Ingersoll-Rand ETA5, ETA2 User Manual

04578092

P7529

Edition 1

January, 2002

Expert Torque Analyzers

ETA2 and ETA5

OPERATORS MANUAL

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OPERATORS MANUAL FOR

MODEL ETA2 AND ETA5 ANALYZERS

This ETA Analyzer is used for calibration or data collection of torque tools, power and hand operated, using external transducer(s). This Analyzer can also be used for joint development and as a failure analysis instrument (using external transducers). Ingersoll-Rand is not responsible for customer modification of units for applications on which Ingersoll-Rand was not consulted.

This symbol is to alert the user and service personnel to the presence of important operating instructions that must be read and understood to prevent personal injury, electrical shock or damage to the equipment.

IMPORTANT SAFETY INFORMATION ENCLOSED -

SAVE THESE INSTRUCTIONS.

READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING THIS PRODUCT.

IT IS YOUR RESPONSIBILITY TO MAKE THIS SAFETY INFORMATION

AVAILABLE TO OTHERS THAT WILL OPERATE THIS PRODUCT.

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN

ELECTRIC SHOCK, FIRE AND/OR SERIOUS PERSONAL INJURY.

04578092

Form P7529 Edition 1 January, 2002

Refer All Communications to the Nearest Ingersoll-Rand Office or Distributor.

Printed in U.S.A.

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PLACING ANALYZER IN SERVICE

• Always install, operate, inspect and maintain this product in accordance with all applicable standards and regulations (local, state, country, federal, etc.).

USING THE ANALYZER

• Always wear eye protection when operating or performing maintenance on this tool.

• Always use Personal Protective Equipment appropriate to the tool used and material worked. This may include dust mask or other breathing apparatus, safety glasses, ear plugs, gloves, apron, safety shoes, hard hat and other equipment.

• Keep others at a safe distance from your work area, or ensure they use appropriate Personal Protective Equipment.

• This tool is not insulated against electric shock.

• This unit is for indoor use only.

• Store idle units. When not in use, units

should be stored in a dry, high or locked location, out of the reach of children.

• Power tools can vibrate in use. Vibration, repetitive motions or uncomfortable positions may be harmful to your hands and arms. Stop using any tool if discomfort, tingling feeling or pain occurs. Seek medical advice before resuming use.

• Keep body stance balanced and firm. Do not overreach when operating this tool. Anticipate and be alert for sudden changes in motion, reaction torques, or forces during start up and operation.

• Ensure work pieces are secure. Use clamps or vises to hold work piece whenever possible.

• Never use a damaged or malfunctioning tool or accessory.

• Keep work area clean, uncluttered, ventilated and illuminated.

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

• Maintain unit with care. Keep unit clean for better and safer performance. Follow instructions for changing accessories. Inspect unit cords periodically and if damaged, have them repaired by an authorized service facility.

• Do not operate this product in explosive atmospheres, such as in the presence of flammable liquids, gases or dust.

• Do not modify this product, safety devices, or accessories.

• Do not use this product for purposes other than those recommended.

• Use accessories recommended by Ingersoll-Rand for your model.

• Don’t abuse the cord. Never use the cord to pull the plug from an outlet. Keep cords away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately.

• Avoid body contact with grounded surfaces such as pipes, metal structures or other electrical products.

• Stay alert, watch what you are doing and use common sense when operating this product. Do not use this product while tired or under the influence of drugs, alcohol, or medication.

• Do not use this product near water or other liquids.

• Do not attach or place external loads on any part of the unit.

• Replace battery with the same or equivalent type recommended by the battery manufacturer. Observe correct polarity when installing battery. Dispose of used batteries according to battery manufacturer’s instructions.

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CAUTION

• The unit should be checked periodically to ensure that the torque readings are accurate.

• DO NOT store the unit in relative humidity above 85%.

• Have the unit calibrated at least once a year.

• Keep the exterior of the unit clean and dry.

• Do not drop or abuse the unit.

• Do not allow chemicals such as ace-

tone, benzene, thinner, ketone or trichloroethylene to come in contact with the housings, as damage will result.

• The instrument should not be subjected to vibration or shock.

Ingersoll-Rand Company makes no warranty or implies any warranty or liabilities due to the misuse or damage resulting from the application of the information supplied by this manual.

