING Always be alert to the potential for personal injury that may be caused by excessive torque applications, careless handling of heavy weights, and out-of-balance or unsafe weight distribution. 1. With the 2000-810-01 Indicator ON, select TORQUE measurement, TRACK mode, and select the UNITs of measure appropriate to the transducer as specified in the calibration check point table in this chapter. 2.
Calibration Suggested Transducer Calibration Check Points, Bars, Hangers and Weights (Sheet 1 of 2) Part No. Bar Hanger Calibration Length Weight Points Check Points Weights to Add (n) = more than 1 Total 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 Suggested Transducer Calibration Check Points, Bars, Hangers and Weights (Sheet 2 of 2) Part No. Bar Hanger Calibration Length Weight Points Check Points Weights to Add (n) = more than 1 Total 40" 40" 40" 40" 40" 15 15 15 15 15 lb lb lb lb 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 Torque/Force Calibrations MULTITEST Torque/Force Transducer Calibration Improper calibration can result in torque measurement errors. Follow these procedures precisely. If an error is made in the procedure, turn the indicator off and begin again. Users are responsible for the results of their transducer calibration. MULTITEST series torque/force transducers can only be calibrated using the 2000-810-01 Indicator.
Calibration 5. Enter code the following code into the display using the DIGIT right and left keys and the up and down VALUE keys: CODE5222 6. Press ENTER. — The LED display reads: SELECT — The LCD display reads: Calibrate CW 7. Press ENTER. — The LED display reads a flashing number in the LSD. — The LCD display read: Enter no. of transducers 8. Using the up and down VALUE keys, enter “1” for a single transducer or “4” for the 4-in-1 transducer. — If you enter "1" skip to step 11. 9. Press ENTER.
Calibration 14. Apply and release full scale torque to the transducer three times in the CW direction, then remove the weights and hanger. Leave the torque arm installed. 15. Press ENTER. — For single transducers, the LED display momentarily reads: ZEROTARE and then LOAD + + 1 with the two plus signs alternating — For 4-in-1 transducers, the LED display reads: ZERO T1 through 4 as each transducer is scanned — The LCD display reads: *CALIBRATION* - upper line Load transducer - lower line 16.
Calibration 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.
Calibration Free Air Correction for Altitude Altitude Meters 200 300 400 500 600 700 800 900 Correction cm/sec2 -.0617 -.0926 -.1234 -.1543 -.1852 -.2160 -.2469 -.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.
2000-800-02 Motorized Loader The 2000-800-02 Motorized Loader is designed as an integral component of the CDI Motorized Control Torque Calibration System, providing a precision output torque of up to 2000 ft lb while requiring only 10 ft lb input. Application The loader is a laboratory grade instrument used for testing and calibrating all torque wrenches, drivers, torque multipliers, nonimpact pneumatic and electric nut runners.
2000-800-02 Motorized Loader Torque/force transducers, purchased separately, are available in ranges from 15-200 in oz, to 200-2000 ft lb. The Motorized Control Loader System features accessory calibration equipment including precision torque bars, certified weights, calibration mounts and stands. Reaction arms, cables, mounting plates and fixtures are also available for testing tensiometers, compression and tension gauges, and torque multipliers.
2000-800-02 Motorized Loader Torque Tester/Calibrator The 2000-800-02 Motorized Loader mounts on a CDI roll cabinet, part number 2000-100-02. An indicator stand mounts onto the loader.
2000-800-02 Motorized Loader Use the 2000-800-02 Motorized Loader to test torque wrenches. Refer to Figure 6-2 for an exploded view of the Loader and components. Figure 6-2: 2000-800-02 Motorized Loader, Exploded View A — Drive Adaptor A drive adaptor couples the wrench to the transducer. Low torque MULTITEST series transducers use an internal-internal drive adaptor and high torque MULTITEST transducers may use an adaptor/reducer.
2000-800-02 Motorized Loader The connector on single transducer cables contains the EEPROM calibration memory chip. Never attempt to remove the connector from the transducer. D — Linear Bearings May be slipped over the reaction pins to reduce friction when testing very small or high resolution electronic wrenches. E — Reaction Pins Hold the reaction block in place.
2000-800-02 Motorized Loader Ball Handle Adaptor Wrenches featuring a ball handle are fixtured using the ball handle reaction adaptor shown in Figure 6-3. Install the adaptor onto the reaction slide using both reaction pins. Fix the adaptor height with the threaded knob.
2000-800-02 Motorized Loader 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 6-4. Figure 6-4: 4-in-1 Transducer on 2000-800-02 Motorized 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.
2000-800-02 Motorized Loader Extension Arm (Accessory) The 2000-800-02 Motorized Loader accepts torque wrenches up to 80" in length. The extension arm is attached as shown in Figure 6-5. A quick release pin is used at the end of the arm to capture the reaction pin slide assembly.
