Ingersoll-Rand 4575759 User Manual
Sensor I® Expert Electronic Wrenches
USER MANUAL
SENSOR I® Expert
User Manual
04575759
Form 7266
Version 005, 08/04
Sensor I® Expert User Manual
NOTE
The wrench should only be used for its intended purpose, i.e., for
tightening, loosening and auditing purposes. It should be operated
using a smooth steady pull at moderate speed on the wrench handle
with both feet firmly placed on floor. Specifications apply to the
wrench only (without additional apparatus). Accuracies cannot be
specified when the wrench is used with torque multipliers or if the
wrench is operated incorrectly.
NOTE
The used of universal joints is not recommended. Use of such devices
may cause inaccuracies in torque and/or angle measurements. The use
of extensions to the handle, or application of force to other parts of the
wrench may cause damage, result in personal injury, or may result in
inaccurate tightenings.
NOTE
Exceeding the maximum torque noted on the wrench may cause damage
to wrench or loss of calibration.
NOTE
Always make sure that the socket is fully engaged on the joint before
tightening begins. Failure to do so may cause inaccuracies in torque
and/or angle measurements.
Sensor I® Expert User Manual
NOTE
If the wrench fails to operate using the recommended procedures
described in this manual, the cause of malfunction should be corrected
by an authorized Ingersoll-Rand technician. For a list of authorized
Ingersoll-Rand technician. For a list of authorized Ingersoll-Rand
service centers, see Appendix D.
NOTE
If calibration equipment is not available, it is recommended that the
wrench be returned to an authorized Ingersoll-Rand service center for
an annual recalibration.
Sensor I® Expert User Manual
Application Guidelines for Accurate Use of the Expert Wrench
To all Expert wrench users
February 15, 1999
What distinguishes the Expert wrench from dial wrenches or other digital
torque wrenches is one very significant feature: angle. The angle
measurement allows users to accurately audit torque dynamically and
perform sophisticated tightening methods such as angle and yield control.
The EZ Angle sensor is a major improvement over previous technology. The
most obvious change is the removal of the external arm on the ratchet
head-eliminating the space constraint. In addition, users no longer need to
find a suitable place to attach the reference arm magnet.
Although the Expert wrench is a rugged industrial tool, to achieve precision
results, it needs to be treated as a precision instrument. The following
outline summarizes the ideal method of use:
Wrench Reset:
The reset process sets the zero reference for both torque and angle. The
wrench must be held steady with no torque applied to achieve a good reset.
It will indicate a fault if excessive torque or angle is applied while resetting.
For best results, attach the socket to the wrench and place it on the
fastener or rest the ratchet head on a table. Hold in the Reset button until
the green Run light illuminates and release. You can then move the wrench
to the fastener, or begin tightening immediately. To achieve angle accuracy
that is better than the documented performance specification place the
entire wrench on a table and hold it completely still during reset. This will
improve the angle accuracy to better than ±2% of the final angle.
Sensor I® Expert User Manual
Dynamic Audit:
The Dynamic Audit feature of the Expert wrench audits residual torque
currently on the fastener after relaxation and other effects have taken
place. On a very hard joint that is audited soon after tightening, this will
consistently equate to installation torque. On a very soft joint or a joint
audited long after the initial tightening, it may be considerably reduced.
Standard methods are open to variance from operator influence. Experienced
auditors try to overcome these difficulties by watching the socket very
closely and moving very cautiously. Other operators may have a tendency to
pull the wrench until the expected value is reached. Although that specific
bolt may end up with the correct torque, it does not tell Quality Control
about any possible problems that are occurring with the fastening
equipment on line.
The Expert wrench helps eliminate this operator influence by capturing the
residual torque after a very small angle is turned regardless of how far or
fast the wrench is pulled. In other words, all that is required is a quick pull
and the processor takes a "snapshot" of the dynamic torque at the pre-set
angle of turn.
To Dynamically Audit Residual Torque:
A table of audit angle values is provided for your convenience. The guiding
principle is to set a sufficient angle of turn to ensure the bolt threads are
moving when the torque snapshot occurs. The longer the fastener, the
greater the required angle.
To ensure that an accurate reading is received, the following procedure
should be followed:
Sensor I® Expert User Manual
1. Set the snug torque to approximately 50% of the expected final torque
reading.
