CDI Torque SURETEST AND 600TL Torque Calibration System User Manual

SURETEST AND 600TL

Model 5000-3

Torque Calibration System

USER’S MANUAL

TABLE OF CONTENTS

Safety Information I

Introduction 1-1

Functional Description and Specifications 2-1

Functional Descriptions 2-1
SURETEST Torque Calibration System 2-1
Base Unit 2-2

• Front Panel 2-2

• Rear Panel (Input/Output) 2-9

Torque Transducers 2-11
Specifications 2-12
SURETEST Torque Calibration System 2-12

• SURETEST Base Unit 2-12

• Transducers 2-13

• 600TL (LOADER) 2-14

Setup and Programming 3-1
SURETEST Torque Calibration System Setup 3-1

Back panel connections 3-1
Setting Up the SURETEST System 3-2
SURETEST Base Unit Controls 3-3
Powering the Equipment 3-3
Transducer Select 3-4
Programming Setup 3-5

• Setting up Date and Time 3-5

• Setting Up High and Low Limits Alert 3-5

• Programming AUTO Settings 3-6

DATA LIST Memory 3-7

• Clear single memory location 3-8

• Clear all memory location 3-8

Setting Up Printer/PC Ports 3-8

Torque Calibration System Setup 4-1
Testing Torque Wrenches and Drivers 4-1
Selecting a Transducer 4-1
Installing a Transducer 4-1
Dial and Bending Beam Torque Wrenches and Screwdrivers 4-2
Adjustable or Preset “Click” Wrenches and Screwdrivers 4-3
Testing Power Tools 4-4
Non-Impact Tools 4-4
Statistical Analysis 4-7

• Displaying Statistical Analysis on LCD 4-7

• Printing Statistical Analysis 4-8

Displaying or Downloading Data List 4-10
How to Use Analog Output (Rear Panel BNC Connector) 4-11

Calibration 5-1
Mounting Details 5-1
Quick Check 5-4
Torque Transducer Calibration 5-7

TABLE OF CONTENTS 1

SURETEST Base Unit Calibration 5-11
Gravitational Effects 5-14
Correction Factors on Test Weights 5-14
Gravitational Charts 5-15

600TL Manual Loader 6-1
Application 6-1
Torque Tester/Calibrator 6-2
Types of Loader Testing 6-5

• Torque Driver Testing 6-5

Accessories A-1
SURETEST System Components and Inventory Control A-1

Optional Transducers and Accessories A-2
Calibration Accessories A-4

TABLE OF CONTENTS 2

Using this Manual

This manual contains instructions for use and setup of the SURETEST 5000-3 Torque
Calibration System. A table of contents and a table of illustrations are provid ed 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.

Example:

For testing procedures refer to Chapter 4—Using the SURETEST 5000-3
System.

Equipment Damage

The possibility of damage to vehicle or equipment is introduced by a signal word
indicating this condition.

Example:

IMPORTANT

The connector on single transducer cables contains the EEPROM calibration memory
chip. Never attempt to remove the connector from the transducer. It is installed with a
permanent adhesive.

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: Danger, Warning and Caution.

TABLE OF CONTENTS 3

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.

The three-part message panel, used with safety messages, uses three different type styles
to further define the potential hazard:

• Normal type states the hazard,

• Bold type states how to avoid the hazard, and warning.

• Italic type states the possible consequences of not avoiding the hazard.

Some safety messages contain visual symbols with signal words.

Example:

WARNING

Flying particles can discharge when applying torque.

• Users and bystanders must wear safety goggles.

• Always wear safety goggles when applying torque.

Flying particles can cause injury.

TABLE OF CONTENTS 4

SAFETY INFORMATION

Safety Information

Important Safety Instructions

This manual contains important safety and operating instructions for CDI 5000-3 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 contai n a si gnal word, a
three-part message.

The signal word indicates the level of hazard in a situation:

• Danger indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury to the operator or bystanders.

• Warning indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury to the operator or bystanders.

• Caution indicates a potentially hazardous situation which, if not avoided, may result in
moderate or minor injury to the operator or bystanders.

The three-part message uses three different type styles to further define the potential
hazard.

• Normal type states the hazard.

• Bold type states how to avoid the hazard.

• Italic type states the possible consequences of not avoiding the hazard.

SAVE THESE INSTRUCTIONS

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. Always turn on the indicator and loader

- I -

SAFETY INFORMATION

so the torque and load values are indicated on the display. The safety relays only work
when the power is on. Flying particles can cause injury.

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.
Entanglement can cause injury.

WARNING

Improper use can cause breakage.

• Read instructions before operating.

• Follow manufacturer’s instructions, safety precautions, and specifications when
operating tools. Broken equipment can cause injury.

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 5000-3 system matches or exceeds each application before

performing a procedure.

• Do not use the 5000-3 system if it makes unusual noises, has loose parts, or shows any
other sign of damage. Have repairs performed at a CDI Service Center before use.

• Do not use chipped, cracked, or damaged sockets and accessories.

• Do not remove any labels. Replace any damaged label.

• Follow good, professional tool practices:

** Pull on a wrench handle ** do not push ** and adjust stance to prevent a possible
fall.
** Do not use extensions, such as a pipe, on a wrench handle.

• When using ratchets, make sure the direction lever is fully engaged in the correct

position.

• Never attempt to test an impact tool on this instrument.

• Always position the 40" arm over the front of the stand as shown. Never extend the test

arm behind the stand. The stand will tip over when weights are applied.

• 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.

- II -

INTRODUCTION CHAPTER 1

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.

Used with precision torque transducers, the SURETEST provides high
speed monitoring of static or dynamic torque inputs. Torque transducers,
purchased separately, are available in ranges from 15-200 in.oz, to 200­2000 ft.lb. and provide system readings with an accuracy of ± 0.25% of
indicated value, or better. A special memory chip is built into each
torque transducer that identifies its range and maintains its calibration
between any other SURETEST with an accuracy of ± 0.5%. The
SURETEST and its transducers may be calibrated by using accessory
precision bars and certified weights.

All readout of torque in ft-lb, in-lb, in-oz, Nm, dNm, cNm, mkg as well
as calibration, statistical analysis and set-up functions are reported on a
versatile 1.5” x 5.5” graphic dot matrix Liquid Crystal Display (LCD).

Set-up and calibration programming is entered using easy-to-use front
panel membrane keys. The number of keys is kept to a minimum. In
addition, concise menus and graphic symbols are used to guide the user
through all set-ups and operations. 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 SEND functions can be set up
for automatic or manual operation.

The SURETEST stores and recalls up to 3000 torque readings and does
statistical analysis on them for downloading to printer or computer. The
statistical report (print out) includes a simple histogram for process
monitoring. True RS-232 serial printer and separate RS-232 computer
COM ports are at the back of the unit.

1-1

INTRODUCTION CHAPTER 1

The SURETEST operates directly from any AC power line between 100
VAC to 230 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. CDI Torque
Products makes no claims as to the suitability of this information for
diverse user applications.

1-2

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2

CHAPTER 2

Functional Description and Specifications

The CDI 5000-3 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 600TL bench top Mechanical
Loader.

Fig 2-1

Base Unit

The SURETEST monitors and displays the torque applied.

Transducer (Accessory)

The loader accepts all 2000 series single transducers directly. Use a 2000-500-02 adapter
kit to mount the 2000-400-02 4-in-1 transducer. For additional information refer to
Appendix A–Accessories.

Loader

Use the 600TL Manual Loader for testing and calibrating all torque wrenches, drivers,
torque multipliers, non-impact pneumatic and electric nut runners. Loader components
are:

• Safety Shield

• Hand Crank

• Transducer Mounting

2-1

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2

SURETEST BASE UNIT
Front Panel

Figure 2-2 SURETEST Front Panel

A- Membrane Function ( F1, F2, F3, F4, F5, F6 ), soft keys,
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.oz

G- Power: On/Off

H- Bar Graph: Each dot represents 10% of transducer full scale.

I- Torque Reading: Full 5-digit reading Plus Sign (for direction)

2-2

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2

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.

• The number of the present data memory location.

Front Panel Membrane Cursor and Function Keys

The SURETEST is supported by a powerful Graphic User Interface (GUI). Set up,
Command, or Control is done by selecting the appropriate Action Item on one of the
provided Menus. Front Panel Membrane Cursor and Functions keys are defined to guide
the User in selecting an Action Item.

There are 6 function (soft) keys:
indicated on the LCD.
To select an Action Item, the User simply presses a Function Key (F1-F6) to get to a
Menu, uses a Cursor Key to move to the Item, then hits ‘ENTER’ .

