STAHLWILLE TORKMASTER 4 torque wrench calibration software Operating Instructions

Operating Instructions
TORKMASTER 4
Version 4.2.1
Operating manual for the TORKMASTER 4
EDUARD WILLE GmbH & Co. KG
Lindenallee 27
42349 Wuppertal, Germany
Tel.:
Facsimile:
Email:
Internet:
+49 202 4791-0
+49 202 4791-200
[email protected]
www.stahlwille.de
© STAHLWILLE 2011
Status: August 2011
Software version: 4.2.1
English translation of the German original
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Operating manual for the TORKMASTER 4
Preface
Key to success
Congratulations on your purchase of a high-quality STAHLWILLE tool.
Firmly based on tradition while embracing new technologies - this has been our guiding
philosophy ever since we started making high-grade tightening tools at our location in
Germany 150 years ago. From the careful selection of steels, the forging process and heattreatment through to the final product, all the crucial steps in the production chain of
STAHLWILLE brand products are in our hands.
STAHLWILLE quality tools are developed consistently in conjunction with customers in all
application fields and then jointly tested down to the last detail to ensure the required
standards are met. This makes STAHLWILLE's practically orientated tools “Key to success” underlining their already legendary reputation for precision, reliability and durability.
STAHLWILLE tools are more durable and, as a result, more economical in use.
Our aim is to contribute to your business success through our high-grade tools. We can offer
decades of experience, frankness and confidence in our dealings with others. Take us by our
word and put us to the test. Take advantage of the benefits of STAHLWILLE quality tools and
keep ahead of your competitors.
STAHLWILLE
Management
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Operating manual for the TORKMASTER 4
Contents
Preface .................................................................................................................................. 3
Contents ................................................................................................................................ 4
Safety instructions ................................................................................................................. 4
Introduction ........................................................................................................................... 5
System requirements............................................................................................................. 5
Preconditions relating to the operator .................................................................................... 5
Installation ............................................................................................................................. 6
Notes on the first start of the program after installation .......................................................... 9
Drivers under Microsoft Windows ........................................................................................ 10
User interface ...................................................................................................................... 15
Main window .................................................................................................................... 15
Connecting electronic tools to be calibrated ................................................................. 18
Quick test mode ............................................................................................................... 19
Administration .................................................................................................................. 21
Database of tool families .................................................................................................. 23
Owner database .............................................................................................................. 25
Tools database ................................................................................................................ 27
User management ........................................................................................................... 29
Program licences ............................................................................................................. 30
Parameters for the transducers ........................................................................................ 31
Instructions for use and examples ....................................................................................... 33
Notes on calibration (factors influencing the accuracy of readings) .................................. 33
Creating a new tool in the database ................................................................................. 34
Example of calibration in accordance with DIN EN ISO 6789:2003 using the PerfectControl
7794-1, 7791 or 7792....................................................................................................... 38
Example of calibration in accordance with DIN EN ISO 6789:2003 using the PerfectControl
7794-2 ............................................................................................................................. 43
Example of test and adjustment mode ............................................................................. 50
Safety instructions
Please observe the safety instructions contained in the operating manuals of the measuring
equipment used.
We would also draw your attention to the section headed >Calibrating instructions< in this
operating manual, where you will find descriptions of factors that may influence the results of
the calibration process.
If torque wrenches are incorrectly adjusted or calibrated, this can lead to corresponding
errors in tightening joints and further consequential damages. Note the manufacturer's
instructions when adjusting and calibrating a torque tool. STAHLWILLE does not accept any
liability for any damage or injury caused as a result of improper operation or use of this
software and any torque wrenches incorrectly calibrated or adjusted or for any consequential
damages.
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Operating manual for the TORKMASTER 4
Introduction
The TORKMASTER 4 software can be used for testing, adjusting and calibrating tools in
conjunction with the perfectControl 7794-x calibrating units, loaders 7791 and 7792 and the
workshop torque tester. The software is intended for recording measured values acquired
from series 772x torque transducers and 7770-x transfer torque wrenches. The software
enables calibrated tools and their data to be organised and managed.
The standard version allows manually operated Type I, Classes A-E and Type II, Classes AG torque tools to be calibrated in accordance with DIN EN ISO 6789. In addition, there is a
calibration method based on DIN EN ISO 6789 which enables individual calibration points to
be repeated during the process. For testing and adjusting procedures, the software offers a
specific testing and adjusting method which can also be activated as a quick-check method.
The functionality of the software can be expanded by the purchase of additional optional
licences; these include customer-specific calibration processes and the adjustment of
transducers using transfer torque wrenches and lever/mass systems.
Please observe the safety instructions and instructions for use contained in the operating
manuals for the transducers, transfer torque wrenches and perfectControl 7794-x calibrating
units and the 7707 W workshop torque tester.