Liabilities due to errors in the manual are only limited to replacement of the manual.

Ingersoll-Rand reserves the right to change information contained in this manual or the program without notice at any time.

All programs and themanual are copyrighted and rights reserved. Reproduction is prohibited without prior permission of Ingersoll-Rand.

The use of other than genuine Ingersoll-Rand replacement parts may result in safety hazards, decreased tool performance, and increased maintenance, and may invalidate all warranties.

Repairs should be made only by authorized trained personnel. Consult your nearest IngersollRand Authorized Servicenter.

• For calibration or repair, return to:

Ingersoll-Rand ETA Dept. 510 Hester Dr. Whitehouse, TN 37188

Ingersoll-Rand IDC ETA Dept. Swan Lane, Hindley Green Nr. Wigan Lancashire, WN2 4EZ U.K.

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WARNING SYMBOL IDENTIFICATION

WARNING

Always wear eye protection when operating or performing maintenance on this tool.

WARNING

Read this manual before operating tool.

WARNING

Always wear hearing protection when operating this tool.

SAVE THESE INSTRUCTIONS. DO NOT DESTROY.

When the life of the tool has expired, it is recommended that the

tool be disassembled, degreased and the parts be separated by material

so that they can be recycled.

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Table of Contents

ETA Analyzer usage and warnings . . . . . . . . . . . . . . . . . . . . . . . . . 1

Placing Analyzer in Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warning Symbol Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

How to use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Packing List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Care and Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Edit Transducer File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Barcode read input for characteristic names and comments. . . . . . 13

Measure Mode (Up to 200 readings stored) . . . . . . . . . . . . . . . . . . 14

Measure Mode Circle--Store Option . . . . . . . . . . . . . . . . . . . . . . . . 16

Direct Measure Mode -- ETA5 ONLY . . . . . . . . . . . . . . . . . . . . . . . . 17

To set up a Characteristic -- ETA5 ONLY . . . . . . . . . . . . . . . . . . . . . 19

Direct Characteristic Mode -- ETA5 ONLY . . . . . . . . . . . . . . . . . . . . 21

To Store Data (single characteristic) -- ETA5 ONLY. . . . . . . . . . . . . 23

To set up a Round -- ETA5 ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . 25

To Store Data by Round -- ETA5 ONLY . . . . . . . . . . . . . . . . . . . . . . 26

To set up a Master Round -- ETA5 ONLY . . . . . . . . . . . . . . . . . . . . 27

To Store Data by Master Round. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

To Display Recorded Data on ETA2 and ETA5 . . . . . . . . . . . . . . . . 29

To View Cp and Cpk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

French Cp and Cpk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

To Erase Stored Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

To Erase Stored Data and Setups on ETA5. . . . . . . . . . . . . . . . . . . 32

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Table of Contents (continued)

Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

To Print details of Setup or Analysis of Data from ETA5 . . . . . . . . . 34

Printing Data to PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

To Set Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

To Set Power Off and Backlight Time Delays. . . . . . . . . . . . . . . . . . 40

To Configure Printer Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

To Display Software Version Number. . . . . . . . . . . . . . . . . . . . . . . . 41

To Set Password Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

To Clear Password Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

To Perform Software Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

To Communicate with a PC using PC Comms Software . . . . . . . . . 44

Printout of Readings taken in Measure Mode . . . . . . . . . . . . . . . . . 45

Printout of Setup and Readings taken by Characteristic . . . . . . . . . 46

Printout of Analysis by Characteristic . . . . . . . . . . . . . . . . . . . . . . . 47

Printout of details of all Characteristic setups . . . . . . . . . . . . . . . . . 48

Printout of Round setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Printout of Readings taken by Characteristic. . . . . . . . . . . . . . . . . . 50

Rotary and Stationary Joint Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Nominal Joint Stiffnesses - Table. . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Bolt Hole Diagram and Sectional View Diagram . . . . . . . . . . . . . . . 53

Parts List - Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

External Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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How to use this Manual

This manual is split into sections describing the steps to be taken to configure the ETA for use in measuring and recording torque values.

There are a number of other parameters which are set from the Software Reset Menu, some of which are detailed elsewhere in this manual.

Pressing after making a selection will take the user on to the next screen.

Pressing will give the user the option to exit to the Misc menu or continue to edit by

Enter

pressing .

Screens can be skipped using the and keys.

