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TorqueStar Plus
Operator's Manual
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Operator's Manual
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Crane Electronics TorqueStar Plus Operator's Manual

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Crane Electronics Ltd
The force in torque management
Crane Electronics Ltd
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Operator’s Manual
TorqueStar Plus Data Collector
Manual 1293-01 Issue 1
Crane Electronics Ltd
Notice
ALL RIGHTS RESERVED. Reproduction of any part of this manual in any form whatsoever,
without the prior permission in writing from Crane Electronics Ltd is forbidden.
Copyright © December 2018 by Crane Electronics Ltd.
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Contents 2 CE Marking & Compliance 3 Product Disposal & About this Manual 4 Packing List 5 Spares & Accessories 5 Features & Dimensions 6 Specifications 7 Hardware 8 Technical Features 8 Icons 9 Start Up 10 Inputs 12 Charging your TorqueStar 13 Connecting a Transducer 13 Manual Transducer Set-up 14 Saving to USB 15 Settings 15 Power Settings 16 Date & Time Settings 17 Global Settings 17 Misc. Torque Settings 18 Settings Measurement 19 Measuring Screen 20 Measurement Options 22 Reading List 24 Statistics 25 Deletion 25 Warning Screens 26
CONTENTS
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Manufacturer: Crane Electronics Ltd Address: 3 Watling Drive
Sketchley Meadows Hinckley Leicestershire LE10 3EY
Tel: +44 (0)1455 25 14 88
Declares that the TorqueStar range has been assessed and complies with the requirements of the relevant CE Directives.
This device complies with part 15 of the FCC rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in particular installations. If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
CE MARKING
COMPLIANCE
Changes or modifications to the TorqueStar range not expressly approved by Crane Electronics Ltd could void
the user’s authority to operate the equipment.
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Applicable in the EU and other European Countries with separate collection systems
The symbol shown here and on the product means that the product is classed as Electrical or Electronics Equipment and should not be disposed with normal commercial waste at the end of its working life.
The Waste of Electrical and Electronics Equipment (WEEE) Directive (2012/19/EU) has been put in place to recycle products using best available recovery and recycling techniques to minimise the impact on the environment, treat any hazardous substances and avoid the increasing landfill.
For more detailed information about recycling of this product please contact your local authority or the Company where you have purchased the product.
Battery disposal to take place in line with the AMENDED BATTERIES DIRECTIVE 2013/56/EU. Batteries must not go to landfill. Check with local legislation.
Crane Electronics declares that this product does not contain any of the 191 Substances of Very High Concern (SVHC’s) identified in the REACH Regulation in used articles make-up.
In Countries outside the EU:
If you wish to discard this product, please contact your local authorities and ask for the correct way of disposal.
Signed for & on behalf of Crane Electronics Ltd.
Name: B. M. Etter Title: Safety & Environmental Advisor Signature of Issuer:
This manual covers the TorqueStar Plus version, working with our range of torque transducers and digital torque wrenches.
Actual screen shots represented in this manual may differ slightly from those on the actual TorqueStar unit, depending on the version.
For information on the operation of one of our digital torque wrenches or torque transducers, please refer to their own manuals.
Software version TorqueStar Plus
PRODUCT DISPOSAL
ABOUT THIS MANUAL
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The following Items are supplied with the TorqueStar Plus dependent on model specification purchased.
1 x TorqueStar Plus 1 x Calibration Certificate 1 x Quick Start Guide (with QR code link to operator’s manual) 1 x 5V PSU Power Adapter 1 x USB to Micro USB connection cable 1 x USB Flash Drive 1 x Carry Lanyard All contents are supplied in a hard plastic case with foam insert.
Please ensure all items are present and notify Crane Electronics Ltd immediately of any shortages.
Additional Batteries 080159 5V PSU Power Adapter TSXXA – 0000 - CRPXXX External battery charger TSXXA – 0000 - CRCXXX USB to Micro USB connection cable 090301 Carry Lanyard 110385 Protective Case TSXXA – 0000 - CRTXXX
PACKING LIST
SPARES AND ACCESSORIES (with Product Code)
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FEATURES AND DIMENSIONS
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Measurement Modes:
Track – Real time torque Peak – Capture of the highest torque Pulse – Special measurement algorithm for use with impulse tools, incorporating pulse count Click – Special measurement algorithm for use with click tools Force – Capture of peak force during cycle Audit – Special measurement algorithm that measures torque after joint moves a certain angle
Measurement Units:
Torque – Nm, lbft, lbin, MNm, Ncm, kgcm, kgm, kNm, klbft, Nmm, ozin Force – kg, kkg, lb, klb, N, kN
Physical Measurements:
Auto Bi-directional torque; angle*; pulse count; RPM in track mode*; cycle time duration (*when using rotary transducer).