If there are any sections of this operating manual you do not understand or if you have any
questions about the product, please do not hesitate to contact our application engineers at
EDUARD WILLE GmbH & Co. KG. You can contact them by phone on +49 202 4791-0 or by
email: [email protected].
System requirements
Operating systems supported:
Microsoft Windows XP, SP3; Windows Vista; Windows 7
Hardware requirements:
1 free USB interface for the STAHLWILLE
USB Adapter 7757-1
Preconditions relating to the operator
To ensure the calibration is performed correctly, it is essential that the operator has been
instructed in the content of the applicable standards (e.g.: DIN EN ISO 6789:2003) and has
fully understood them. Lack of knowledge or understanding of these standards and
regulations can result in the results of calibrations being inaccurate.
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Operating manual for the TORKMASTER 4
Installation
Installation of the software is explained below. For the installation on a Windows PC you will
require local administrator rights at the very least. If you do not have those rights, please
contact your system administrator.
Insert the CD-ROM and run the file named >TORKMASTER.exe<.
Acknowledge the warning message by clicking >Yes<
Select your preferred language for the installation procedure.
Note: This is not the language used for the software interface itself. The TORKMASTER
software will first run in the default language for your operating system but this setting can be
changed later to one of the other available languages via the Basic settings in the
TORKMASTER software.
Acknowledge the message by clicking >Next<
Please read and accept the licence conditions to install the software. Then click
>Next< to continue the installation.
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Operating manual for the TORKMASTER 4
Select the preferred installation folder.
Select a name for the start menu entry in Windows.
The window will display a summary of the selected options for the installation.
Continue the installation by clicking >Install<.
The TORKMASTER 4 software will now be installed on your PC.
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Operating manual for the TORKMASTER 4
Click >Finish< to complete the installation.
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Operating manual for the TORKMASTER 4
Notes on the first start of the program after installation
If you had an older version of TORKMASTER 4 on your PC, you will see a message when
you run the new version for the first time. Please confirm the message, which will enable the
existing database to be converted to the required format for the new TORKMASTER
software.
If, after running the program for the first time, the software does not detect the USB hub
(there will be a corresponding message in the TORKMASTER 4 status bar), or if the
transducer connected directly to the PC produces a steady warning sound, the driver for the
USB hub has not been correctly installed. This problem can be solved by referring to the
notes in the section headed >Drivers under Windows<.
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Operating manual for the TORKMASTER 4
Drivers under Microsoft Windows
Occasionally, the driver is not correctly installed under Windows. If this happens, it is
because Windows has installed its own native driver. This becomes noticeable if the
TORKMASTER software does not detect the transducer and no serial number or readings
are displayed. The status bar of the TORKMASTER 4 will state that the USB hub could not
be found. To correct this, proceed as follows:
Run the Windows Device Manager via the Control Panel (you will probably require
Administrator rights) and select the properties of the USB device by right-clicking the
name of the device:
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Operating manual for the TORKMASTER 4
Select >Update driver<:
Select >Search the computer for updated drivers<.
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Operating manual for the TORKMASTER 4
Navigate to the STAHLWILLE installation folder via the >Browse...< button.
Select the device named >Stahlwille USB Device<.
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Operating manual for the TORKMASTER 4
Select the data medium and then select C:\Program Files\Stahlwille\USB Driver *
* The actual path will depend on where you originally installed the Torkmaster software.
Click >Next< to install the driver.
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Operating manual for the TORKMASTER 4
The driver will now be correctly installed.
Now close all the windows and restart the TORKMASTER software.
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Operating manual for the TORKMASTER 4
User interface
Main window
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No.
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Function / description
Select the calibrating unit. If it is an automatic calibrating unit, you will see the serial
number of the connected loader. If it is a manual loader and tester, you will have to
select the unit manually via the pull-down menus.
Serial number of the connected reference (transducer). If two references are required
for a calibration, both serial numbers will be displayed. Reference 1 is the unit
currently connected.
Field for entering the search string for the device to be calibrated. This can be either
the serial number or the ident no. of the device.
If the serial or ident no. is shown in red, this means it has not yet been stored in the
database. For a calibration, the device to be calibrated must first be entered in the
database. Refer to the section headed “Creating a new tool”.
Selecting the calibration method. This selection is via the pull-down menu. The
entries may differ depending on the software licence.
Standard methods:
Test & adjustment, quick test, DIN EN ISO 6789:2003 and based on DIN EN ISO
6789:2003.
Function keys (description on the following page)
Display of the last reading made.
Display of the current reading.
Bar graph showing the full measuring range of the reference device.
Graphical display of torque development over time.
No.
Function / description
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Operating manual for the TORKMASTER 4
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The green area describes the target field based on the relevant temporal parameters
taken from DIN EN ISO 6789:2003 (X axis) and the display deviation value for the
torque wrench as defined in the database (Y axis).
Display of the cut-out value (first peak) detected.