The following method is adopted throughout this manual.

Keys to be pressed will be shown as the key legend in large type: Example

Any special instructions or point to note will be shown as:

Enter

INSTRUCTION TO BE FOLLOWED

Refer to the table of contents to find action to be performed.

Follow instructions for key presses required to carry out required action.

Note: It is possible to change the default primary character on dual function

keys. ie: when text is entered into various fields, it is possible to set the ETA to default to either the numerals or text as the primary character (the alternate character is selected by pressing the shift key before typing). To set this:

From main menu:

Press then press (Misc)

Press then press (Software Reset)

Press the 7 times to access the ‘Shift key’ menu

Select between options 1 ‘Characters’ or 2 ‘Numbers’ using:

Press Screen will prompt “End of setup”

MENU MENU

Press to return to main menu

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The following items, except those listed as optional, are included with the ETA unit:

1 x ETA Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ETA

1 x Camera (Neck) Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ETA-STRAP

1 x 9 way D type to 9 way D type PC cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ETA-PC99

1 x 9 way D type to 25 way D type Printer cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . ETA-P925

1 x 25 way D type to 25 way D type Port Saver . . . . . . . . . . . . . . . . . . . . . . . . . . . . ETA-PS25

1 x Fastcharge Charging Unit (Max. current 1 A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ETA-BC

1 x Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7464

1 x Warranty Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50807

1 x Carrying Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ETA-CASE

1 x Certificate of Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89937759

Packing List

(Dwg. TPA1821)

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Care and Storage

When not in use the unit should be returned to the supplied carry case.

This unit is designed for indoor use only

Operating temperature range 5-40 degrees C

Storage temperature range 0-50 degrees C

Battery Charging

The batteries in the ETA unit are shipped fully charged.

In continuous use with a transducer connected, the batteries have a life of at least 8 hours.

With the unit switched off from a 10% charge state, the batteries will fully discharge in 2550 days. To prevent the loss of all setup data, the unit has additional battery backup for the internal memory.

Automatic Power Off

To conserve battery life in use, the unit will switch off automatically after a predefined period. Pressing the on key will restore the unit to the last display prior to powering off.

The membrane keypad may be wiped clean with a soft damp cloth. The unit is not waterproofed and spillages should be avoided.

THIS UNIT CONTAINS NO USER SERVICEABLE PARTS. ONLY QUALIFIED SERVICE PERSONNEL SHOULD REPLACE OR FIT PARTS.

Fast Charge

The ETA’s should only be recharged with the supplied ETA-BC (Model MPP3OUS12) Battery Charger. ETA’s, are supplied with internal NiMH (Nickel Metal Hydride) batteries. These are environmentally friendly batteries presenting no problems for safe disposal and are capable of sustaining a rapid recharge. From fully discharged, the unit will require a charging period of approximately

2.5 hours.

To charge the batteries following a period of use, connect the supplied charger to the charging socket on the back of the unit and plug the charger into a suitable supply. The green LED will come on to indicate the machine is charging and will start to flash when the unit is fully charged. If the red LED comes on, this means there is a problem and usually indicates a faulty battery.

The Fast Charge method gives an increase in the effective life of the charged batteries.

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Edit Transducer File

Failure to input proper information may result in inaccurate readings.

The following instructions for “Edit Transducer File” must be followed before any reading or measurements can be taken.

This section may be skipped if you are using an Ingersoll-Rand TSD, TRD or Crane UTA Series Transducer.

There are 5 types of transducers and inputs which the ETA will accept.

1. High Output (H/O). These transducers have an internal amplifier and give an output signal level of 1-2 Volts.

2. Industry Standard (IS). These trans- ducers have no internal amplifier. The exact span or rated torque will be marked on the transducer nameplate. The sensitivity of these transducers is 2 mV/V., they are fitted with a 350 Ohm bridge.

3. Serial. These are digital type transducers and produce an RS232 signal.

4. Keypad (KPD). This is an optional keypad which connects to the ETA.

5. Keyboard (KEY). Keyboard on ETA.

Use of any of the above 5 types of inputs requires that settings are made in the transducer file before any measurements can take place. The procedure for entering settings follows.