Compatible Input Devices:
IS, UTA, and Multi, including WrenchStar Multi, cable products compatible, Analog or digital.
Plug & Play Transducer Data:
Auto ID of all Crane UTA/Multi products. The following information is read from the chip in the transducer ­torque range, angle encoder data, serial number, calibration due date.
Data Storage:
999 readings in storage mode.
Basic Statistics:
Count, range, mean, min, max, standard deviation.
Advanced Statistics (Available in TorqueStar Plus only with an upgrade):
Cm, Cmk, Cp, Cpk
Auto Print / Data Output:
Easy selectable output to AutoPrint or CSV. Interface to simple PC package that outputs the print data to an Excel spreadsheet.
Cycle Status Indication:
Audible buzzer and LED HI/OK/LO torque status. User definable.
Operating Languages:
English, Chinese, Czech, French, German, Italian, Hungarian, Spanish, Swedish, Polish, Portuguese, Turkish.
SPECIFICATIONS
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Construction:
High strength injection moulding. Protective rubberised trim to alleviate secondary damage. Soft rubber trim surrounding tough internal chassis. Can survive 1.8m drop.
Display:
Colour Backlit 4”screen (86mm x 52mm)
Keypad:
Easy clean keypad. 11 Keys including 5 function keys, 5 soft directional keys and on/off key.
Power:
Universal 5V charger or USB charger.
Power Management:
User selectable auto power-off: Between 0 - 200 minutes. Screen contrast and brightness adjustment.
Battery Pack:
Lithium Ion - User swappable. Charge time: 3 hours with appropriate charger current. Chargeable via USB or 5V charger.
Input/output ports:
25 pin ‘D’ type transducer port (female) (digital or analogue). Micro USB (2.0) for power and export. Standard USB type A (On The Go). 5V DC power port for use with mains power DC charger.
Zero Stability:
<± 0.1% FSD/ °C.
Static Accuracy:
± 0.25% FSD of connected transducer.
Operating Environment:
Temperature: -20 to +50 °C. Humidity 10-75% non-condensing. Ingress protection rating: IP45
.
Torque Measurement
Display to 5 significant figures. Sample every 20 micro seconds.
Angle Measurement:
Quadrature phase input. Display angle to 0.1 degrees, Sample every 1000 micro seconds.
Warranty:
12 months parts and labour against faulty workmanship or materials.
HARDWARE
TECHNICAL FEATURES
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Measurement Modes:
Settings:
Languages:
Transducer Screen:
Statistics screen:
ICONS – TorqueStar Plus
Peak
Click
Track
Pulse
Audit
Settings
Date/Time
Global
Misc.
Torq u e
Information
Misc.
Power
English
French
German
Italian
Swedish
Spanish
Portuguese
Hungarian
Chinese
Polish
Czech
Turkish
Transducer
Edit
Refresh
Delete
Back
Back
Statistics
Save
Print
Peak Angle
Force
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Reading List Screen:
Turning on your TorqueStar:
Turn on the TorqueStar by pressing the on/off button situated below the arrowed keypad. Pressing this button whilst the TorqueStar is on will turn it off.
The first screen you will see is as below.
1) Model
2) Transducers available
3) Serial Number S/N, Torque Module latest
release, HMI Module latest release, Keyboard latest release
4) Advised calibration due date for this data
collector
5) Features unlocked
It confirms what version of TorqueStar you have. In the screenshot above it tells you that you can use Analogue and Digital Transducers only. RF Transducers can only be used with the TorqueStar Pro.
In the top right hand corner it will show the current level of battery life and whether it is being charged or not. Charging is denoted by a lightning flash.
The Serial Number of the model you have is displayed, along with the latest software release for the Torque module, HMI Module and Keyboard. The opening screen also shows the Calibration due date of the model you have.
Back
Readings
Print
Add
Comment
Delete
Comment
1 2 3
4
START UP
5
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If you press the green button or wait the TorqueStar will load its settings for a few seconds and the load screen will be displayed.
If no transducer is plugged in then this screen will appear.
Please connect a transducer. See ‘Connecting a Transducer’ set up.
If a transducer is already plugged in then depending on what Span Nm it will automatically populate the LSL, Target torque and USL. If the transducer has angle this will also automatically be populated.