2. Set the capture angle (see chart).
3. The operator must then pull the wrench approximately 30° over a period
of no more than 2 seconds. Pulling the wrench past the desired audit
angle will not have an adverse effect on the audit reading - it will be
"captured" at the correct audit angle. The captured torque can be viewed
when the parameter shown on the display is "Tq".
Joint Grip Length* (d = bolt diameter)
Joint Type
Hard/Medium 2° 3° 4° 6°
Soft 2° 4° 6° 8°
2d
≤
*The grip length is the total length of the bolt located within the assembly
pieces. Keep in mind that adding socket extensions will also call for an
increase in angle.
2d - 5d 5d - 10d >10d
This chart is offered as a guideline only. The optimum value for the capture
angle will be influenced by the overall joints stiffness, joint configuration,
and frictional conditions. Application testing is recommended to determine
the most accurate value for the specific joint under audit.
Sensor I® Expert User Manual
To Tighten to a Torque
Set the torque value to your target torque, and set high and low torque and
angle limits if desired. Snug is set automatically to a default value. This is
the point from which the angle is activated. The default snug values for all
models are listed in the TOLL DESCRIPTION Technical data table in Chapter
2. Reset the wrench before tightening. The OK light will go on and an alarm
will sound when the target is reached. If the wrench is pulled too slowly for
a long period (<10° per second for model 40, <5° per second for more than
5 seconds for all other models), the wrench will signal an error by sounding
several short beeps.
To Tighten to an Angle
Set the snug torque and target angle as well as any high and low torque and
angle limits. Reset the wrench before tightening. The Ok light will go on and
an alarm will sound when the target is reached. If the wrench is pulled too
slowly for a long period (<10° per second for 5 seconds for model 40, <5°
per second for more than 5 seconds for all other models), the wrench will
signal an error by sounding several short beeps.
To Tighten to Yield
Snug torque should be set to approximately 50% of the expected proof load
torque of the bolt in use. Set any required torque or angle limits, and select
your joint type-hard, normal or soft. Reset the wrench before tightening.
The OK light will go on and an alarm will sound when the target is reached.
If the wrench is pulled too slowly for a long period (<10° per second for 5
Sensor I® Expert User Manual
seconds for model 40, <5° per second for more than 5 seconds for all other
models), the wrench will signal an error by sounding several short beeps.
NOTE
When using EVS-models, avoid ratcheting when the torque is in the
vicinity of the snug torque and between snug and the yield point.
Sensor I® Expert User Manual
TABLE OF CONTENTS
Sensor I® Expert User Manual
TABLE OF CONTENTS
CHAPTER 1: INTRODUCTION ........................................................... 1
CHAPTER 2: TOOL DESCRIPTION ..................................................... 3
Functions of Components
CHAPTER 3: WRENCH OPERATION INSTRUCTIONS ............................. 15
General Information .................................................... 15
Operation ................................................................... 15
Primary Operation Modes .............................................. 15
Setting Torque Units
Torque Control Tightening Procedure
Dynamic Audit
Yield Control
Angle Control
CYCLE COUNTER ........................................................... 25
Resetting the Cycle Counter
QUALITY CONTROL LIMITS AND STATISTICS ...................... 26
Setup and Viewing Quality Control Limits
Deleting Quality Control Limits
Use of Quality Control Limits
Statistics
CUSTOM TIGHTENING MODES ......................................... 30
Setup and Storage of Custom Tightening Modes
Retrieving Custom Tightening Modes
Identifying Custom Tightening Modes
Clearing Custom Tightening Modes
DATA STORAGE AND RETRIEVAL ...................................... 33
Setup of Wrench for Data Upload
Data Out During Tightening
Data Out at End of Tightening
Parameter Dump
End of Tightening Data Dump
Tightening Curve Storage
Tightening Curve Data Dump
i
Sensor I® Expert User Manual
TORQUE MULTIPLIER FUNCTION ...................................... 40
Setup of a Torque Multiplier
Use of a Torque Multiplier
LEFT HAND FASTENERS ................................................. 42