80% marking in accordance with DIN EN ISO 6789:2003.
Bar graph display for the restricted measuring range (±25% of target).
Status bar for application notes (yellow / black), action notes (grey / green) and fault
messages (yellow / red).
Comment field. Optional comments can be entered here at any point until the
calibration is saved. The comment is stored in the database together with the
calibration data. Comments cannot be modified subsequently.
Display of calibration readings
Display of a summary of the calibration (after saving).
Description of the graphical user interface:
100% (target value)
target range
(green field)
0.5 s
4.0 s
80% of target
last readings (black)
current reading
(green)
The max. vertical value of the target range is represented by the display deviation value for
the torque wrench as stored in the database under tool group.
The width of the target range is provided by the requirements of the standard used for the
calibration (in this case: DIN EN ISO 6789:2003).
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Operating manual for the TORKMASTER 4
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If a function is not available, the corresponding keys will be greyed out.
No.
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Function / description
Repeat calibration. This initiates a new calibration. If the previous calibration was not
saved, it will be aborted.
Repeat last measurement.
Reset transducer.
Resend the last calibration step to the calibrating unit. This enables interrupted
calibrations (e.g. after an error) to be continued.
Opens the TORKMASTER database and the basic settings.
Read saved test and calibration data.
Print calibration certificate. Depending on the basic settings, the calibration certificate
can be displayed, printed or saved as a PDF file in a folder defined in the basic
settings. Clicking this button saves the calibration in the database and performs the
preset option.
Save calibration in the database.
Show comment field. Comments can only be entered up to the point where the
calibration is saved.
Marking of the calibration as either “as found” or “as left” calibration.
Expansion of the menu with additional functions (output graph, export calibration
(CSV format) and open operating manual).
Move the mouse pointer over the serial
number of the tool being calibrated, the
references or the individual readings and
hover the pointer over one of these to
display the context menu. The context
menu contains important details about
the value.
If the tool is a torque wrench, the details
will be taken from the database, if it is a
transducer, the data stored will be shown
and with the measured values, you will
see the target and actual values
including the associated errors.
Any readings outside the tolerance range
will be shown in red.
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Operating manual for the TORKMASTER 4
Connecting electronic tools to be calibrated
If electronic tools are to be calibrated with the perfectControl 7794-2 or 7794-3 and adjusted,
they have to be connected to the calibration system via the port at the rear. Details can be
seen in the operating manual for the calibration system.
To initiate communication between the calibration system and the tool to be calibrated, click
the button above the edit box for the serial number (see illustration).
Once communication has been established, the serial number in the edit box is shown on a
grey background.
If it is not possible to establish communication with the tool, the system will abort the attempt
after 60 seconds. In some cases, it is not possible to set up an automatic connection with the
tool to be calibrated due to its hardware configuration. In such cases, the tool can be
calibrated manually.
If, at this point, the torque tool is not already stored in the database, it will be automatically
added. The current tool settings will be used.
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Operating manual for the TORKMASTER 4
Quick test mode
The TORKMASTER also has a quick test mode. This mode is particularly recommended
when the STAHLWILLE 7707 W workshop torque tester is being used to document the test
results.
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No.
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Function / description
Reset transducer.
Opens the TORKMASTER -78 database and the basic settings.
Print calibration certificate. Depending on the basic settings, the calibration certificate
can be displayed, printed or saved as a PDF file in a folder defined in the basic
settings. Clicking this button saves the calibration in the database and performs the
preset option.
Field for entering the search string for the device to be calibrated. This can be either
the serial number or the ident no. of the device.
If the serial or ident no. is shown in red, this means it has not yet been stored in the
database.
Free-text entry of the target value of the test. Enter the required value and confirm by
pressing ENTER. The value becomes the target value.
Take maximum possible scale reading from the tool database.
Take 60% scale reading from the tool database.
Take 20% scale reading from the tool database.
Change direction of loading, provided the tool being calibrated has been entered in
the database as being usable in both directions.
Show / hide comment fields
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Operating manual for the TORKMASTER 4
The quick test mode can be activated via the basic settings menu. Proceed as follows:
Open menu >Administration< (>Verwaltung<)
Activate the >Quick test< (>Schnelltest<) checkbox (green arrow)
Click the >Save< key (>Speichern<)
Close the menu
Exit Torkmaster and restart
If the quick test mode checkbox has been activated, TORKMASTER will always run in this
mode until the checkbox is deactivated again.
The quick test mode is used for testing torque tightening tools. The tools to be tested must
first be entered in the database. Target values can be preset using the <20%>, <60%> and
<100%> keys. The edit box can be used to enter any required intermediate values.
The results of the quick test are saved under the predefined serial number for that torque
tightening tool.
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Operating manual for the TORKMASTER 4
Administration
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No.
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No.
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Function / description
Standard search settings. It is always possible to search by serial number and ident
number. The display shows either the ident number or the serial number.