In addition to the
(←), Right (→). The GUI also provides Prompts to further assist the user in navigating

the Menus.

‘ENTER’ key, there are 4 Cursor Keys : Up (↑), Down (↓),, Left

F1 through F6. Their respective uses are clearly

Power Up Sequence

Upon power up, the SURETEST automatically performs Self-tests and displays the
results. Any detected non-functional hardware will be reported on th e LCD. If a 4-in-1
transducer is connected, the SURETEST performs ZEROTARE, then displays the
following default menu while continuously checking for any activity from an input
transducer :

The user can either press F1 to display previously collected data (if any) or enter Setup
Mode, F2. Any detected torque measurement will cause the SURETEST to enter
Measurements mode where the following menu is displayed:

2-3

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2

The SURETEST returns to the default menu from the measurements mode in the event there is no selection
/ input by the User for more than two minutes. 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. INTERNAL DIAGNOSTIC

11. ABOUT

1. Select Mode

Selects either TRACK, PEAK HOLD, FIRST PEAK, or POWER mode.

• TRACK : continually makes Torque Measurements.

• PEAK : makes Torque Measurement at the Highest Peak.

• 1.PEAK : makes Torque Measurement at the First Peak.

• POWER : makes Torque Measurement at the Highest Peak at a faster rate.

2. Select Unit

Selects the following Torque units on LCD display:
Nm, dNm, cNm, mkg, cmkg, ft. lb., in. lb., in. oz.

2-4

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2

3. Select Language

Selects either English, German (Deutsch), French (François), Spanish (Español).

4. Manufacturer’s Defaults:

Default: Min. Track 0.1% ; Min. Peak 1%.
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.

Selection: Automatic Clear, Automatic Store and Automatic Send data out (to RS-232 port).
Selection: Delay 9 seconds then clear the Display, Manual Store and Manual Send.

Selection: Automatic Clear, Automatic Store and Manual Send.

2-5

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2

6. Edit Limits

Sets up high torque limit preset. (-->) (F4) to go Down 1 line.
Sets up low torque limit preset. (<--) (F5) 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’ (F2) to activate the change. Press ‘Clear” (F1) to Clear All Limit set-up.
Press ‘Escape’ (F3) to Exit. Last setup is retained.

7. Clock Adjust

Edits DATE/TIME programming function.

To adjust the Clock, use Left (←) or Right (→) cursor key to get to Day, Month, Year, Hour,
Minute, or Second field. Then use Up (↑), Down (↓), cursor key to increment or decrement the
respective value.
Press and hold the cursor key to change the value quickly.

Press ‘ENTER’ to activate the change.

8. Calibration

This enables the User to perform calibration of the SURETEST base unit and transducers.
(Refer to chapter 5).

2-6

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2

9. Edit Parameters

Sets up serial communications protocol.
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. Internal Diagnostic

For Manufacturer’s use only.

11. About

This provides relevant information regarding the Manufacturer, the software version, and the serial
number of the SURETEST device.

12. Other Features:

Provides manual ZERO TARE.
Stores present measurement to memory (Data 0001 in the example below).

2-7

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2

Sets up memory clear options in RECALL mode.
Recalls memory data to display.

Format (F3) calls Statistical analysis to display.

Send (F4). Send data to printer.

Sends all memory data, statistical analysis and histogram to printer port.
Sends data list with or without date-time stamp to computer / printer.

Manually clears display in PEAK, FIRST PEAK, POWER TOOL modes.

2-8

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2

SURETEST BASE UNIT
Rear Panel (Input/Output)

Figure 2-3 SURETEST Rear Panel

A - Solenoid Control (Hirose RM15TRD-12S)

(for use with optional 2000-600-02 Loaders)

PIN FUNCTION
10 Loader Relay Common
11 Loader Relay CCW Limit
12 Loader Relay CW Limit

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. Maximum load = 5 mA.

When using the 4-in-1 transducer, zero outpu t flu ctuates until one of the transducers is scan
selected by applying 5% of full scale torque.

C - Foot Pedal Switch Input

(used to send output to printer)

D - Fuse Holder

Use AC fuse at specified rating only. ( 3.15 Amp).

E - Input AC Voltage

Automatic Selection of any AC voltage from 100VAC to 230VAC, 50-60 Hz, 50 W.

2-9

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2

F- PRINTER PORT (DB-9P)

PIN FUNCTION
2 Receive
3 Transmit
5 Ground

G- OPTIONAL (DB-9P)

PIN FUNCTION
2 Receive
3 Transmit
5 Ground

H- TRANSDUCER INPUT (DB-37S)

PIN FUNCTION
1 not used
2 ground
3 smart chip - bit 2
4 smart chip - bit 0
5 single xducer (-) signal
6 single xducer (+) signal
7 ground
8 4-in-1 xducer (-) signal 2
9 4-in-1 xducer (+) signal 2
10 ground
11 4-in-1 xducer (-) signal 4
12 4-in-1 xducer (+) signal 4
13 4-in-1 xducer LED 2
14 4-in-1 xducer LED 4
15 loader relay CW limit
16 not used
17 not used
18 ground
19 bridge excitation (+3V)
20 not used
21 smart chip - bit 3
22 smart chip - bit 1
23 ground
24 ground
25 4-in-1 xducer (-) signal 1
26 4-in-1 xducer (+) signal 1
27 ground
28 4-in-1 xducer (-) signal 3
29 4-in-1 xducer (+) signal 3
30 no transducer
31 4-in-1 xducer LED 1
32 4-in-1 xducer LED 3
33 loader relay CCW limit
34 loader relay common
35 Vcc (
36 ground
37 bridge excitation (+3V)

+5V@100 ma. max)

2-10

FUNCTIONAL DESCRIPTION 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. For additional information, refer to Chapter 5—Calibration.
After a transducer is calibrated, it provides ±0.5% system accuracy with any SURETEST
System. If the transducer and SURETEST are calibrated together, the system accuracy
increases to ±0.25%.

Transducer Dimensions/Transducer Torque Range

(Refer to table on page 2-13).

Display Resolution for Transducers

Calibration also results in a specified display resolution on the SURETEST. Display
resolution is dependent on the type of transducer being used. Display resolutions for the
specified transducer are shown on page 2-14.

SURETEST torque transducers can withstand an overload of 110% of full range. The
SURETEST alarms, (audible beep and display “OVER” ) at 110% of rated capacity.

To protect the tool under test or to serve as a fastener installation torque preset alert, the
SURETEST produces a constant audible tone when the input torque exceeds the SET
LOW limit. It then produces a pulsating tone when the input torque exceeds the SET
HIGH limit.
The SURETEST Base Unit ignores inputs less than 0.1% of full range in TRACK mode,
1% in PEAK HOLD mode, 7% in FIRST PEAK and POWER TOOL modes.
With the 4-in-1 transducers, the SURETEST System ignores inputs less than 1% of full
range after scan select.

2-11

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2

Specifications

SURETEST TORQUE CALIBRATION SYSTEM Specifications

System Accuracy

±0.25% of reading @ 25°C with SURETEST Base Unit and transducer calibrated together.

(SURETEST Transducers used with, but not calibrated to, another SURETEST Base Unit provide a
system accuracy of ±0.5% of reading @ 25°C.

Temperature Drift +0.03%/°C (+0.017%/°F).

Display

5.5” X 1.5” backlighted LCD graphics display, 240x64 dot matrix., 0.67” torque digits character
height.

Display Capacity

16 bit A/D, 5 digits ±32,000 counts. Sample rate, 2000 sample/sec., display rate 5 updates/sec.
Refer to transducer range & resolution charts on page 2-13 and 2-14.

Language Select
English, German, French and Spanish.

Bar Graph
Zero to transducer full-scale. Resolution, 10 major divisions, 100 minor divisions.

Units of measure

Ft. lb., in. lb., in. oz., Nm, dNm, cNm, mkg, cmkg.

(Refer to transducer range and resolutions charts on pages 2-13 and 2-14.

Measurement Modes

Track, Peak Hold, First Peak, Power Tool.

Keypad

Sealed membrane keypad with audible feedback featuring “Softkey” user interface.
Features: Zerotare; Mode, Units and Language select; High and Low limits setup; Auto Store,
Clear and Send select; Clock adjust; Calibration; and RS232 programming.

Data Storage/Recall with Date-Time Stamp.

3,000 measurements
Remote contact, (optional foot pedal) manual send to printer.

Statistical Analysis

Max, Min, Range, Mean, Sigma N, Sigma, Cp, Cpk, %Error, Go, Nogo, Printout Histogram.

Serial Output Ports
Printer, RS232 True, 300-19.2k Baud, 8 data bit, 1 stop bit, no parity, (default 9600 Baud).
Optional Computer COM port, as above, (default 19.2k Baud).