For ETA5:

At main menu, press (Configure) then

press (Edit Tx)

Screen will show

Transducer

B (Current set-up) Complete set-up

The ‘B’ indicates that this is the ‘B’ file in memory. It is the first of 8 memories (labelled B to I) reserved for the saving of transducer set-ups. Your most used transducer setting should be stored in this memory.

The remaining memories (C to I) may be

accessed by pressing .

Press

Select input type H/O, I/S, SER, KPD or

KEY using ; press .

Enter

For ETA2:

At main menu, press (Edit Tx)

Depending on type of type selected above, continue set-up by following the appropriate section.

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If you have chosen I/S

Select units of measure - inlb, ftlb etc. using press

Type in transducer span- press

Type in mV/V press

Type in Bridge resistance press

Type in Pulses Per Rev (only for angle type) press

Type in Serial Number press

To set-up another transducer press

Enter

Select another memory (B to I) using the keys and press

To return to the main menu, press

If you have chosen SER

Select location of decimal point using press

Enter

Select Baud Rate, Data Bits, Stop Bits and Parity in the same manner

To set-up another transducer press

Select another memory (B to I) using the keys and press

To return to main menu press

Enter

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If you have selected H/O

Select units of measure- inlb, ftlb, etc. using

Note: High Output devices usually produce an output voltage of approximately 1-2 Volts. This analogue voltage signal will not be exact and may not be linear. If you are using a device that has a nominal 1Volt output, we suggest that you multiply the span of your transducer by 2.5 to determine the new span setting.

Type in your new span; press

Type in Serial Number; press

Screen will indicate ‘End of Set-up’; press to return to main menu

Enter

Connect your high output device and select measure mode

(refer to instruction sheet for measure mode only)

Use an independent measuring device to apply a torque to the transducer and check the reading on the independent unit against the reading shown on the ETA. It will be necessary to return to the ‘Edit Tx’ menu option and adjust the span setting until the two readings agree. You may have to repeat the above procedure several times until your high output transducer is correctly calibrated.

If you have selected KPD

Select location of decimal point using then press

Select Parity- Odd, Even or Disabled using then press

To set-up another transducer press

Select another memory (B to I) using the keys and press

Enter

To return to main menu press

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If you have selected KEY

Select location of decimal point using then press

To set-up another transducer press

Select another memory (B to I) using the keys and press

To return to main menu press

Enter

Barcode read input for characteristic

names and comments

It is possible to scan a barcode name in ETA5 at certain prompt lines. The input of a barcode is allowed at the characteristic name prompt in store characteristic, direct characteristic and edit characteristic modes. In addition it is also possible to scan a barcode in the comment field in store characteristic only. Edit characteristic and normal store behave in a slightly different manner to direct characteristic. The ETA5 will accept most barcode reading formats, but not all.

General Operational Method for Scanning Bar Code Data

Connect the Bar Code Reader ETA-BAR to the Printer/PC connector at the rear of the ETA5. Barcode readings can generally be taken at the prompt to input data (Characteristic name or a comment) when the flashing cursor is on the screen. This can be on a blank line or following a line of data (an existing characteristic or a comment). When the cursor is flashing, scan the code with a barcode reader and observe the screen. If the flashing cursor disappears, the code has been captured - wait a few seconds for the data to appear in the display. If the flashing cursor remains, re-scan the code until it is accepted.

When the data is displayed, press to continue. From this point, follow the instructions

Enter

as for normal data input.

When entering data via the Bar Code Reader into a comment field, make sure you have reserved enough characters in the comment field to accept the code. If the number of characters scanned in exceeds the number reserved, the ETA5 will beep and refuse to accept the data. Refer to the instructions on Configuration for more details.

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Measure Mode (Up to 200 readings stored)

To start, press

Press

Press (measure)

Plug in transducer; press

Enter

select proper transducer using

then press

Enter

If using I/S or H/O type transducers continue with instructions. If using SER, KPD or KEY, you are now ready to take measurements.

Select units of measure using ; press

Select Peak, Track, Impulse or ‘Click Dip’ using ; press

Use Peak for direct drive tools, Track for diagnostics, Impulse for pulse tools, and ‘Click Dip’ for click wrenches.

Select measurement direction using (Right is clockwise. Left is anti-clockwise);

Enter

press

Select ‘Cycle end Time’ using ; press (normal is 0.5 sec.)