Settings for the printer icon in the main window.
Name of the employee carrying out the calibration.
Temperature during calibration. This has to be manually recorded and entered. The
default setting is 21°C.
Language setting. The default is the language of the operating system. It is however
possible to select a different language. If the language of the operating system is not
supported, all text will be displayed in English.
Language settings for the calibration certificate. The default is the language of the
operating system. It is however possible to select a different language. If the
language of the operating system is not supported, all text will be displayed in
English.
Saving the modified basic settings.
Restoring default settings.
Function / description
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Save current settings as new defaults.
Close the window.
Only applies to indicating calibration tools:
Representation of tool results in the calibration certificate (instead of reference
results). According to DIN EN ISO 6789:2003, the reference results should be given
(checkbox deactivated).
Activating this option does not influence the calculated, displayed deviation between
the tool being calibrated and the reference.
Mathematical filter of torque signal. This can be used to increase the accuracy for
static measurements.
Only activate this function if you are doing static measurements!
This function only applies to indicating torque wrenches. If this option is selected, the
perfectControl with automatically ramp up to the preset. The operator enters the
reading displayed on the torque wrench manually.
The parameters for the transducer may only be modified by a system administrator.
Number of days for the advance warning of an impending recalibration.
If this function has been activated, the TORKMASTER will give advance warning of
impending recalibrations for all tools that are subject to compulsory recalibration at
specific intervals. If a zero is entered, the function is disabled.
The program can use its own login and user administration system instead of the
Windows logon.
Name of the laboratory manager whose name is to appear on calibration certificates.
STAHLWILLE USB hubs used to use different USB ident numbers in the past. If any
ident number is to be accepted, this field must be activated as otherwise only the
current adapters will be accepted.
Activating this field will enable transducers equipped with firmware 2.xx to be
accepted.
Warning: If this field is activated, there will not be such a high standard of protection
for transducers!
Path for saving automatic PDF calibration certificates. Hover the mouse pointer over
this field to see the options for a generic path
Save calibration certificates automatically as PDF files after the calibration has been
saved.
Run TORKMASTER in quick test mode. Refer to the section headed >Quick test
mode<.
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Operating manual for the TORKMASTER 4
Database of tool families
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General tool-specific data of the tool to be calibrated are stored in the tool family. Before a
tool can be calibrated, it must first be allocated to a tool family. In addition, every tool to be
calibrated must have an owner and individual tool parameters entered with it (e.g. serial
number).
STAHLWILLE tools are already stored in the database. Third party tools can be added by the
operator.
The settings must follow the manufacturer's instructions and corresponding relevant
standards and regulations.
No.
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No.
Function / description
Function key for expanding the menus.
Manufacturer of the torque wrench.
Catalogue number / designation of the torque wrench.
Starting value for the measuring range of the torque wrench.
Scale of the torque wrench.
Recalibration interval of the torque wrench. If a specific recalibration interval is
entered on the Tool tab, this will have priority.
Finishing value for the measuring range of the torque wrench.
Function / description
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Operating manual for the TORKMASTER 4
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Unit of measure of the torque wrench.
Display deviation value of the torque wrench.
Confirm entries and save the new or modified data record.
Copying a data record.
Select the data record to be copied and then confirm by clicking the >Copy< button.
Any required changes can then be made to the new data record (e.g. manufacturer,
measuring range or unit of measure). Save the new data record by clicking >Apply<
and close the dialogue box.
Note: The data record must have a different name because it is not permitted to have
multiple names with differing parameters in the database.
Cancel data entry or editing of a data record.
Delete a data record. It is only possible to delete a data record if no tools have been
allocated to that tool family. An error message will occur otherwise.
Continue on the next tab.
Filter bar. Tools entered in the database can be sorted by a number of criteria.
List of all the tools entered in the database.
Close the window.
Edit box for the automatic filter function within the database. This filter is applied to
the first column of the database shown. Double-clicking the corresponding column
heading allows you to sort by that column as the first column.
Additional standards-specific details relating to that tool. Details below.
Marking of the tool for clockwise and anticlockwise tightening.
Additional settings for calibration in accordance with DIN EN ISO 6789:2003:
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When entering parameters, note the manufacturer's instructions and the DIN EN ISO
6789:2003 requirements.
No.
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Function / description
Calculate the values for the calibration points (20, 60 und 100%).
Type of torque wrench in accordance with DIN EN ISO 6789:2003.
Class of torque wrench in accordance with DIN EN ISO 6789:2003.
Starting value for the measuring range of the torque wrench.
20% calibration point. If the torque wrench is to be calibrated at calibration points
other than the standard ones, individual changes can be entered manually.
60% calibration point. If the torque wrench is to be calibrated at calibration points
other than the standard ones, individual changes can be entered manually.