Analog Output

+(CW), -(CCW) 1.8V at transducer full range. Linearity ±1% of reading, ±100mV zero offset.

Loader Control Relays

Two, normally open, from rated 12VDC@1/2A close contact at 110% CW or CCW of torque

transducer range, and release at 105% (open contact). (For use with optional 2000600 Manual
Loader)

2-12

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2

Power Requirements

100-230 VAC, 50-60 HZ, 50 W, automatic voltage selection. Fused at 3.15 A.

Environmental

Operating Temperature: 10-32ºC, ( 50 to 90ºF)
Storage Temperature: -20-50ºC, (-2 to 122ºF)
Temperature Drift: +0.011%/ºC, (0.006%/ºF)
Humidity: up to 85% non-condensing

Weight

8.4 lbs.

Dimensions

11.0” Wide, 4.5” High, 13.0” Deep with handle/bail

TRANSDUCER Specifications

Accuracy

±0.2% of reading @ 25ºC, within specified range, when used as prescribed with the 600TL.

RANGE AND DIMENSIONS

STOCK No. TORQUE RANGE DRIVE
2000-4-02 5-50 in.oz. ¼ “ Ext.
2000-5-02 15-200 in.oz. ¼ “ Ext.
2000-6-02 4-50 in.lb. ¼ “ Ext.

2000-65-02 15-150 in.lb. ¼ “ Ext.

2000-7-02 30-400 in.lb. 3/8”Ext.

2000-8-02 80-1000 in.lb. 3/8”Ext.
2000-10-02 10-125 ft.lb. ½” Ext.
2000-11-02 20-250 ft.lb. ½” Ext.
2000-12-02 60-600 ft.lb. ¾” Ext
2000-13-02 100-1000 ft.lb. 1” Internal
2000-14-02 200-2000 ft.lb. 1” Internal

2000-400-02

4 –in- 1

Environmental

Operating Temperature: 10-32ºC, ( 50 to 90ºF)
Storage Temperature: -20-50ºC, (-2 to 122ºF)
Temperature Drift: +0.02%/ºC, (0.011%/ºF)
Humidity: up to 90% non-condensing

4-50 in.lb. ¼ “ Ext

30-400 in.lb. 3/8”Ext.

80-1000 in.lb. 3/8”Ext.

20-250 ft.lb. ½” Ext.

2-13

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2

SURETEST

mkg cmkg ft. lb. in. lb. in. oz. Nm dNm cNm

2000-4-02
2000-5-02
2000-6-02
2000-65-02
2000-7-02
2000-8-02
2000-10-02
2000-11-02
2000-12-02
2000-13-02
2000-14-02

2000-400-02

600TL Loader Specifications

Input torque (Hand crank)
6 ft. lb. maximum

Output torque

600 ft. lb. maximum
30º Rotation

Dimensions

Weight

65 lbs.

Optional Calibration Fixturing (load arms and weights)
±0.05% accuracy

.00001 .0007 .00005 .0006 .01 .00007 .0007 .007
.00003 .003 .0002 .002 .04 .0003 .003 .03
.0001 .01 .0008 .01 .2 .0011 .011 .11
.0003 .03 .002 .03 .5 .003 .03 .3
.001 .1 .006 .08 1.2 .009 .09 .9
.002 .2 .016 .2 3.2 .02 .2 2
.004 .4 .03 .3 5 .03 .3 3
.007 .7 .05 .6 10 .07 .7 7
.016 1.6 .12 1.4 n/a .16 1.6 16
.03 3 .2 3 n/a .3 2.7 n/a
.05 5 .4 5 n/a .5 5 n/a

.0001 .01 .0008 .01 .2 .001 .03 .3
.001 .1 .006 .08 1.2 .009 .09 .9
.002 .2 .016 .2 3.2 .02 .2 2
.007 .7 .05 .6 10 .07 .7 7

48.1” wide (with deflection beam fully extended), 26” high (with SURETEST on bracket), 29”
deep (from crank handle open with SURETEST on bracket)

Transducer/Display Resolution

2-14

SETUP AND PROGRAMMING CHAPTER 3

CHAPTER 3

SETUP AND PROGRAMMING

CDI 5000-3 TORQUE CALIBRATION SYSTEM SETUP

Figure 3-1: CDI 5000-3 Torque Tester/Calibrator/Loader Setup

Back panel connections

A - 600TL Manual Loader
B - SURETEST Base unit
C - Smart 4-in-1 Transducer & Bracket adaptor
D - Transducer cable
E - Smart Single Transducer
F - Analog Output
G - Foot pedal switch
H - Power cables (100/230 VAC)
I - Printer cable
J - Personal computer cable

Note: Cable (J) is connected to the Optional Port for software upgrades only.

3-1

SETUP AND PROGRAMMING CHAPTER 3

Setting Up the CDI 5000-3 Torque Calibration System

1. Bolt the loader to a sturdy location.

2. Install Pivot tube, Extension arm and Bracket. Adjust to desired position then lock using three
setscrews shown on Fig. 3-2.

3. Install the SURETEST unit to the bracket and lock the unit using the two side knobs.

4. Install slide assembly (2100-0018), then lock using the side knobs as shown on Fig. 3-3.

5. Install the appropriate transducer or standoff (for 4-in-1) to the loader drive.

6. Install two quick release pins, part number 2000-195-13.

7. For 4-in-1 unit, install 4-in-1 bracket (2000-500-02) to the standoff as shown of Fig. 3-3 and
insert two quick release pins (2000-195-13). Slide 4-in-1 (2000-400-02) on the bracket and
align the selected transducer over the loader drive. Tighten the left knob first, then the top
knob.

Note: To use the two small transducers, remove the 4-in-1, rotate 180 degrees, and reinsert.

8. Connect the transducer cable, part number 2000-900-120, between the SURETEST and
transducer.

9. Install the safety shield to the front of the 600TL.

10. Pull Extension tube (to test wrench with extension) as shown on Fig. 3-2 until lock pins snap.

For testing procedures refer to Chapter 4—Using the Torque Tester.

3-2

SETUP AND PROGRAMMING CHAPTER 3

SURETEST Base Unit Controls

Refer to the illustration below when performing the power-up and prog r amming procedures.

Figure 3-5: SURETEST Controls

– SURETEST Graphic 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 a self-test and momentarily displays the results on

the display.

• With no transducer installed, the display then reads:

• When a

power is on, the display momentarily reads:

Zerotare prompt

3-3

pplying power with the transducer connected, or when connecting a transducer while the

SETUP AND PROGRAMMING CHAPTER 3

4-in-1 Transducer Installation

When a 4-in-1 transducer is installed, the following is displayed:

The Engineering Unit are in. lb.

The Engineering Unit are ft. lb.

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, pr ess
ENTER(↵). The number of successful calibration checkpoints, (CCW, CW) is shown at the top right
for each transducer. Once selected, the display reads as show below.

NOTE: To return to the scan mode, press ENTER (↵).

Single Transducer Installation:

When a single transducer is installed, the following is disp layed:

The user can enter Setup mode then proceed to make torque measurements.

3-4

SETUP AND PROGRAMMING CHAPTER 3

Setup Programming

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 (→) (Up (↑) or Down (↓) Cursor to select (reverse video)
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.

(day to month to year and seconds to minutes to hours will roll over but not back)

5. Press ENTER (↵) to update date and time and to return to measurements mode.

Setting Up High and Low Limits Alert

Use HIGH and LOW Limits Alert to protect the tool under test or serve as a fastener
installation torque preset alert. The SURETEST produces a constant audible tone when
the input torque exceeds the LOW limit. It then produces a pulsating tone when the input
torque exceeds the HIGH limit.

It is necessary to program these limits if statistical analysis is to draw a histogram, whi ch
includes reporting out-of-limit parameters.

Changing transducers does not automatically change HIGH and LOW limits.

Setting High or Low Torque Limits

1. Press (Setup).

2. Scroll Down (↓) to select Edit limits.

The display reads:

3-5

SETUP AND PROGRAMMING CHAPTER 3

3. Press Enter (↵). The display reads:

4. Press --> (F5) or <-- (F6) to select High or Low 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 (↑) or

Down
(↓) cursor, respectively. Continue until all digits are set.

8. Press (Save) to save and to return to measurements mode.

Set-up AUTO Settings

Use AUTO Settings to program the CLEAR, STORE and SEND functions for
automatic or manual operation. Use these functions in PEAK HOLD, POWER TOOL
and FIRST PEAK modes to STORE torque measurements to memory, CLEAR the
display, and SEND the last measurement captured on the display to the printer or PC.
Auto STORE and SEND are initiated at either auto or delayed CLEAR operations.