If you wish to change the LSL, Target Torque and USL then you will see that there is a cyan line under the populated limits. You can toggle using the up and down arrow keys to highlight the angles limits as well. Press the green button and you will be taken to the screen below.
Torque Angle
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Use the left and right arrows to move to the Limit that you wish to change. When highlighted press the green button. To change the Limits use the Up and Down arrows and the Left and Right arrows to go to another number. Once you have set the desired number, press the green button. Continue following the process until all your limit settings are correct.
If you are changing a transducer or changing the Limits then this will reset all the results.
If all is OK then press the green ‘tick’.
If this screen isn’t displayed then press the back button to return to the measuring screen.
TorqueStar Plus has connectivity using the following;
1) Micro USB
2) USB
3) 25-way D-type female transducer
port
4) 5V DC Power Supply
INPUTS
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Charging can be done in two ways:
1) Connect Micro USB on the TorqueStar to USB on a
laptop/PC or USB charger.
2) Connect the 5V DC port with a DC power supply.
Plug the male 25-way D-type connection on the transducer to the female connection port on the back of the TorqueStar Plus.
All Crane UTA transducers will automatically be recognised. Industry Standard (IS) Transducers will have to be manually inputted (See transducer set-up).
You can store up to 10 x IS transducers. Use 1 x UTA transducer and have 10 x IS stored or you can connect 5 x UTA transducers at simultaneously time by using a 5-Way transducer switching box.
5-Way auto transducer switching box: Allows connection of up to 5 transducers and the capability to switch between them with ease. Automatic recognition of UTA’s and no hardware modifications required to connect. Uses 25-way D-type interface.
Part Number: TO-899-09CR-0-0 RS232 Cable Port to Port: CBL-757-0-0-0-0
CONNECTING A TRANSDUCER
CHARGING YOUR TORQUESTAR
2 2 1
1
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To manually set up an IS or force transducer select the settings icon from the main screen and then the transducer icon.
You will come to this screen enabling you to set up a transducer. Press the edit icon to manually input the type of transducer you wish to connect.
Change the transducer properties by using the Left and Right key. Use the Up and Down arrows to navigate the screen.
You can also delete a transducer by pressing the delete icon and press the green button or the green ‘tick’ to accept and the red ‘cross’ to not delete.
You can always refresh to pair a UTA to the TorqueStar if you have one attached or search for one by pressing the refresh icon.
Transducer: Set the number of the transducer as you see fit. The TorqueStar can store 10 transducers.
Type: Scroll down to type if you are adding an Industry Standard (IS) transducer or Force. All Crane transducers
are recognised. The same will work for RF (TorqueStar Pro only). Use arrows to change from IS to Force.
Serial number: To input the serial number, use the keypad to highlight the serial number. Press the green button on the keypad to highlight the first digit. Use the Up and Down arrows to change this digit and move left and right to highlight additional digits for editing. Once completed press the green button.
Span: To input the span use the same process as for inputting a serial number.
Transducer units: Select the measurement unit that you wish to use by using the left and right arrow keys.
Available are: Nm / lbft / lbin / MNm / Ncm / kgcm / kgm / kNm / klbft / Nmm / ozin if IS transducer and N, kN, Kg, kkg, lb, klb if Force transducer.
Pulses per revolution (PPR), Millivolts/Volt, Bridge resistance, Torque @ mV/V: To input these details, follow the same process as inputting a serial number. Millivolts/Volt can be between 0.500 to 8.000. Bridge resistance cannot be 0000.
MANUAL TRANSDUCER SET UP
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Saving readings to a USB device:
Insert a USB device into the back of the TorqueStar. The standard USB socket can be located at the rear of the unit and is sealed with a plastic protector. Remove the protector and insert the USB device.
USB port protector. Insert USB.
When clicking on the Save Icon, you will be asked to insert a USB Stick. The USB Icon will appear on the screen.
The USB Memory Stick icon will automatically go green and save the readings to the USB Stick if attached.
Saves in folder \Crane\Export Filename [MeasureMode] Date_Time.csv Date & Time format altered in settings and represents time of export.
Settings can be accessed by pressing the Settings Icon: The first setting screen is the measure mode settings (see later).
SETTINGS
SAVING - USB
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The ‘Back’ icon will take you back to the previous screen.
will take you to further settings icons as follows:
Transducer Splash Screen Misc.