100% calibration point. If the torque wrench is to be calibrated at calibration points
other than the standard ones, individual changes can be entered manually.
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Operating manual for the TORKMASTER 4
Owner database
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Every tool to be calibrated must be assigned to an owner. The “owner” might be the
customer of a calibration laboratory or a production cell within the production facility.
No.
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Function / description
Function key for expanding the menus.
Abbreviation of the owner (alphanumeric).
Name of the owner
Contact details of the owner
Address of the owner
Function key for adding a new data record to the database
Function key for copying an existing owner.
Cancel entry of a new owner
Delete an owner from the database. It is only possible to delete an owner if no tools
have been allocated to him / her
Function key for entering more details for a tool (individual parameters of a tool)
Filter bar. Owners entered in the database can be sorted by a number of criteria.
List of all the owners entered in the database.
No.
14
Function / description
Edit box for the automatic filter function within the database. This filter is applied to
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Operating manual for the TORKMASTER 4
15
the first column of the database shown. Double-clicking the corresponding column
heading allows you to sort by that column as the first column.
Close the window.
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Operating manual for the TORKMASTER 4
Tools database
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This is where the individual parameters for a tool are entered. It is a precondition that the
corresponding tool family and the owner have already been entered.
No.
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No.
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Function / description
Function key for expanding the menus.
Select the abbreviation for the owner. You can choose between the pull-down menu
(arrow on the right) to display the complete list or simply start typing in the box. The
autotext function will then automatically restrict the list to those applicable.
Choice of tool family. You can choose between the pull-down menu (arrow on the
right) to display the complete list or simply start typing in the box. The autotext
function will then automatically restrict the list to those applicable.
Serial number of the tool to be calibrated. Use this number to search for the tool in
the database.
User specific ident number (e.g. test equipment number) of the tool. Use this number
to search for the tool in the database.
Enter the calibration interval if this deviates from the one entered in the tool family.
Function key for adding a new data record to the database.
Function / description
Cancel entry of a new tool.
Delete a tool from the database.
Returns to the main menu and loads the tool (torque wrench) for calibration.
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Operating manual for the TORKMASTER 4
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Returns to the tool family to enable any necessary modifications.
Filter bar. Click a column header to sort the tools.
List of all the tools entered in the database.
Edit box for the automatic filter function within the database. This filter is applied to
the first column of the database shown. Double-clicking the corresponding column
heading allows you to sort by that column as the first column.
Close the window.
Date of next calibration of the torque wrench. This may be a specific date, or
calendar week or year. This is essential data if you wish to use the automatic
advance recalibration notification function.
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Operating manual for the TORKMASTER 4
User management
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User management can be used to restrict the functionality of the software.
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Function / description
Function key for expanding the menus.
Name of the user.
Permissions level.
Sign-in name at operating system level.
Function key for adding a new data record to the database.
Cancel entry of a new user.
Delete a user from the database.
Assign the user a password or change a password (Administrator rights required).
Filter bar. Click a column header to sort the users.
List of all the users entered in the database.
Close the window.
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Operating manual for the TORKMASTER 4
Program licences
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The functionality of the TORKMASTER software can be expanded by purchasing additional
licences (TORKMASTER Premium). Examples of expansion packs are special-purpose
calibrating or adjustment workflows (DKD-R 3-8 or ASME B107.300).
To provide a licence, we would require the MAC ID of the network adapter of the PC to be
used. As an alternative, you can provide us with the USB device ID of the STAHLWILLE
USB hub. These details are displayed in the edit box and have to be communicated to
STAHLWILLE to enable us to generate the licence file.
No.
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6
Function / description
Edit box for the licence key
To open the licence file.
Function key for adding a new licence.
Filter bar. Click a column header to sort the licences.
List of all the licences entered in the database.
Close the window.
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Operating manual for the TORKMASTER 4
Parameters for the transducers
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The variable parameters can be entered here for the reference modules (transducers). The
transducers have to be connected to the PC via the USB hub for this function.
We recommend entering these data before you use each transducer for the first time.
No.
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8
Function / description
Display of the transducer type. This data record is permanently stored in the
transducer.
Measuring range of the transducer type. This data record is permanently stored in
the transducer.
Serial number of the transducer. This data record is permanently stored in the
transducer.
Function key for saving the parameters in the transducer that is connected to the PC.
User specific ident number (e.g. test equipment number) of the tool.
User specific number of the tool to be calibrated.
Commissioning date of the transducer (format: DD/MM/YYYY). A calendar view will
open via the pull-down menu (arrow on right).
Recalibration interval of the transducer.
No.
Function / description
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3
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7
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10
11
Date of next calibration of the transducer (format: DD/MM/YYYY). A calendar view
will open via the pull-down menu (arrow on right). This date also appears in the
calibration certificate generated with TORKMASTER.