2000-800-02 Motorized Loader Motorized Control Box MOTORIZED CONTROL BOX EMERGENCY STOP F1 F2 F3 F4 SYSTEM CONTROL ON RUN OFF STOP MADE IN U.S.A. Fig 6-6 Front Control Panel. Front Panel Membrane Function Keys The MCB has a Liquid Crystal Display (LCD) which is mounted on an attractive front panel. ALL set-ups and control commands are easily entered via the membrane Keys: F1 To change / select the Mode. F2 For Diagnostic only. F3 Reserved. F4 Reserved.
2000-800-02 Motorized Loader An important step prior to any MCB operation is the establishment of a reference position for the motor. This is called "homing" and can be performed either as an integral part of the selected Mode or as an independent step (Ref. Manual Mode). WARNING Make sure that NO Wrench is in the Loader while in Homing operation or in ZEROTARE mode.
2000-800-02 Motorized Loader Loader Rear Panel Interconnect The 2000-800-02 Motorized Loader rear panel is shown in Figure 6-7. Basic Set-up: WARNING Disconnect the main power line before making system inter-connections. POWER AMPLIFIER BOX MOTORIZED CONTROL BOX SMART 4IN1 TRANSDUCER P/N 2000-400-02 P/N 2000-810-50 P/N 2000-810-60 TORQUE / FORCE / ANGLE TESTER P/N 2000-810-01 5 . IN. - 4OZ. 00 MAXIMUM POWER SWITCH 3.75 - 50 IN.LB. MAXIMUM 10-150 IN.LB.
2000-800-02 Motorized Loader Using the Motorized Controller (For Torque measurement only!) The Motorized Control Loader consists of the Motorized Control Box (MCB) and the Motorized Loader. The system is typically used in conjunction with a Torque Measurement Device, such as the 2000-810-01. The MCB controls the motor to generate a force which is applied to a wrench while the 2000810-01 measures the resulting torque. When the target torque is reached, the MCB will stops the motor.
2000-800-02 Motorized Loader 1. In case of an emergency, push E-STOP (Emergency STOP) to shut down the motor. 2. Push System Control OFF (Red) button to suspend system operations. Push System Control ON (Green) button to resume system operations. Click Mode: 3. In case of a system error, use hand crank to release wrench. ( This mode is used to check or test the Click wrenches ). · Setup the Torque Tester: ** Mode: First Peak ** Select an appropriate Unit (ft-lb, Nm, etc.
2000-800-02 Motorized Loader If the Loader is not in the Home Position, the Display shows: *** CLICK MODE *** Make sure there is no wrench in Loader Then hit Run Make sure there is no wrench in Loader. Press RUN key to start Homing. The LCD display then reads: *** CLICK MODE *** Moving to home Position 001 Sec *** CLICK MODE *** Put wrench in Loader Then Hit Run. Place wrench onto Loader. Press RUN key to Start. The motor starts applying force to the handle of the Torque Wrench.
2000-800-02 Motorized Loader NOTE: If the wrench has no click or bad-click the display reads: *WARNING* No Click Detected Any key to Backup Press ANY key to return to the Home position. PLEASE Clear Tester Reading. Moving to home Position SEC 001 The MCB will release the applied force and prompt the Operator to clear the display on the Torque tester. The wrench can now be safely replaced.
2000-800-02 Motorized Loader DIAL , BEAM OR SCREW DRIVER MODE: ( This mode is used to check or test the Dial wrenches ). · Setup the Torque Tester: ** Mode:- Peak or TRACK ** Select an appropriate Unit (ft-lb, Nm, etc.) · Setup the Motorized Control Box: ** Press F1 key to select Dial Mode. The LCD display reads: *** MODE (Dial) *** Press Run to Start Press RUN key to start Dial Mode: The LCD Display reads: *** DIAL MODE *** Target Cycle 50.
2000-800-02 Motorized Loader If the Loader is not in the Home Position, the Display reads: *** DIAL MODE *** Make sure there is no wrench in Loader Then hit Run Make sure there is no wrench in Loader. Press RUN key to start Homing. Then LCD display reads: *** DIAL MODE *** Moving to home Position 001 Sec *** DIAL MODE *** Put wrench in Loader Then Hit Run. The Motor starts applying force to the handle of Torque Wrench. *** DIAL MODE *** Target: 050.
2000-800-02 Motorized Loader After adjustment, press ANY key to return to main menu: *** DIAL MODE *** Target: 050.00 ft-lb Cycle: 1/5 Backing up 15% The MCB continues until all cycles are completed.