Power Date & Time Global Miscellaneous Torque
Click on the Settings Icon. Click on the Miscellaneous Icon. Click on the Power Icon.
You can change the ‘Power Off’ time by using the Up and Down arrows to highlight the current minutes. Use the Left and Right arrows to toggle between time limits. You can set ‘Never Off’ or between 1 – 200 minutes.
The same process is followed to change the ‘Backlight Off’ setting. The ‘Buzzer’ can be toggled on or off and the ‘Brightness’ can be changed from 20% - 100%. A lower brightness saves battery power. ‘Battery’ level is an indicator to the unit’s power status. If an external power source is connected, then it will show as 100%.
POWER SETTINGS
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Click on the Settings Icon. Click on the Miscellaneous Icon. Click on the Date/Time.
Date Format – Using the Up and Down arrows you can navigate. Highlight the ‘Date Format’ and press of the left or right arrows to change the format. There are three to choose from: DD/MM/YYYY, MM/DD/YYYY, YY/MM/DD.
Date – To change the date, highlight the current date stored, press the green OK button and use the Up and Down arrows to change the dates. A Left or Right keys switch between day, month and year. To save press the green button.
Number Format – Dot or Comma for decimal place.
Time Format – Set how you want the time displayed. HH:MM:SS, HH:MM using the left and right arrow keys.
Time – Highlight the current time, press the green OK button and then you can use the arrow keys to change
the time, using the Left and Right arrows to move between the hours, minutes and seconds.
Click on the Settings Icon. Click on the Miscellaneous Icon. Click on the Global Icon
Language Settings.
Use the left and right arrow keys to change the language in the TorqueStar. Available languages are: English, French, German, Chinese, Polish, Hungarian, Italian, Portuguese, Spanish, Turkish, Swedish, Czech.
DATE & TIME SETTINGS
GLOBAL SETTINGS
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Click on the Settings Icon. Click on the Miscellaneous Icon. Click on Misc. Icon
Use the Up and Down arrows to navigate and use the left and right arrows to set the user requirement.
- Stream to USB updates torque value to USB
continuously whilst taking readings. Stream is on Micro USB port.
- The span of connected transducer can be added to
stream.
- FIFO is First In First Out. If off, it can only take 999
readings. If on, you can see the last 999 readings.
- Auto Print sets print out for the end of results and in
reading list. Press to access Auto Print set­up.
Auto-print set up.
Use the left and right arrows to change the settings, use the up and down arrows to scroll through the menus.
If you have a TorqueStar Plus you can purchase an upgrade to ‘graphs’. Once purchased, access via the miscellaneous settings icon, press the unlock icon. Use the arrow keys to input the code to upgrade.
When in the reading list, pressing the green button will show a graph of the readings. Graph analysis is only available in TorqueStar Plus via upgrade or is as standard for the TorqueStar Pro.
The icon switches between Torque vs Time, Angle vs Time and Torque vs Angle.
MISCELLANEOUS TORQUE SETTINGS
READING TRACE
UNLOCK CODE
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A red cross (cursor) will highlight feature found on that measure mode. You can zoom in (except on Torque vs. Angle)
The up and down arrow keys change the speed of cursor movement. The parameter values at the cursor position are displayed on the right hand side of the graph. The plus and minus icons allow you to zoom in and out of the trace. Zoom in centres on the cursor and you can zoom in until all trace points are displayed.
The save icon saves the results.
Save to folder \Crane\Traces\ [MeasureMode] Date_Time.csv
If taking more than 999 readings (FIFO on) they will only see traces for the last 998 readings.
Using the Up and Down arrows on the device you can select the setting that you require. Using the Left and Right arrows will change the setting to what you require.
Once completed you can press the return key to go back to the measurement screen.
Units = Displayed torque units
Direction = Clockwise, Anti-clockwise, Auto
Cycle end time = 0.2s, 0.5s, 1.0s, 2.0s, 5.0s, 10.0s
Freq. response = (Hz) 75, 151, 256, 307, 384, 542, 768, 921, 1024, 1536, 2304, 3072, 4608
The menu slot is the number from the left of screen that measure icon occupies
Audit angle shown when measure mode is Audit.
SETTINGS MEASUREMENT SCREEN
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Measuring Screen:
The symbols across the top of the screen are:
Icon appears relevant to the screen you are currently in.
The TorqueStar has 999 readings capability. Number of readings are displayed. (Changes from /999 to +000 when it has more than 999 FIFO readings)
If this Icon is Green it means that everything is ready to measure.
If this icon is Red then something needs to be actioned and it cannot take a measurement.