RESET ADJUSTMENT (EVS-models only) ............................ 43
CHAPTER 4: BATTERY CHARGING .................................................... 51
CHAPTER 5: DIAGNOSTICS AND TROUBLESHOOTING .......................... 49
Introduction
Torque Channel A/D Display
Angle Reference Arm Test Mode
Battery Level Test Mode
EZ Angle Test Mode
Membrane Keypad Test Mode
Head Position Test
Buzzer and LED Test Mode
Display/Serial Link Test Mode
Software Version Number Test
Time-out Adjustment
CHAPTER 6: CALIBRATION ............................................................. 53
General Information .................................................... 53
Torque Calibration ....................................................... 54
Angle Reference Arm Calibration (EA - models) ................ 56
EZ Angle Calibration (EVS - models) ............................... 56
Appendix A ................................................................................. 62
Sample Reports ........................................................... 62
Parameter Dump .......................................................... 62
End of Tightening Data Dump ........................................ 63
Tightening Curve Data Dump ......................................... 65
Data Out During Tightening .......................................... 66
Data Out at End of Tightening ....................................... 66
Appendix B ................................................................................. 67
Appendix C ................................................................................. 69
Appendix D ................................................................................. 77
ii
Sensor I® Expert User Manual
CHAPTER 1
Introduction
Sensor I® Expert User Manual
INTRODUCTION
The SENSOR 1® EXPERT WRENCH is a hand-operated portable tightening
system with a battery-powered microprocessor control system. In addition
to standard torque and angle control tightening capabilities, it provides a
Yield Control mode of tightening and Dynamic Torque Auditing. It is suitable
for laboratory, production, quality control, maintenance and field service.
The control system is powered by a rechargeable NiMH battery located
inside the wrench handle (model 125, 250 & 400) or in the lower portion of
the control unit (model 40). The wrench has a toggle lever used to select
the ratchet direction. Angle reference is either measured internally by the EZ
angle or via an attachable spring arm with a magnet (EA-models).
Attachable spring arms can be fitted with options such as suction cups or
alligator clips.
The digital display shows a digital readout of either dynamic torque peak
torque, or angle. Audible signals and displays indicate the completion of
tightening for Dynamic Torque Audit, Torque Control, Yield Control (elastic
limit of bolt), or Angle Control procedures.
1
Sensor I® Expert User Manual
CHAPTER 2
Tool Description
Sensor I® Expert User Manual
TOOL DESCRIPTION
Technical Data 40 125 250 400
Length: 13.5” (343 mm) 26” (665 mm) 42.5” (1080 mm) 48.5” (1232 mm)
Square Drive: 3/8” (9.5 mm) 1/2” (12.5 mm) 3/4” (19mm) 3/4” (19 mm)
Weight:
Tool 2.4 lb (1.1 Kg) 5 lb (2.3 Kg) 12 lb (5.5 Kg) 13.8 lb (6.3 Kg)
Control Unit 2.2 lb (1.0 Kg)
Torque Operational Range: 4.5-45 Nm 20 - 170 Nm 108-340Nm 130-540 Nm
(45-450 dNm) 15 - 125 lb.ft. (80-250 lb.ft) 100-400 lb.ft
3.3-33 lb.ft.
(40-400 in-lb)
Minimum Snug Torque 2.3 Nm (23 dNm) 10 Nm 24 Nm 24 Nm
(default value for 1.7 lb.ft. (7 lb.ft.) (18 lb.ft.) (18 lb.ft.)
Torque control mode) (20 in-lb)
Torque Resolution: 1 in-lb 0.1 Nm 0.1 Nm 0.1 Nm
Torque Accuracy: Full Scale ± 1 % ± 0.5 % ± 0.5 % ± 0.5 %
Maximum Angle:
Angle Resolution:
Angle Accuracy:
Angle Reference
Arm (EA-models)
EZ Angle* (EVS-models) ±4 % ±4 % ±4 % ±4 %
Power Supply Voltage 7.5 V 7.5 V 7.5 V 7.5 V
Operating time between 5.5 hours 5.5 hours 5.5 hours 5.5 hours
charges
Charging time 14 hours 14 hours 14 hours 14 hours
Battery Charger Input Voltage 220/110 V 220/110 V 220/110 V 220/110 V
Operating Temperature Range
* Under recommended conditions
o
1999
o
1
o
±1
0
0-50
C0-50
1999
o
1
o
±1
o
0
C0-50
o
1999
o
1
o
±1
0
C0-50
1999
o
1
o
±1
o
0
C
3
Sensor I® Expert User Manual
NOTE
These specifications apply to the wrench and its control system only
(without additional apparatus). Accuracies cannot be specified when
the wrench is used with torque multipliers or if the wrench is operated
incorrectly.