This function prevents the transducer from being reset when it is under load. When
using the transducer together with a perfectControl 7794-2 or 7794-3, this function
must be selected. The function is intended to prevent damage to the transducer if the
equipment is incorrectly used, but also prevents measuring errors resulting from
incorrect operation of the tare button.
Close the window.
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Operating manual for the TORKMASTER 4
Instructions for use and examples
Notes on calibration (factors influencing the accuracy of readings)
The results of a calibration may be falsified by the following factors:
•
•
•
•
•
•
Climatic conditions
o Room temperature (absolute value and stability)
18 - 28°C and ≤ 1K temperature change during calibration
o Temperature of the tool being calibrated
We recommend storing the tool to be calibrated in the laboratory for 24 hours
before attempting to calibrate it.
o Relative humidity
Transducer
o Display accuracy / measurement uncertainty
o Scan rate
o Influence of lateral forces
o Point at which the unit is reset
o The way the transducer is fixed
Alignment of the tool to be calibrated
o Horizontal or vertical alignment
o Level position of the tool to be calibrated with reference to the base (e.g. ±3°)
o Position of the point of application of force (variation in the lever arm)
o Shift of the point of application of force during the measurement process
o Support for the point of application of force
Adaptation of the tool to be calibrated
o Calibrating insert tool and alignment of the square drive
o Reduction adapter for matching the insert tool to the transducer
o Use of ratchets or male square drives with a ball end. Both insert tools will
have a considerable influence on the results of the calibration due to their
tolerances, which are a result of the production process. This is why we
recommend using special calibration insert tools.
Detecting the trip point
o Scan rate of the transducer
o Tightening speed of the torque wrench
o Point at which the transducer is reset
o Parameters for detecting the trip point
Human error
o Knowledge and experience of using the calibration technology being applied
o Knowledge of the requirements in the standards and regulations applicable
o Knowledge of the tools being calibrated
o Non-observance of instructions contained in the various documents
Operating instructions
Standards and regulations
We recommend carrying out an FMEA (failure mode and effects analysis) on the calibration
process to identify any possible process defects and their consequences and take
corresponding corrective action to prevent these defects.
Apply Ishikawa logic: Manpower, Method, Machine, Matter and Means
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Operating manual for the TORKMASTER 4
Creating a new tool in the database
Below we show an example for creating a completely new clicking torque wrench (Type II /
Class A) in accordance with DIN EN ISO 6789:2003 in the TORKMASTER database. This
requires four steps:
1. Create a tool family
2. Create an owner
3. Create a tool
4. Start calibration
Open the database.
Select the >Tool family< (>Werkzeuggruppen<) tab.
Click >Add< (>Hinzufügen<).
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Operating manual for the TORKMASTER 4
Enter the manufacturer of the tool (>Hersteller<).
Enter a unique name for the tool. (>Katalognr.<) Note: The name is the identifier
within the database. If you wish to create a number of tools of the same type but e.g.
with different units of measure, the unique names have to show this difference.
Example: 730D/10_Nm and 730D/10_inlb.
Enter the starting point of the scale.
Enter the end point of the scale (>Meßbereich< right-hand box).
Select the unit of measure (pull-down menu).
Enter the scale resolution (>Skaleneinteilung<).
Enter the display deviation value (>Toleranz<).
Enter the recalibration interval (>Kalibrierinterval<).
Activate the appropriate checkboxes for the permitted directions of loading (here: only
clockwise (>rechts<)).
Select the type in accordance with DIN EN ISO 6789:2003 (>Messart<).
Select the class in accordance with DIN EN ISO 6789:2003 (>Klasse<).
Enter the three scales for calibration (>Skalen<). Press >Recalculate< (>(neu)
errechnen<) to have the values automatically recalculated.
If necessary, adjust the number of dummy measurements.
Click the >Add< button (>Hinzufügen<) to create the new tool family.
Click >Next< (>Vor<) to advance to the >Tools< tab (>Werkzeuge<). If the owner of
the tool is not yet in the database, select >Owners< (>Eigentümer<) to add the name.
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Operating manual for the TORKMASTER 4
Enter an abbreviated name (matchcode) (>Abkürzung<) for the user. Note: This
matchcode is the identifier within the database.
Enter the company and/or name (>Firma/Name<).
Enter the contact details (>Kontakt/Abteilung<).
Enter the street address (>Straße<).
Enter the town (>Stadt (Land)<).
Click the >Add< button to create the new owner (>Hinzufügen<).
Click >Next< (>Vor<) to advance to the >Tools< tab (>Werkzeuge<).
Select the owner (>Eigentümer<). You can enter the beginning of the name if it is
known. In the list that then appears, select the correct entry with the mouse or using
the arrow keys and press enter to select.
Select the torque tightening tool (>Katalognr.<). You can enter the beginning of the
name if it is known. In the list that then appears, select the correct entry with the
mouse or using the arrow keys and press enter to select.