Use the manual modes to:

• Store the present reading by pushing STORE, (F5) in all measurements modes.

• Clear a captured display by pushing CLEAR, (F6) in measurements modes.

• Send a measurement to the printer/port by pushing SEND, (F4) in measurements

modes.

Use the automatic modes to:

• Store the last measurement, and/or

• Send the last measurement to the printer/port by initiating the auto or delayed function.

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 input

STORE (F5) must be pressed manually to save the last reading. Auto CLEAR must be
selected to use auto STORE and auto SEND.

3-6

SETUP AND PROGRAMMING CHAPTER 3

To Program AUTO CLEAR, STORE, or SEND:

1. Press (Setup).

2. 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 characters 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.

STORE, press Up (↑) or Down (↓) cursor to select "man" (manual) or "auto"

(automatic).

SEND, press Up (↑) or Down (↓) cursor to select "man" (manual) or "auto"
(automatic).

5. Press ENTER (↵) to save ‘Auto settings’ and to return to measurements mode.

DATA LIST Memory

When changing sensors, 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.

3-7

SETUP AND PROGRAMMING CHAPTER 3

Clear Single Memory Location

Use the procedure in this section to clear a single memory location.

1. Press (Data) (F1) to enter data list display. The display reads:

2. The units and present memory location are given on the top line. The total number
of memory locations are to the right -- separated by a forward slash (/). The bar
graph to the right of the data list ind icates how far in th e list the current data d isplay
is positioned. Use the Up (↑) or Down (↓) Cursor to select data.

+018.82 in.lb., Time: 09:46 Date: July 01, 1999 ; Location 9 of 11

3. Press (DEL 1) (F5) to delete one data entry (reverse video).

The display automatically updates, (decrements by one) the total memory locations
on the top line.

Clear All Memory Locations

Use the same above procedure for single memory location. Press (Clear) (F6) to

clear

all memory locations. The following warning appears:

Select “Yes” to clear all memory.

An audible alarm sounds momentarily. The SURETEST automatically returns to
measurements mode.

Setting Up Printer Port

The SURETEST is equipped with two RS-232 serial communications ports for use with
an external printer or personal computer. The transfer rate is programmable (for printer
port only) from 300 to 19.2K baud rate with 8 data bits, 1 stop bit and no parity. The
recommended default is 19200 baud for Optional Port and 9600 for Serial Printer.

Communication setup as: (300 – 19200), 8 Data bits, 1 Stop Bit, No Parity

Connect the Printer port to a computer or printer. All (serial) communications will take
place under User’s command(s) Edit Parameters set-up mode.

3-8

SETUP AND PROGRAMMING CHAPTER 3

1. Press Setup

2. Scroll Down (↓) to select Edit Parameters

3. Press Enter (↵) the display read:

4. Press --> (F4) and <-- (F5) keys to select parameter to change.

5. Use Left (←) and Right (→) cursors to select digit to change.

6. Use Up (↑) or Down (↓) cursors to increment or decrement digit.

7. Press Enter (↵) to accept changes and return to measurements mode.

3-9

TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4

CHAPTER 4

CDI 5000-3 TORQUE CALIBRATION SYSTEM SETUP

This chapter contains information on how to test, measure, and use the CDI 5000-3
Torque Calibration System.

Testing Torque Wrenches and Drivers

To use the CDI 5000-3 Torque Calibration System for torque wrench testing, a
transducer of the appropriate range is fitted to the 600TL Manual Loader.
The Loader provides a stop that holds the torque wrench handle fixed and rotates the
transducer under the wrench drive. The system applies a precise, monitored torque to the
wrench. For additional information refer to Chapter 6 600TL Manual Loader.

Selecting a Transducer

When selecting a transducer, choose a single transducer that covers the low to high-end
capacity of the torque wrench. Although possible, it is best not to change transducers
between calibration checkpoints. For example: to test or calibrate a 20 to 100 ft.lb.
wrench, use the 2000-10-02 transducer, which covers the range between 10 and 125 ft. lb.

Installing a Transducer

Install the transducer by lining up the red mark with the “TORQUE” label on the loader.
For additional information refer to 600TL Manual Loader.

• When changing or replacing transducers, adjust HIGH and LOW limits to remain

within the capacity of the tool under test. For additional information refer to Chapter 3
Setting Up High and Low Limits Alert.

• If you must retain the statistical analysis, do not change HIGH and LOW limits after

changing the transducers and be careful not to exceed the wrench capacity.

The procedures provided in this manual are general. You may use or establish your own
testing procedures, techniques or standards.

4-1

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 to
use HIGH and LOW limit alert, data STORE, display CLEAR, printer SEND and
STATistical analysis features.

2. Press Setup then Select Unit to select the desired engineering unit of measure on the
display. It is easiest to match that of the tool under test.

3. Press Setup then Select Mode to select TRACK mode.

4. Install the tool onto the torque transducer-loader. Slowly apply clockwise (CW) torque
using the Loader crank handle until the indicator d isplays the full scale torque for the
tool. Release the torque and repeat twice again to exercise the tool and the transducer.

When applying torque by hand, make sure to hold the drive end of the tool perfectly in
line with the transducer drive to minimize side loading errors.

5. Remove the tool from the transducer-loader and press Zerotare.

6. Press Setup then Select Mode to select PEAK HOLD mode.

7. Reinstall the tool and slowly apply CW torque to the first checkpoint or calibration point
recommended by the manufacturer. If the point is not specified, use the desired working
torque or about 70% of full scale.

8. Read the tool display. The percentage difference between the SURETEST and tool
readings should not be greater than the sum of their respective accuracies.

Example:

When tool accuracy is 4% and SURETEST System accuracy is 0.25%, readings should
be within ±4.25%.

9. Release the torque, CLEAR the 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’s full scale.

10. Repeat steps 4 through 9 in the counter clockwise (CCW) direction.

4-2

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.

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 to
use HIGH and LOW limit alert, data STORE, display CLEAR, printer SEND and
STATistical analysis features.

2. Press Setup (F3) then Select Unit to select the desired engineering unit of measure as
displayed on the display. It is easiest to match that of the tool under test.

3. Press Setup Select Mode to select TRACK mode.

4. Adjust the tool for maximum “click” setting. Install the tool on the torque transducer­loader. Slowly apply torque using th e loader crank handle until the tool clicks or the
SURETEST displays 100% of the full-scale capacity for the tool. Release the torque and
repeat twice again to exercise the tool and the transducer.

When applying torque by hand, make sure to hold the drive end of the tool perfectly in
line with the transducer drive to minimize side loading errors.

5. Remove the tool from the transducer-loader and press Zerotare.

6. Press Setup then MODE to select FIRST PEAK mode.

When testing “click” screwdrivers, it may be easier to use the PEAK HOLD mode on
the SURETEST to capture the maximum applied torque reading.

7. If featured, adjust the micrometer or preset knob on the tool to the first check point
recommended by the manufacturer, or the desired working torque, or approximately 70%
of its full scale torque.

8. Reinstall the tool and apply torque until the wrench “clicks.”

9. Release the torque and note the FIRST PEAK or PEAK HOLD reading. The
percentage difference between the SURETEST reading and tool setting should not be
greater than the sum of their respective accuracies.

Example:

When the tool accuracy is 4%, and the SURETEST accuracy is 0.25%, then readings
should be within ±4.25%.).

10. CLEAR the display and reapply torque for each of the remaining checkpoints
recommended by the tool manufacture. If no recommendation is available, test at
minimum torque, 60% and 100% of full scale.

11. Repeat steps 4 through 10 in the opposite direction, if required.

4-3

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. The difference is also due to individual
fastener installation characteristics that exhibit anywhere from a gradually increasing run­down torque, (soft-joint) to a free speed, sudden dead stop, (hard-joint). The way in
which a particular operator responds to the tool’s reaction forces can also be reflected in
the resulting torque measurements.

A joint rate simulator is required when testing a power tool to allow start-up rotation of
the tool’s armature. The simulator is experimentally adjusted to replicate the average
joint hardness of the intended work. Joint rate simulators that may be used with
transducers ranging from 50 in lb to 1000 in lb are:

• 50 in. lb. max, part number 900-0-01KIT

• 400 in. lb. max, part number 900-2-01KIT

• 1000 in. lb. max, part number 900-3-01KIT

Be sure to operate any pneumatic or electrical power tool according to the manufacturer’s
recommendations.

Non-Impact Tools

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 to
use HIGH and LOW limit alert, data STORE, display CLEAR, printer SEND and
STATistical analysis features.

2. Press Setup (F3) then select UNIT to select the desired engineering unit of measure as
displayed on the LCD display. It is easiest to match that of the tool under test.