2000-800-02 Motorized Loader TASK TERMINATION / CANCELLATION Use STOP Key to cancel the current operation in ALL modes. For example, when the motor is running in Click (or Dial) mode, *** CLICK MODE *** Target: 50.00 ft-lb Cycle: 1/5 Speed: 100% Press STOP Key to suspend the motor movement. *** CLICK MODE *** Target: 50.00 ft-lb Cycle: 1/5 CANCEL *** CLICK MODE *** Target: 50.00 ft-lb Cycle: 1/5 Any Key to Back up! Press any key to return to the Home position. *** CLICK MODE *** Target: 50.
2000-800-02 Motorized Loader The MCB then returns to main setup menu. *** CLICK MODE *** Press Run to Start The wrench can now be safely replaced.
2000-800-02 Motorized Loader MANUAL MODE Press F1 key to select Manual mode: *** MODE MANUAL *** Press Run to Start Press RUN key to start Manual mode. *** MODE MANUAL *** to engage motor Left- Right Speed 000% Press and hold (Left cursor) to move motor in the CCW direction. Press and hold (Right cursor) to move motor in the CW direction. The motor speed starts at 0%, and increases up to 100%. The direction LED indicator will also light up.
2000-800-02 Motorized Loader 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 2000-800-02 loader crank for precision torque application. Certain torque screwdrivers, "T" handled drivers, electric or pneumatic nut runners, and non-impact power tools must be tested by hand.
2000-800-02 Motorized Loader Force Testing The 2000-800-02 Motorized Loader and MULTITEST series transducers can be configured to deliver compression and tension loads. The 2000-810-01 Indicator also provides measurement, display, storage and statistical analysis of FORCE inputs. A 12" load arm attaches to the transducer drive which mathematically cancels the length factor from the torque measurement. For example, a 250 ft lb transducer translates into 250 lbf (pounds force).
2000-800-02 Motorized Loader safety features LIMITING SWITCHES The limiting switches on the loading mechanism will automatically stop the motor before damage is done to the loading mechanism. To restart the motor reverse the direction of the load. “ OVER TORQUE ” PROTECTION FOR TRANSDUCER IN USE The motor will stop when the transducer in use has reached an “OVER RANGE” condition. This protects the transducer from permanent damage.
Appendix Accessories This appendix contains information on replacement parts and accessories that are available from Consolidated Devices, Inc.,1-800-525-6319. Refer to Figure A-1, below, for drawer and cutout arrangement information.
Accessories Motorized Control System Components and Inventory Control Component Description Drawer-Cutout 2000-100-02 ¬ 2000-100-2 2000-100-3 2000-100-4 2000-100-5 2000-100-7 2000-100-8 Roll cabinet Foam insert Foam insert Foam insert Foam insert Foam insert Foam insert 6 7 8 9 3 4 2000-800-02 2000-810-0 2000-56-0 2000-111-0 2000-810-60 2000-810-50 2000-810-22 9800-303 2000-50-1 9502-500 2000-173-1 2000-173-2 S/343-50-2 S/2000-173-11 2000-173-6 100ST-I RYE-12 RYD-6 FA12E 2000-114 2000-195-12 Motoriz
Accessories Optional Transducers and Accessories Component Description 2000-5-02 1/4" ext. drive 342-20 2000-6-02 1/4" ext. drive 342-20 2000-65-02 1/4" ext. drive 342-20 2000-7-02 3/8" ext. drive 342-41-2 2000-8-02 3/8" ext. drive 342-41-2 2000-10-02 1/2" ext. drive 65-26-3 2000-11-02 1/2" ext. drive 65-26-3 2000-12-02 3/4" ext. drive 65-78-2 2000-13-02 1" int. drive 2000-226-2 2000-14-02 1" int.
Accessories A-4 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 8-F Retention pin 8-I 2000-50-2 Cable, Indicator to serial printer 2000-900-121 Cable, smart cable replacement 2000-750-02 Torque screwdriver testing kit 2000-260-0 Tensiometer testing kit 2000-261-0 Force (tension) gauge kit 2000-262-0 Force (compression) gauge kit 2000-263-02 Force arm kit 900-0 Joint rate
Accessories Calibration Accessories Calibration of the 2000-810-01 Indicator and MULTITEST series transducers is recommended at least every 1 year. Component 2000-250-02 2000-250-0 2000-150-01 2000-152-3 2000-221-0 2000-154-8 Description Drawer-Cutout Calibration stand kit Stand Transducer mounting block 3/8" Square drive adaptor 1-1/4" Square drive adaptor 1-1/4" - 3/4" Drive reducer 7E 7E 7E 200 in oz - 2000 ft lb arm and weight set 2000-320-0 200 in.oz - 2000 ft-lb weight set Weights 2500-310-1 0.
Accessories Component Description 200 in oz - 250 ft lb arm and weight set 2000-321-0 Weights 2000-310-1 2500-310-1 2500-310-5 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 Drawer-Cutout 200 in oz - 250 ft lb weight set 0.2 oz Hook (1) 0.3 oz Hook (1) 0.