Enter the serial number (>Seriennr.<). Note: This unique number is the reference
within the database.
Enter the test equipment number or label (>Identnr.<).
Enter the recalibration interval (>Kalibrierinterval<).
Enter the date for the next calibration (>Nächste Kalibrierung<). This may be a
specific date, or calendar week or year. This is essential data if you wish to use the
automatic advance recalibration notification function.
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Operating manual for the TORKMASTER 4
Click the >Add< button (>Hinzufügen<) to create the new tool.
Click >Next< (>Vor<) to advance to the main menu.
Select the calibration method
Start the calibration process and follow the instructions in the status bar of the
TORKMASTER software.
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Operating manual for the TORKMASTER 4
Example of calibration in accordance with DIN EN ISO 6789:2003
using the PerfectControl 7794-1, 7791 or 7792
Below we show an example for calibrating a clicking torque wrench (Type II / Class A) in
accordance with DIN EN ISO 6789:2003 using the perfectControl 7794-1 and manual
operation. The procedure applies also to loaders 7791 and 7792, and if the software is used
together with the 7707 W workshop torque tester.
Preconditions:
• The TORKMASTER software must be installed and running.
• A transducer must be connected to the PC via the USB hub.
• The software will automatically detect the transducer and the serial number of the
transducer will appear in the field >1st reference< (>1. Referenz<).
• Torque is displayed.
• There are no faults in the equipment.
Calibration:
Select a >Calibrating unit< (>Kalibriereinrichtung<).
First check the tool to be calibrated for any signs of damage or cracks and check that
the scale is easily legible.
To run the calibration, enter the serial number, as an alternative the ident number,
under >Tool to be calibrated< (>Kalibriergegenstand<). If the number is shown in red,
the tool being calibrated has not yet been defined in the database. In this case, you
will have to enter its details in the database first (see section on tool database).
If the tool being calibrated is already in the database (serial number shows in black),
you can now select the >Calibration method< (>Kalibriermethode<). In this example,
the tool is to be calibrated in accordance with DIN EN ISO 6789:2003.
Select the corresponding adapter and a suitable calibrating insert tool. If necessary,
use reducing adapters but never combine several reduction adapters! This will falsify
the calibration results. Place the torque wrench in the calibrating unit and align it in
accordance with the provisions in the regulations. Note the calibration instructions on
the effects of external factors.
On the torque wrench, set the highest value for the dummy measurements.
Note: Always adjust from a lower to a higher value.
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Operating manual for the TORKMASTER 4
Now follow the instructions shown in the status bar and do 5 dummy
measurements by applying force via the handwheel. While applying force,
ensure that the trip point is always within the target area, which is shown in
green. If force is applied too fast, the trip point will be before the green area
(t <0.5 s), and if it is applied too slowly, the trip point will be behind the green
area (t >4 s).
Completely remove the torque wrench, reduction piece and the adapter.
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Operating manual for the TORKMASTER 4
Press the tare / reset button (>Tara<). Ensure the torque displayed on the unit does
not change at all before the tare button is pressed.
Now set the value shown in the status bar on the torque wrench. It is possible to
define different calibration points in the database (under tool family
(>Werkzeuggruppe<)). As an example, this could be the starting point of the scale if
this is less than 20%.
Now load the wrench.
Please apply load to 120 N m, then release
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Operating manual for the TORKMASTER 4
Now set the value shown in the status bar on the torque wrench.
Now load the wrench.
Please apply load to 200 N m, then release
Now set the value shown in the status bar on the torque wrench.
Now load the wrench.
Calibration completed. Please save or print the data
After the fifth loading, the software recognises that the calibration has been
completed. You can now label the calibration as either “As found” or “As left” and/or
enter a comment in the comments field. You can then save or print the calibration.
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Operating manual for the TORKMASTER 4
The software will now display the calibration summary. The software is now ready for
the next calibration. Any values outside the tolerance range will be shown in red.
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Operating manual for the TORKMASTER 4
Example of calibration in accordance with DIN EN ISO 6789:2003
using the PerfectControl 7794-2
Below we show an example for automatically calibrating a clicking torque wrench (Type II /
Class A) in accordance with DIN EN ISO 6789:2003 using the perfectControl 7794-2.
Preconditions:
• The perfectControl must be powered on, the TORKMASTER software installed and
running.
• The software will automatically detect the calibrating unit.
• The serial number of the unit is displayed in the >Calibrating unit<
(>Kalibriereinrichtung<) field and the serial number of the transducer in the >1st
reference< (>1. Referenz<) field.
• Torque is displayed.
• There are no faults in the equipment.
Calibration:
Select a >Calibrating unit< (>Kalibriereinrichtung<).
First check the tool to be calibrated for any signs of damage or cracks and check that
the scale is easily legible.