3. Press Setup (F3) then MODE to select TRACK mode.

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 SURETEST 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.

4-4

TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4

Figure 4-1: Power Tool Test Setup

A - Power Tool
B - Joint Rate Simulator
C - 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. Repeat steps 7 through 9 twice again to exercise the tool-simulator assembly and the
SURETEST transducer.

11. Remove the power tool from the loader-transducer and press Zerotare.

12. Press Select Mode to select POWER (TOOL) mode.

13. While holding the power tool drive perfectly in-line with the transducer drive, reinstall
the tool onto the simulator and energize the to ol until its motor stalls or, if featured, the

4-5

TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4

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.

Given the variables typical of power tools and fastener joint dynamics, a number of
readings should be taken and averaged to best determine the accuracy and repeatability
for each tool.

4-6

TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4

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 HIGH and LOW limits are established, draws a simple histogram of the
results. These features are very useful in statistical process control (SPC) management.
Statistical analysis can be previewed on the display or sent directly to a printer/computer
port. For additional information on setting up printer or PC ports, refer to Chapter 3—Set
Up and Programming in this manual.

Displaying Statistical Analysis

1. Press Data (F1) select Transducer screen (F2) from measurements mode.
Then Format (F3).

2. Repeatedly press Up or Down Cursor Key to scroll through the display as shown the
example below:

Figure 4-2: Statistical Analysis Display

3. Press Escape (F1) to return to measurements mode.

Note: The histogram is only available through the printer/computer port.

Value: 0009
Mean: 07.559 in-lb
Min: 06.768 in-lb
Max: 08.206 in-lb
Range: 01.437 in-lb
SigmaN 00.526 in-lb
Sigma 00.558 in-lb
Cp: 0.3287
Cpk 0.2636
%Err 33.333%

-NoGo 1
+NoGo 2

4-7

TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4

Printing Statistical Analysis

1. Press Data (F1) in select Transducer screen or (F2) in measurements mode.
then Press Format (F3).

2. Press Send (F4) to display the Print out menu.

Use Down (↓) key to select Send Statistics then press Enter (↵) to Print.
See example printout below.

3. Press Escape (F1) 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 : 251.55 in-lb

0001 254.45 in-lb
0002 253.91 in-lb
H0003 254.89 in-lb
0004 252.89 in-lb
0005 253.42 in-lb
0006 253.31 in-lb
0007 252.40 in-lb
0008 252.49 in-lb
0009 252.61 in-lb
L0010 251.49 in-lb

4-8

TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4

** R E S U L T **
Data : 0010
Max : 254.89 in-lb
Min : 251.49 in-lb
Range : 3.4039 in-lb
Mean : 253.19 in-lb
Sig.n : 0.9755 in-lb
Sigma : 1.0283 in-lb
Cp : 0.5348
Cpk : 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 251.88 in-lb<
C 252.20 in-lb<
D 252.53 in-lb<
E 252.86 in-lb<
F 253.20 in-lb<
G 253.53 in-lb<
H 253.85 in-lb<
I 254.19 in-lb<
J 254.51 in-lb<

254.85 in-lb

Figure 4-4: Sample Statistical Data Printout

4-9

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 (F1) in select Transducer screen or (F2) in measurements mode.

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. Torque readings are to the left of the Time
and Date. The last reading is highlighted.

3. Use Up (↑) or Down (↓) key to view the data list.

4. Press Escape (F1) to return to measurements mode.

Downloading Data List to Printer

1. Press Data (F1) from select Transducer screen or (F2) in measurements mode.

2. Press Send (F4).

The display reads:

Figure 4-5: Data Download Display.

3. To download the raw data list, select Send raw data then Press Enter (↵).

4. To download the data list plus date-time stamp, press Down (↓) to select
Send Data, time/date then press Enter (↵) to print.

5. Press Escape (F1) to return to measurements mode.

4-10

TORQUE CALIBRATION SYSTEM SETUP CHAPTER 4

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 +1.8 volts, full clockwise (C W) torque
applied and approximately -1.8 volts, full counter clockwise (CCW) torque
applied. Zero offset is within ±100 mv. Linearity is better than ±1% of
reading.

When used with the 4-in-1 transducer, zero output varies with the scan of the
four transducers. Select one of the four by applying at least 5% of its full range
torque to it. Press ENTER (↵) to return to scanning.

1. To program the SURETEST Base Unit, refer to Chapter 3—Set Up
and Programming., use HIGH and LOW limit alert, data STORE,
display CLEAR, printer SEND and STATistical analysis features.

2. Press Select Mode to select the TRACK mode.

3. Connect the recording or monitoring equipment to the ANALOG
OUTPUT port using a BNC coaxial connector.

4. With no torque applied, measure the ANALOG OUTPUT voltage and
adjust or program your equipment for zero.

5. Apply full range torque to the transducer in the CW direction.

6. Measure the ANALOG OUTPUT voltage and adjust or program your
equipment to display the full range torque value.

7. Apply full range torque to the transducer in the CCW direction.

8. Measure the ANALOG OUTPUT voltage and adjust or program your
equipment to display the full range torque value.

4-11

CALIBRATION CHAPTER 5

CHAPTER 5

CALIBRATION

The SURETEST Torque Calibration System is factory calibrated using precision torque
test arms, certified weights and laboratory grade equipment.

This chapter contains calibration instructions and information for the SURETEST System.

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. SURETEST series transducers must be positioned horizontally, with torque
applied within ±15 degrees of horizontal.

As shown in Figure 5.1, 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.

Figure 5-1: Single Low Torque Transducer Mounting Detail

5-1

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.

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 5-2.

Figure 5-2: Single High Torque Transducer Mounting Detail

The 2000-12-02, 600 ft lb transducer, requires the 1-1/4" to 3/4" drive reducer, supplied, to couple to
the 40" test bar.

5-2

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. Remove separated adapter 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 adapter plate using six 1/2"x13 hex head bolts, each torqued to 75 ft. lb.
using the torque wrench, and 3/4” open end adapter, supplied.

5. After calibration, re-install the internal drive plate and bottom plate using appropriate 1/2"x13
screws, torquing them to 75 ft lb. Also re-install the separated adapter to the calibration b lo ck.

Appropriate hangers and weights are listed in the calibration checkpoint table in this chapter.
Notice that the weight of the hanger is included in all measurements. The hanger must be removed
to set ZERO tare on the SURETEST Base Unit.

4-in-1 Transducer Mounting Detail for Calibration

The 4-in-1 transducer mounts upright with integral transducers in the horizontal position. This
transducer may be mounted to a

• Wall using four 1/4" bolts torqued to 10 ft. lb., or

• Sturdy table using a right angle bracket. Refer to Figure 5-3.

Figure 5-3: 4-in-1 Transducer Mounting Detail

5-3

CALIBRATION CHAPTER 5

The 4-in-1 transducer may also be mounted to the calibration stand, shown in Figure 5-1, using the
standoff fixture and bracket assembly. For this mounting configuration t he t wo sli de knobs must be
loosened and four 5/16-18 bolts attached to secure the 4-in-1 transducer to the bracket assembly.

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 SURETEST ON, select TRACK mode, and select the UNITs of measure appropriate to
the transducer as specified in the calibration checkpoint table in this chapter.

2. Install the transducer to be checked and allow a 5-minute warm up period to stabilize the electronic
circuits and transducer elements.

3. Transducers are mounted horizontally for calibration as instructed in Mounting Details in this
chapter. Mount the 4-in-1 transducer to a sturdy bench using the bracket provided. Mount single
transducers horizontally using the accessory stand and block. Attach the specified torque test bar,
wheel or butterfly, secured with its drive retention screw, and install the specified hanger for
clockwise (CW) torque application.

4. Apply and remove the full range torque for the transducer three times.

5. Remove the weights and hanger, but leave the arm attached, and press Zero (F1).

6. At each of the check points specified for the transducer in the calibration check point table (in this
chapter), apply torque in the CW direction and verify the display readings are within 0.25% of
applied torque. If any reading is out of specification, proceed to Calibrating SURETEST Torque
Transducers in this chapter.

7. Repeat Steps 3 through 6 in the counter clockwise (CCW) direction.

When using the 2-1/2" or 5" test wheel, a small “S” hook is supplied to provide a positive
zero bias in the direction (CW or CCW) that the calibration is performed. Do not remove
the “S” hook when setting zero tare.