Select frequency response using ; press

Type in Max torque value; press

Type in Min torque value; press

Enter

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Type in threshold value; press

Enter

Note: When selecting a threshold torque value the ETA will ignore any

torque that is below this value. You cannot take another reading until the applied torque falls below this value.

Type in amount of Dip; press

Select Second Parameter using ; press

Enter

If the setup and transducer has not been changed since the ETA was last used you are now ready to take torque measurements.

Pressing after taking a series of readings will result in statistical information being dis-

played (Range, mean and standard deviation) for the stored readings.

To return to measure mode, press

If you have selected ‘Click Dip’ type in the amount of ‘Dip’ to be sensed; press

Enter

Note: 5% of torque for 0 to 100 Nm and 10% of torque for over 100 Nm

generally provide excellent results.

You are now ready to take torque measurements. When finished press

Note: When taking readings you can change the set-up parameters by

pressing the up arrow

Changing any of the set parameters will result in the ETA prompting to erase all data.

To erase stored readings, press

To return to setup screens, press

Enter

Example: You have been measuring in a right hand direction and you want to

switch to left hand.

Press the up arrow twice, change from right hand to left hand. Screen will prompt to erase

all data.

Press to erase all stored readings and return to the measure screen.

Enter

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Printing of stored readings from measure mode

Pressing from the measure mode will result in all stored readings being printed to an attached printer or computer.

Note: Transducer needs to be connected to ETA.

Measure Mode Circle-Store Option

Circle-Store is a function to increase the number of stored readings to extend beyond the normal maximum of 200 readings possible in measure mode. With the circle-store option selected, readings will be accepted beyond the 200 limit but the first readings taken will be lost. Effectively the last 200 readings taken will be stored but the user is not limited to taking only 200 readings.

To select this option:

From main menu

Press then press (Misc’)

Press then press (Software Reset)

Press the 6 times to access the Circle-store menu

Select option 2 ‘Circle-store On’ using ; press

Press Screen will prompt: “End of setup”

Press to return to main menu

MENU MENU

Enter

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Direct Measure Mode - ETA5 ONLY

(Ingersoll-Rand TRD, TSD or

Crane UTA Type Transducers)

Direct measure mode allows an operator to connect different transducers which may have different spans and an angle output, and can switch between them using an external T switch. This is a display only function and readings are not stored or printed out.

To start, press

press

press (Direct)

press (Direct Measure)

press (Setup)

select units of measure using ; press

select peak, track, Impulse or ‘Click Dip’ using ; press

Enter

select measurement direction using (Right is clockwise. Left is anti-clockwise);

press

select ‘Cycle end Time’ using ; press

select frequency response using ; press

type in the Threshold Percent (mx 50.0; mn 0.0), and press

type in amount of Click (mx 100.0 Nm; mn 0.0 Nm), and press

Enter

select ‘Second Parameter’ using ; press

Screen shows “End of Setup”, press to exit

MENU MENU

press to return to main menu

Enter

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The READ option allows you to read the torque from a connected transducer.

From the main menu, press (Direct)

press (Direct Measure)

press (Read)

If no transducer is connected, display will prompt: “Insert Tx” (transducer)

connect transducer and press

Screen will show the span of the connected transducer and the torque measured in units selected at setup. The display will show the last reading taken until the next torque input exceeds the threshold level set.

Note: If password protection has been set on Direct measure, then exit is by

password only. A correct password returns you to the setup read submenu. Entering three incorrect passwords will force the user back into read mode. See password protection later in this book.

Enter

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To set up a Characteristic - ETA5 ONLY

To set up a job

To start, press

press

plug in transducer

press (Configure)

press (Edit Char)

Type in Job Name ______________________ , press

Enter

Alternatively, when the cursor is flashing, you may connect a Bar Code Reader to the Printer/PC connector on the back of the ETA5 and scan the information from a barcode. Scan across the label (from left or right) and watch the display. If the flashing cursor disappears, the reading has been captured; wait a few seconds for the reading to be displayed. If not, re-scan until the data is accepted.

When the information is displayed on the screen, press

Type in number of samples __________________ , press

Type in number of subgroups ________________ , press

Select transducer ID using , press

Enter

Select units of measure using , press

Enter

Select ‘Peak’, ‘Impulse’, or ‘Click’ using ; then press

Select measurement direction using ; then press

Select cycle end time using ; then press

Enter

+ 46 hidden pages