Current ‘Measurement Mode’ is displayed
Battery level indicator. A flash will appear when charging.
THE MEASURING SCREEN
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Measurement screen
LSL = Lower Specification Limits Tar = Target Torque USL = Upper Specification Limits
If a reading is below the Target Torque a number of
things will happen.
1. Torque reading will be yellow when the fixing is
under-tightened.
2. An audible, single beep will be emitted.
3. The yellow LED light on the TorqueStar will
illuminate.
If the target torque is achieved there will be two audible beeps and the TorqueStar’s green LED will illuminate. If the USL is reached then the fixing is too tight the torque reading will be in red and three audible beeps will be heard and the red LED will illuminate.
The top reading is the torque measurement value and the lower readings will be angle (or secondary parameter) if applicable.
Measurement mode
Direction of rotation
Last reading taken
Last angle measurement
Duration
Angle
Transducer serial no.
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The symbols across the bottom of the screen are your action keys. Pressing the corresponding soft-key will give you access to other modes and settings.
Choose Measurement Mode
Readings list
Statistics
Delete
Settings
On the front Measuring Screen press the ‘Measurement Mode’ Icon.
You will then see four different Measuring Modes.
Peak Peak Angle Click Track
MEASUREMENT OPTIONS
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Pressing the ‘shift’ arrow icon will take you to additional measurement modes.
Pulse Audit Force
When you choose the measurement mode you require, this takes you back to the measurement screen and as long as a transducer is connected, you can begin to measure.
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Pressing the readings list icon will take you to the readings screen.
The ‘Save’ icon will let you save your reading to a USB stick. Insert the USB stick and save to USB. For further information go to the ‘Saving – USB’ section in this manual.
The ‘Print’ icon will allow you to print your readings using format in Auto Print settings.
Pressing the ‘Add Comment’ icon will open a window of text comments. These are different comments the user is able to add to a reading to give details of any issues that occurred during the tightening process. Once the required text is highlighted press the ‘ok’ key to confirm and add this to the reading.
Comments Available:
Operator Error / Slipped / Fastener Missing / Fastener Location / Prod. Down time / Not on Station Production Error / Patch Bolt Set / Loose Fastener / Wrong Fastener / Tool Malfunction / Low Volume / Track Stop / Crossed Thread / Stripped / Bad Part / Part Shortage / Not Determined
If an incorrect comment has been entered then you can delete the comment. Pressing the ‘Add Comment’ icon again and you can add another comment.
The ‘Back’ icon will take you back at any time to the measurement screen.
READING LIST
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Statistics
This will show various different statistics taken from the readings taken by the user. They are as follows:
- Qty - Mean
- Min - Max
- Sigma - Range
- Cp - Cm
- Cpk - Cmk
You can save these statistics to USB by connecting them into the back of the TorqueStar and pressing the button corresponding to the ‘save’ icon. This will then open up another window where the user can save these values. Name Statistics Date.Time.csv in \Crane\Export. The statistics are for displayed parameter.
The device also gives the unit the option to print out the statistics, this is done by connecting a printer and then pressing the keyboard button which corresponds with the ‘printer’ icon.
The ‘Back’ icon will take you back at any time to the measurement screen.
Measuring Screen:
If you have taken a reading and you wish to delete it, you can press the ‘Delete’ icon on the screen.
This will then send you to the delete screen where you can either accept the deletion or reject it. You can also use the Up and Down arrows to select ‘Delete All’ and this will delete all the readings currently taken.
STATISTICS
DELETION
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Transducer Screen:
If you make an error you can always delete the transducer from the list.
If you decide to change settings whilst in the middle of
readings then you will be warned. If this is what you wish
to do then press the green button, if not press the
button.
Warning messages similar to this will appear if you try
and attach or select the wrong transducer for the job
required.
The TorqueStar will warn you if your memory is full. You
will need to upload to a USB, print out your results or
delete readings.
WARNING SCREENS
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If you are trying to select a transducer that is not
compatible or choose the wrong one then you will be
issued with a warning message. You can go back using the
red ‘back’ key.
If you have selected the wrong units then you will see
this message.
If you attach a new transducer whilst in the middle of readings then this will erase all the results. Press the green ‘tick’ or the red ‘cross’.
Whilst in measuring mode with a selected transducer if
you decide to change the measurement mode then all reading results will be reset.
If you start pulling torque before you are in the measuring screen then you will be warned that the
‘Zero Offset’ is over-ridden by a certain %.
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