5-4

CALIBRATION CHAPTER 5

Suggested Transducer Calibration Check Points, Bars, Hangers and Weights

(Sheet 1 of 2)

Part Bar Hanger Calibration Check Weights to Add Total
No. Range Length Weight Points Points (n) = more than 1 Weight

2000-4-02

5-50 in oz 2.5" none 1 5.0 in oz 5.0 in oz 2 oz 2 oz

2.5" none 2 10.0 in oz 10.0 in oz 4 oz 4 oz

2.5" 1/2 lb 3 20.0 in oz 20.0 in oz none 8 oz

2.5" 1/2 lb 4 30.0 in oz 30.0 in oz 4 oz 12 oz

2.5" 1/2 lb 5 50.0 in oz 50.0 in oz 4 oz, 1/2 lb 20 oz
2000-5-02

15-200 in oz 2.5" none 15.0 in oz 2 oz, 4 oz 6 oz

2.5" 1/2 lb 1 20.0 in oz 20.0 in oz none 1/2 lb

2.5" 1/2 lb 2 40.0 in oz 40.0 in oz 1/2 lb 1 lb

2.5" 1/2 lb 3 80.0 in oz 80.0 in oz 1/2 lb, 1 lb 2 lb

2.5" 1/2 lb 4 120.0 in oz 120.0 in oz 1/2 lb, (2) 1 lb 3 lb

2.5" 1/2 lb 5 200.0 in oz 200.0 in oz 1/2 lb, (2) 2 lb 5 lb

2000-6-02

4-50 in lb 5.0" 1/2 lb 4.0 in.lb 0.3 oz, 0.5 oz, 4 oz 0.8 lb

5.0" 1/2 lb 1 5.0 in lb 5.0 in lb 1/2 lb 1 lb

5.0" 1/2 lb 2 10.0 in lb 10.0 in lb 1/2 lb, 1 lb 2 lb

5.0" 1/2 lb 3 20.0 in lb 20.0 in lb 1/2 lb, 1 lb, 2 lb 4 lb

5.0" 1/2 lb 4 30.0 in lb 30.0 in lb 1/2 lb, 1 lb, (2) 2 lb 6 lb

5.0" 1/2 lb 5 50.0 in lb 50.0 in lb 1/2 lb, 1 lb, (4) 2 lb 10 lb

2000-65-02

15-150 in lb 5.0" 1/2 lb 1 15.0 in lb 15.0 in lb 1/2 lb, 2 lb 3 lb

5.0" 1/2 lb 2 30.0 in lb 30.0 in lb 1/2 lb, 1 lb, (2) 2 lb 6 lb

5.0" 1/2 lb 3 60.0 in lb 60.0 in lb 1/2 lb, 1 lb, (2) 5 lb 12 lb

5.0" 1/2 lb 4 90.0 in lb 90.0 in lb 1/2 lb, 2 lb, (3) 5 lb 18 lb

5.0" 1/2 lb 5 150.0 in lb 150.0 in lb 1/2 lb, (2) 2 lb, (5) 5 lb 30 lb

2000-7-02

30-400 in lb 10.0" 1/2 lb 30.0 in lb 1/2 lb, 2lb 3 lb

10.0" 1/2 lb 1 40.0 in lb 40.0 in lb 1/2 lb, 1 lb, 2 lb 4 lb

10.0" 1/2 lb 2 80.0 in lb 80.0 in lb 1/2 lb, 2 lb, 5 lb 8 lb

10.0" 1/2 lb 3 160.0 in lb 160.0 in lb 1/2 lb, (3) 5 lb 16 lb

10.0" 1/2 lb 4 240.0 in lb 240.0 in lb 1/2 lb, 1 lb, 2 lb, (4) 5 lb 24 lb

10.0" 1/2 lb 5 400.0 in lb 400.0 in lb 1/2 lb, 1 lb, (4) 2 lb, (6) 5 lb 40 lb

2000-8-02

80-1000 in lb 10.0" 7-1/2 lb 80.0 in lb 1/2 lb 8 lb

10.0" 7-1/2 lb 1 100.0 in lb 100.0 in lb 1/2 lb, 2 lb 10 lb

10.0" 7-1/2 lb 2 200.0 in lb 200.0 in lb 1/2 lb, 2 lb, (2)5 lb 20 lb

10.0" 7-1/2 lb 3 400.0 in lb 400.0 in lb 1/2 lb, 2 lb, (2)5 lb, (2)10 lb 40 lb

10.0" 7-1/2 lb 4 600.0 in lb 600.0 in lb 1/2 lb, 2 lb, (2)5 lb, (4)10 lb 60 lb

10.0" 7-1/2 lb 5 1000 in lb 1000 in lb 1/2 lb, 2 lb, (2)5 lb, (4)10 lb, (2)20 lb 100 lb

2000-10-02

10-125 ft lb 10.0" 7-1/2 lb 10 ft lb 1/2 lb, (2) 2 lb 12 lb

10.0" 15 lb 1 12.5 ft lb 12.5 ft lb none 15 lb

10.0" 15 lb 2 25.0 ft lb 25.0 ft lb (3) 5 lb 30 lb

10.0" 15 lb 3 50.0 ft lb 50.0 ft lb 5 lb, (2) 10 lb, 20 lb 60 lb

10.0" 15 lb 4 75.0 ft lb 75.0 ft lb (3) 5 lb, (2) 10 lb, (2) 20 lb 90 lb

10.0" 15 lb 5 125.0 ft lb 125.0 ft lb 5 lb, 10 lb, 20 lb, (2) 50 lb 150 lb

5-5

CALIBRATION CHAPTER 5

Suggested Transducer Calibration Check Points, Bars, Hangers and Weights

(Sheet 2 of 2)
Part Bar Hanger Calibration Check Weights to Add Total
No. Range Length Weight Points Points (n) = more than 1 Weight

2000-11-02

20-250 ft lb 10.0" 15 lb 20.0 ft lb (2) 2 lb, 5 lb 24 lb

10.0" 15 lb 1 25.0 ft lb 25.0 ft lb 5 lb, 10 lb 30 lb

10.0" 15 lb 2 50.0 ft. lb 50.0 ft. lb 5 lb, (2) 20 lb 60 lb

10.0" 15 lb 3 100.0 ft. lb 100.0 ft. lb 5 lb, (2) 50 lb 120 lb

10.0" 15 lb 4 150.0 ft. lb 150.0 ft. lb 5 lb, (3) 20 lb, (2) 50 lb 180 lb

10.0" 15 lb 5 250.0 ft. lb 250.0 ft. lb 5 lb, (4) 20 lb, (4) 50 lb 300 lb

2000-12-02

60-600 ft lb 40" 15 lb 1 60.0 ft lb 60.0 ft lb 1 lb, 2 lb 18 lb
40" 15 lb 2 120.0 ft lb 120.0 ft lb 1 lb, (2) 10 lb 36 lb
40" 15 lb 3 240.0 ft lb 240.0 ft lb 2 lb, 5 lb, 10 lb, (2) 20 lb 72 lb
40" 15 lb 4 360.0 ft lb 360.0 ft lb 1 lb, 2 lb, 10 lb, (4) 20 lb 108 lb
40" 15 lb 5 600.0 ft lb 600.0 ft lb 5 lb, (3) 20 lb, (2) 50 lb 180 lb

2000-400-02

4-50 in lb 5" 1/2 lb 4.0 in lb 0.3 oz, 0.5 oz, 4 oz 0.8 lb
(4-in-1) 5" 1/2 lb 1 5.0 in lb 5.0 in lb 1/2 lb 1 lb

5" 1/2 lb 2 10.0 in lb 10.0 in lb 1/2 lb, 1 lb 2 lb
5" 1/2 lb 3 20.0 in lb 20.0 in lb 1/2 lb, 1 lb, 2 lb 4 lb
5" 1/2 lb 4 30.0 in lb 30.0 in lb 1/2 lb, 1 lb, (2) 2 lb 6 lb
5" 1/2 lb 5 50.0 in lb 50.0 in lb 1/2 lb, 1 lb, (4) 2 lb 10 lb

30-400 in lb 10" 1/2 lb 30.0 in lb 1/2 lb, 2 lb 3 lb
10" 1/2 lb 1 40.0 in lb 40.0 in lb 1/2 lb, 1 lb, 2 lb 4 lb
10" 1/2 lb 2 80.0 in lb 80.0 in lb 1/2 lb, 1 lb, (3) 2 lb 8 lb
10" 1/2 lb 3 160.0 in lb 160.0 in lb 1/2 lb, (3) 5 lb 16 lb
10" 1/2 lb 4 240.0 in lb 240.0 in lb 1/2 lb,1 lb, 2 lb, (4) 5 lb 24 lb
10" 1/2 lb 5 400.0 in lb 400.0 in lb 1/2 lb,1 lb (4) 2 lb, (6) 5 lb 40 lb