NOTE
The use of universal joints is not recommended. Use of such devices
may cause inaccuracies in torque and/or angle measurements.
NOTE
Exceeding the maximum torque, noted on the wrench, may cause
damage to wrench or loss of calibration.
4
Sensor I® Expert User Manual
Functions of Components
Expert 125, 250 and 400 Models
Wrench Housing
Incorporates all the electronics and digital display.
Wrench Handle
Houses the charger/data port connector for battery charging and serial
port communications.
Wrench Head
Contains the angle reference arm potentiometer (EA-models) and ratchet
head. The wrench head can be indexed 600 either side of the wrench body
for ease of reading the display.
NOTE
Factory Calibration of models 125, 250 and 400 was conducted with the
wrench head in the normal, non-indexed position. This position is
recommended where high accuracy of angle values is required. If the
wrench is to be used in the ±60o indexed position and angle accuracies
equal to or better than ±10% are required, then recalibration of angle
in the indexed position is recommended.
Torque accuracy remains unaffected by indexing the wrench head.
5
Sensor I® Expert User Manual
Functions of Components
Expert 40
Handheld Tool
Consists of the ratchet head, reset switch, cable and the angle
measurement device. The head cannot be indexed relative to the handle.
The plug at the end of the tool cable connects to the receptacle on the
lower portion of the Control Unit.
Control Unit
Houses the electronics, power supply and interface connectors for the tool
cable and battery charger/data communications port. The tool connects
to the receptacle in the lower portion of the Control Unit. The front panel
on the upper portion of the Control Unit is the same as all other Expert
Wrenches.
6
Sensor I® Expert User Manual
1. Control System Status Lights
These lights are used to signal operating status:
RUN The control system is ready to begin a cycle.
SNUG The torque applied to the fastener has reached the snug torque setting.
OK The fastener has been tightened correctly in the selected tightening mode.
FAULT One or several of the following fault conditions has occurred:
a) Operator Error
b) Low Battery
c) Torque Overrange
d) System Failure
e) Wrench not held steady enough during calibration (Reset)
f) Wrench is being pulled too slowly.
g) The mode or parameter adjustment knob has been changed since last reset.
h) Ratchet head has been indexed since last reset.
7
Sensor I® Expert User Manual
2. Mode Selector Switch
Selects the particular tightening mode: Torque Control, Dynamic Audit,
Yield Control and Angle Control. This switch also allows you to select
the Setup mode to adjust communications parameters, setup and
restore custom modes, and perform diagnostics
3. Reset Button
Used to power up the wrench, reset the wrench before every new
tightening procedure, to set torque and angle values, and to clear
certain fault conditions. When the Reset button is held in, the top
functions on the membrane key pad can be selected.
4. Parameter Adjustment Knob
When the Reset button is held in, this knob adjusts the value of the
parameter being displayed.
8
Sensor I® Expert User Manual
5. Digital Display
Provides a digital readout of parameters selected:
A) These segments show the item being displayed on the main display:
Pk is peak torque
An is angle
Ld not used
Tq is dynamic torque
B) These segments indicate limits:
LT is low torque limit
HT is high torque limit
LA is low angle limit
HA is high angle limit
C) These segments will light when serial data during tightening or serial data at
the end of tightening are selected. They will also flash when data is being sent
through the serial port.
RX = receiving, TX = transmitting
D) This segment will light when CCW ("-LEF") has been selected.
E) These segments display the values of torque and angle.
F) These segments light when statistical information is being shown on the
display.
9
Sensor I® Expert User Manual
G) This segment will light when the wrench is in calibration mode for torque or
angle.
H) This segment indicated that degrees of angle are being displayed on the
screen.
I) These segments indicate the cycle number for the tightening or the mode
number when in setup mode.
J) These segments indicate the units for torque.
K) These segments indicate the joint type selection for yield control.
L) This segment lights when the torque applied to the wrench is over the
maximum allowable limit.
M) This segment indicated a low battery condition.
N) This segment lights when torque and angle offsets are being calculated.
O) This segment will light when a torque multiplier is programmed for use with a
particular fastening mode.
P) This segment will flash when a particular tightening mode has reached its limit
of 1,000 tightenings. This segment will light continuously when the wrench
has reached its limit of 2,500 total tightenings for all the tightening modes.
10
Loading...