To run the calibration, enter the serial number, as an alternative the ident number,
under >Tool to be calibrated< (>Kalibriergegenstand<). If the number is shown in red,
the tool being calibrated has not yet been defined in the database. In this case, you
will have to enter its details in the database first (see section on tool database).
If the tool being calibrated is already in the database (serial number shows in black),
you can now select the >Calibration method< (>Kalibriermethode<). In this example,
the tool is to be calibrated in accordance with DIN EN ISO 6789:2003.
Select the corresponding adapter and a suitable calibrating insert tool. If necessary,
use reducing adapters but never combine several reduction adapters! This will falsify
the calibration results. Place the torque wrench in the calibrating unit and align it in
accordance with the provisions in the regulations. Note the calibration instructions on
the effects of external factors.
On the torque wrench, set the highest value for the dummy measurements.
Note: Always adjust from a lower to a higher value.
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Operating manual for the TORKMASTER 4
Please set to 200 N m, then press Start/CCW
Press the Start button.
Preload to 200 N m
The perfectControl will now run the dummy measurements fully automatically.
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Operating manual for the TORKMASTER 4
Remove the tool, then press Tara/Reset
Remove the torque wrench completely.
Press the tare button on the unit. Ensure the torque displayed on the unit does not
change at all before the tare button is pressed.
Please set to 40 N m, then press Start/CCW
Replace the torque wrench in the unit. Ensure it is perfectly horizontally aligned and
that the anti-pinch mechanism is correctly set. If the software shows a torque reading
after the wrench has been replaced in the unit, this is a sign that the torque wrench is
not correctly positioned. The torque is generated by lateral forces being applied. If the
torque wrench is incorrectly positioned, this can falsify the calibration.
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Operating manual for the TORKMASTER 4
Close the hood
Now set the value shown in the status bar on the torque wrench.
Press the Start button on the unit.
Apply load of 40 N m
The perfectControl will now run the loadings fully automatically.
Please set to 120 N m, then press Start/CCW
Now set the value shown in the status bar on the torque wrench.
Press the Start button on the unit.
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Operating manual for the TORKMASTER 4
Apply load of 120 N m
The perfectControl will now run the loadings fully automatically.
Please set to 200 N m, then press Start/CCW
Now set the value shown in the status bar on the torque wrench.
Press the Start button on the unit.
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Operating manual for the TORKMASTER 4
The perfectControl will now run the loadings fully automatically.
Returning to zero position
The perfectControl will return the torque wrench to its home position after the
calibration has been completed.
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Operating manual for the TORKMASTER 4
After the fifth loading, the software recognises that the calibration has been
completed. You can now label the calibration as either “As found” or “As left” and/or
enter a comment in the comments field. You can then save or print the calibration.
The software will now display the calibration summary. The software is now ready for
the next calibration.
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Operating manual for the TORKMASTER 4
Example of test and adjustment mode
Below we will show how a clicking torque wrench (Type II / Class A) is tested and adjusted
using the perfectControl 7794-2.
Preconditions:
• The perfectControl must be powered on, the TORKMASTER software installed and
running.
• The software will automatically detect the calibrating unit and the serial number of the
unit will appear in the field >Calibrating unit< (>Kalibriereinrichtung<).
• The serial number of the transducer will appear in the >1st reference<
(>1. Referenz<) field.
• Torque is displayed.
• There are no faults in the equipment.
Test and adjustment:
First check the tool to be calibrated for any signs of damage or cracks.
To run the test and adjustment, enter the serial number, as an alternative the ident
number, under >Tool to be calibrated< (>Kalibriergegenstand<). If the number is
shown in red, the tool being calibrated has not yet been defined in the database. In
this case, you will have to enter its details in the database first (see section on tool
database).
If the tool to be calibrated is already defined in the database, you can select the
>Calibration method< (>Kalibriermethode<). In this example, we want to test and
adjust the tool. Select >Test and adjustment< (>Test und Justage<).
Select the corresponding adapter and a suitable calibrating insert tool. If necessary,
use reducing adapters but never combine several reduction adapters! Place the
torque wrench in the calibrating unit and align it in accordance with the provisions in
the regulations. Note the calibration instructions on the effects of external factors.
On the torque wrench, set the rated value for the dummy measurements.
Press the Start button.
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Operating manual for the TORKMASTER 4
From the list, select the value you wish to use to test & adjust the tool. As well as the
calibration points defined in the database: low value (20%), medium value (60%) and high
value (100%), it is also possible to enter a freely defined value (just enter in the field and
press Enter.).
The status bar will show appropriate instructions. You can now perform this loading as often
as required by simply pressing the Start button.
Please set to 400 N m, then press Start/CCW
The test and adjustment data can also be stored in the database. The data can be printed or
saved in a PDF file. Note that a maximum of 10 data points can be printed.
Note: After completing the adjustment, ensure you load the torque wrench several times to
prevent mechanical settling tendencies from influencing the subsequent calibration process.
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