80-1000 in lb 10" 7-1/2 lb 80.0 in lb 1/2 lb 8 lb
10" 7-1/2 lb 1 100.0 in lb 100.0 in lb 1/2 lb, 2 lb 10 lb
10" 7-1/2 lb 2 200.0 in lb 200.0 in lb 1/2 lb, 2 lb, (2)5 lb 20 lb
10" 7-1/2 lb 3 400.0 in lb 400.0 in lb 1/2 lb, 2 lb, (2)5 lb, (2)10 lb 40 lb
10" 7-1/2 lb 4 600.0 in lb 600.0 in lb 1/2 lb, 2 lb, (2)5 lb, (4)10 lb 60 lb
10" 7-1/2 lb 5 1000 in lb 1000 in lb 1/2 lb, 2 lb, (2)5 lb, (4)10 lb, (2)20 100 lb

20-250 ft lb 10" 15 lb 20.0 ft lb (2) 2 lb, 5 lb 24 lb
10" 15 lb 1 25.0 ft lb 25.0 ft lb 5 lb, 10 lb 30 lb
10" 15 lb 2 50.0 ft. lb 50.0 ft. lb 5 lb, (2) 20 lb 60 lb
10" 15 lb 3 100.0 ft. lb 100.0 ft. lb 5 lb, (2) 50 lb 120 lb
10" 15 lb 4 150.0 ft. lb 150.0 ft. lb 5 lb, (3) 20 lb, (2) 50 lb 180 lb
10" 15 lb 5 250.0 ft. lb 250.0 ft. lb 5 lb, (4) 20 lb, (4) 50 lb 300 lb

5-6

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 data is calculated and then stored in the FLASH memory chip of the transducer b y th e
microcontroller in the Indicator.

WARNING

Always be alert to the potential for personal injury and equipment damage that may be
caused by excessive torque applications, careless handling of heavy weights, and out-of­balance or unsafe weight distribution.

Equipment

• Precision test arms and certified calibration weights.

• Test stand.

Procedure

1. Turn the SURETEST ON. Refer to the calibration check point table in this chapter for the

transducer calibration check points, as well as the specified arms, hangers and weights.

2. Install the transducer being calibrated and allow a 5 minute warm up period to stabilize the

electronic circuits and transducer elements.

3. Mount the 4-in-1 transducer upright, drives horizontal, as shown in Figure 5-3, or mount

single transducers horizontally using the accessory stand and block as detailed in Figure 5-2.
Attach the specified torque arm, secured with the drive retention screw, and install the
specified hanger for clockwise (CW) torque application. Use the “S” hook on the 2-1/2" or 5" bars.

4. 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. Press Setup (F3).

5. Use Down (↓) Cursor key to select Calibration. Press ENTER (↵).

5-7

CALIBRATION CHAPTER 5

6. Enter the following code into the display using the Cu rsor Keys: 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 ‘

8. Using the Up (↑) or Down (↓) Cursor keys, enter “

or enter “4” for the 4-in-1 transducer.

9. Press ENTER (↵). The display reads:

Select transducer by applied torque on it, LED will lit.

Yes’. Press Enter (↵) .

1” for a single transducer,

5-8

CALIBRATION CHAPTER 5

Press Unit (F2) key and select the desired torque unit.

10. 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 torque to one of the transducers until “ Full Scale UNITS shows on display.

Note: Example graphics are for 50 in-lb transducer.

11. Press ENTER (↵).

12. Press any key to initiate Zerotare. The LCD displays:

then:

13. Apply torque using the precision arm, hanger or certified weights listed as calibration point 1 in the
calibration check point table in this chapter. When the reading is stable, push and hold the Up (↑) or Down
(↓) Cursor Keys to get the correct torque value reading. Repeat the procedure for points 2, 3, 4, and 5 of the
same table as shown below:

Apply 10% Torque = 5 in.lb

5-9

CALIBRATION CHAPTER 5

13. Press (Accept) to accept the calibration value (1

st

Cal point).

Apply 20% Torque = 10 in. lb.

14. Press (Accept) to accept the calibration value (2

nd

Cal point) .

Apply 40% Torque = 20 in. lb.

16. Press (Accept) to accept the calibration value (3

rd

Cal point) .

Apply 60% Torque = 30 in. lb.

17. Press (Accept) to accept the calibration value (4

th

Cal point) .

Apply 100% Torque = 50 in. lb.

18. Press (Accept) to accept the calibration value (5

th

Cal point) .

The display will show: Saving …. then show the Calibration table.

19. Remove all weights and the arm.
Press any key, go back to Select mode.

Calibration CCW:

(Go to step 7 then select CCW)

20. Select "Calibrate CCW” on the LCD display.

Apply and release full scale torque to the transducer three times in the CCW direction then
remove the weights and hanger, wait for about 15 seconds.

21. Repeat steps 12 through 19, applying all torque in the counter clockwise (CCW) direction.

5-10

CALIBRATION CHAPTER 5

22. All readings show minus sign (-). Press F1 twice to return to measurement mode.

SURETEST Base Unit 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 fixture as shown in Figure 5-2.

Figure 5-2. Calibration fixture

Procedure

1. With the power off, plug the calibration fixture into the TRANSDUCER INPUT
connector at the back of the SURETEST Base Unit.

2. Turn the power on. After initialization, the LCD display reads:

No Transducer Connected

3. Press Soft Key Setup (F3) to get to Setup Menu.

Use Down (↓) Cursor key to scroll down to Calibration Item.

Press ENTER (↵). The display reads:

5-11

CALIBRATION CHAPTER 5

4. Enter the following code into the display using th e Cursor Keys:
( Left (←), Right (→) to select digit ; Up (↑), Down (↓) = increment/decrement value ;

Enter (↵) to accept )

5111. Then press

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:

3.0211 volts

Program the measured voltage into the SURETEST Base Unit using the Cursor Keys. (Use Up (↑),
Down (↓), Left (←) and Right (→) Cursor Keys to match the SURETEST display to the millivolt­meter). Then Press ENTER (↵) to accept.

5. Next, the display reads:

Short pins 5 and 6 together on the calibration fixture. Then hit Enter (↵) key.

6. Next, the display reads:

Remove the short between pins 5 and 6 of the calibration fixture.

Using a laboratory millivolt meter, measure the voltage across pins 5 and 6.

5-12

CALIBRATION CHAPTER 5

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:

Saved.

9. Turn the power to OFF. Remove the calibration fixture.

5-13

CALIBRATION CHAPTER 5

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. After an analysis is made for a given location, it is often found that the
correction factor is insignificant.

Two methods of correction are provided. They are:

• Correction Factor For Check Point Readings adjusts the calibration readings without changing

the applied weight.

• Correction Factor For Weights adjusts the weight applied without changing check point readings.

For additional information refer to Gravitational Charts in this chapter.

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. Multiply the check point in the calibration charts by the factor calculated in step 4 to obtain the

corrected check point readings while using the original weight.

Correction Factor for Weights

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 980.665 cm/sec/sec.

5. Calculate the reverse of the calculation in step 4 by dividing it into 1.

6. Multiply the weight given for each checkpoint in the calibration charts by the inverse factor,

calculated in step 5, and use this corrected weight with the original check point readings.

5-14

CALIBRATION CHAPTER 5

Gravitational Charts

The charts in this section are taken from CRC Handbook of Chemistry and Physics, 58th Edition.
CRC Press, Inc., 18901 Cranswood Parkway. Cleveland, Ohio 44128.

Acceleration Due to Gravity for Sea Level at Various Latitudes

Latitude, degrees Acceleration, cm/sec2 Latitude, degrees Acceleration, cm/sec2
0 978.039 46 980.711

5 978.078 48 980.892

10 978.195 50 981.071

15 978.384 52 981.247

20 978.641 54 981.422

25 978.960 56 981.592

30 979.329 58 981.757

32 979.487 60 981.918

34 979.652 65 982.288

36 979.822 70 982.608

38 979.995 75 982.868

40 980.171 80 983.059

42 980.350 85 983.178

44 980.531 90 983.217

Free Air Correction for Altitude

Altitude, m Correction, cm/sec2

200 -0.0617
300 -0.0926
400 -0.1234
500 -0.1543
600 -0.1852
700 -0.2160
800 -0.2469
900 -0.2777

5-15

MANUAL LOADER CHAPTER 6

600TL - 600 ft. lb. Capacity

Manual Loader

The 600TL Manual Loader is designed as an integral component of the CDI 5000-3 Torque
Calibration System providing a precision output torque of up to 600 ft.lb.

Application

The loader is a laboratory grade instrument used for testing and calibrating all torque wrenches,
drivers and electric nut runners

Transducer Rotation

The manual hand crank provides up to 30° of transducer rotation in both clockwise (CW) and
counter clockwise (CCW) directions (±15° from mid-rotation).

CDI 5000-3 Torque Calibration System

Components included in System are:

• Base Unit (SURETEST)

• 600TL

• 2000-12-02, 600 ft.lb. transducer

• 2000-400-02, 4-in-1 transducers

• 2000-500-02 Adapter Kit

When the 600TL interfaces with the SURETEST unit and the 2000 series of torque transducers,
the SURETEST Torque Calibration system provides precision loading, monitoring and data
acquisition of torque, within ± 0.25% accuracy.

System capabilities include, data storage, retrieval, statistical analysis and automatic downloading
to a printer or computer.

Accessory Torque transducers, purchased separately, are available in ranges from 15-200 in. oz, to
200-2000 ft. lb. The CDI 5000-3 Torque Calibration system features accessory calibration
equipment including precision torque bars, certified weights, calibration mounts and stands.

6-1

MANUAL LOADER CHAPTER 6

Torque Tester/Calibrator

Figure 6-1: Installation multiple transducers

A- Quick release pin (Transducer)
B- 4-in-1 Transducer Standoff
C- 600TL (Manual Loader)
D- Side thumb screw
E- 4-in-1 Adapter Bracket
F- Multiple Transducers
G- Drive Adaptors
H- SURETEST
I- Top thumb screw
J- Tube, Load (Part of rest assembly)
K- Rest, Adjustable
L- Reaction Slide Assembly
M- Safety shield
N- Hand Crank
P- Extendable Reaction Bar
R- Linear Bearing Assembly

Quick Release Pins

Four quick release pins must be installed to lock the standoff to the adapter bracket and loader.

Slide thumb screw

Two knobs on the bracket are used to align the selected transducer over the loader drive. Tighten
the left knob first, then the top knob. The wrench or driver to be tested is then coupled to the
selected transducer using an internal-internal adapter.

4-in-1 Adapter Bracket

Holds the 4-in-1 transducer horizontal to the loader.

IMPORTANT

Adjustable rest on the load tube may be raised or lowered to level the wrench prior to
loading. It is normal for the wrench handle to rise as it levels itself under load.

6-2

MANUAL LOADER CHAPTER 6

Drive Adaptor

A drive adaptor couples the wrench to the transducer. Low torque 2000 series transducers use an internal­internal drive adaptor and high torque SURETEST transducers may use an adaptor/reducer.

Transducer (Accessory)

The loader accepts 2000 series single transducers directly. The 2000-400-02 4-in-1 transducer can be
mounted using a 2000-500-02 adaptor kit. For more information, refer to Appendix A–Accessories.

Multiple Transducer - Mounting

Multiple Transducers (2000-400-02) must be installed into the loader using a 4 in 1 Transducer Standoff
(B) and a 4 in 1 Adapter Bracket (E) as shown in Fig.6-1 and 6-2. Each transducer must be properl y al i gned
before use. The transducer is properly aligned when the square drive of the transducer is approximately in
line with the extendable reaction bar ( P). For easier alignment use the marked lines on the 4 in 1 Adapter
Bracket as a guide. Aligning the top edge of the Multiple Transducer with each marked line on the 4 in 1
Adapter Bracket, provides proper alignment for each transducer. When aligning the 50 in. lb. transducer,
the 4 in 1 Adapter Bracket, together with the Multiple Transducer, must be rotated in the 4 in 1 Transducer
Standoff (B) for 180 degrees prior to alignment, to avoid interference with the Safety Shield (M).

Reaction Slide Assembly ( R )

The Linear Bearing Assembly is to be used over the reaction pins for wrenches that are more sensitive to
side loading (some electronic type wrenches) and for wrenches that can not be fully loaded if supported just
on the reaction pin (fixed head dial type torque wrenches).

Extendable Reaction Bar (P)

The Reaction Bar can be extended to accommodate wrenches up to 43 inches long.
There are two lock positions for the slide bar. Only the first one is to be used for testing. The last lock
position is just a safety stop before slide bar completely disengages from the loader.

6-3

MANUAL LOADER CHAPTER 6

Figure 6-2 Set up for Dial indicating, Deflection Beam and Micro-Adjustable Torque Wrenches.

1- 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 and securing it using two quick release pins.

IMPORTANT

The connector on single transducer cables contains the EEPROM calibration memory
chip. Never attempt to remove the connector from the transducer.

2- Hand Crank

Turn hand crank on the loader to apply torque.

3- Reaction Slide Assembly’s

The reaction slide is positioned so that the reaction pins straddle the wrench handle at the hand
hold position specified on the wrench.

6-4

MANUAL LOADER CHAPTER 6

Types of Loader Testing
Torque Driver Testing

An optional torque screwdriver testing kit, 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 600TL 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. Double check to be sure that the transducer you
choose is capable of handling the maximum torque that you will apply. Hold the tool exactly in
line with the transducer drive while testing. Off-axis side loading may compromise the test or
calibration of the tool.

6-5

ACCESSORIES APPENDIX A

Appendix A

Accessories, included

SURETEST 5000-3 Torque Calibration System Components

Component Description

5000-ST SURETEST Digital Monitor

600TL Manual torque loader

2000-12-02

2000-400-02 4-in-1 transducer kit

Multiple transdu cer
1/4" ext. drive, 4-50 in. lb.
3/8" ext. drive, 30-400 in. lb.
3/8" ext. drive, 80-1000 in. lb.
1/2" ext. drive, 20-250 ft. lb.
342-40 1/4" internal adaptor
342-41-1 1/4"–3/8" internal adaptor
342-41-2 3/8" internal adaptor
65-26-3 1/2" internal adaptor
343-25 Right angle mounting bracket

2000-500-02 4-in-1 transducer adaptor kit

2000-195-13 Quick release pin (2)

S/343-500-0 Bracket assembly

S/343-50-2 Standoff fixture

¾” - 60 - 600 ft. lb. transducer with socket

A-1

ACCESSORIES APPENDIX A

Appendix A

Accessories, optional

Component Description

2000-4-02 1/4" ext. drive 5 – 50 in. oz. Transducer with socket

2000-5-02 1/4" ext. drive 15 - 200 in. oz. Transducer with socket

2000-6-02 1/4" ext. drive 4 -50 in. lb. Transducer with socket

2000-65-02 1/4" ext. drive 15 - 150 in. lb. Transducer with socket

2000-7-02 3/8" ext. drive 30 - 400 in. lb. Transducer with socket

2000-8-02 3/8" ext. drive 80 - 1000 in. lb. Transducer with socket

2000-10-02 1/2" ext. drive 10 - 125 ft. lb. Transducer with socket

2000-11-02 1/2" ext. drive 20 - 250 ft. lb. Transducer with socket

A-2

ACCESSORIES APPENDIX A

Component Description

2000-50-1 Cable, Indicator to PC

950-79 Foot Pedal Switch (Data Send foot switch)

2000-50-2 Cable, Indicator to Serial Printer

2700-900-121 Cable, Smart Cable Replacement

2100-0750 Torque Screwdriver Testing Kit

900-0-1KIT Joint Rate Simulator; 50 in. lb. max.

900-2-01KIT Joint Rate Simulator; 400 in. lb. max.

900-3-01KIT Joint Rate Simulator; 1000 in. lb. max.

A-3

ACCESSORIES APPENDIX A

Calibration Accessories

Calibration of the SURETEST Indicator and 2000 series transducers is
recommended at least every 1 year.

Component Description

2000-250-02 Calibration stand kit

Includes: Stand
Transducer mounting block
½ - 3/8" Square drive adaptor
1-1/4" Square drive adaptor
1-1/4" - 3/4" Drive reducer

Weights, Hangers and Arms

2000-320-0 50 in. oz. - 2000 ft. lb. Cap. Weight Set #1
Weights, Qty

8 50 lb. Block Weight
5 20 lb. Block Weight
4 10 lb. Block Weight
6 5 lb. Slotted Weight
4 2 lb. Slotted Weight
2 1 lb. Slotted Weight
1 ½ lb. Slotted Weight
1 4 oz. Slotted Weight
1 2 oz. Slotted Weight

Hangers

390-2-2 4 oz. Weight hanger
2000-301 8 oz. Weight hanger
2000-304-0 7.5 lb Weight tray

2000-302-0 15 lb Weight tray

2000-303-0 50 lb. Weight tray

Torque Arms

2500-50-0 2.5" Radius wheel
2000-151-0 5" Radius wheel
2000-152-0 10" Radius butterfly
2000-154-0 40" Calibration arm

A-4

19220 San Jose Ave.

City of Industry, CA 91748-1497

FORM 20-2100-CDI