MULTITEST - CDI Torque Products

USER MANUAL
TFC2000-0-03
NSN 6635-01-327-4461
MULTITEST
Electronic Torque/Force/Angle
Calibration System
MANUAL P/N 2000-760-02
19220 San Jose Avenue • City of Industry, California 91748-1497
(626) 965-0668 / (800) 525-6319 • Office Fax (626) 810-2759 • Sales Fax (626) 965-2410
Visit our website at: www.cditorque.com
CDI ENGINEERING TECHNICAL SHEET
Subject:
TFC 2000 CALIBRATOR WITH MULTITEST (2000-610-02)
Accuracy and usable range of transducer
Transducers supplied with Multitest System have a calibration range defined
from 10% to 100% of Full Scale [FS].
Accuracy is as indicated in the Certificate of Calibration unless otherwise
stated.
Issued by: David Duvan, V.P. of Engineering
Date issued: May 24, 2006
Suggested Transducer Calibration Check Points, Bars, Hangers and Weights
for 2500-400-02 (Multiple Transducer Assembly, 0.25% Accuracy)
Range
Bar
Hanger Calibration
Length Weight Points
Check
Points
Weights to Add
(n) = more than 1
40 - 400 in oz
5"
5"
5"
5"
5"
1/2 lb
1/2 lb
1/2 lb
1/2 lb
1/2 lb
1 40.0 in oz
2 80.0 in oz
3 160.0 in oz
4 240.0 in oz
5 400.0 in oz
40 in oz
80 in oz
160 in oz
240 in oz
400 in oz
none
1/2 lb
1/2 lb, 1 lb
1/2 lb, (2) 1 lb
1/2 lb, (2) 2 lb
3.75 - 50 in lb
5"
5"
5"
5"
5"
5"
1/2
1/2
1/2
1/2
1/2
1/2
1
2
3
4
5
3.75 in lb
5.0 in lb
10 in lb
20 in lb
30 in lb
50 in lb
4 oz
1/2 lb
1/2 lb,
1/2 lb,
1/2 lb,
1/2 lb,
10 - 150 in lb
30 - 400 in lb
lb
lb
lb
lb
lb
lb
5.0 in lb
10.0 in lb
20.0 in lb
30.0 in lb
50.0 in lb
1
1
1
1
lb
lb, 2 lb
lb, (2) 2 lb
lb, (4) 2 lb
Total
Weight
1/2 lb
1 lb
2 lb
3 lb
5 lb
0.75
1
2
4
6
10
lb
lb
lb
lb
lb
lb
5"
5"
5"
5"
5"
5"
1/2
1/2
1/2
1/2
1/2
1/2
lb
lb
lb
lb
lb
lb
1
2
3
4
5
15.0 in lb
30.0 in lb
60.0 in lb
90.0 in lb
150.0 in lb
10 in lb
15 in lb
30 in lb
60 in lb
90 in lb
150 in lb
1/2
1/2
1/2
1/2
1/2
1/2
lb, 1 lb
lb, 2 lb
lb, 1 lb, (2) 2 lb
lb, 1 lb, (2) 5 lb
lb, 2 lb, (3) 5 lb
lb, (2) 2 lb, (5) 5 lb
2
3
6
12
18
30
lb
lb
lb
lb
lb
lb
10"
10"
10"
10"
10"
10"
1/2
1/2
1/2
1/2
1/2
1/2
lb
lb
lb
lb
lb
lb
1
2
3
4
5
40.0 in lb
80.0 in lb
160.0 in lb
240.0 in lb
400.0 in lb
30 in lb
40 in lb
80 in lb
160 in lb
240 in lb
400 in lb
1/2
1/2
1/2
1/2
1/2
1/2
lb, 2 lb
lb, 1 lb, 2 lb
lb, 2 lb, 5 lb
lb, (3) 5 lb
lb,1 lb, 2 lb, (4) 5 lb
lb,1 lb (4) 2 lb, (6) 5 lb
3
4
8
16
24
40
lb
lb
lb
lb
lb
lb
Amendment for Multitest Loader Manual: May 24, 2006
Table of Contents
MULTITEST Indicator Manual .................................................................................................... 1
Torque Tester/Calibrator Manual ..............................................................................................
2
Low Torque Station Manual .......................................................................................................... 3
Force Testing Manual ...................................................................................................................
Maintenance Instructions
4
............................................................................................................. 5
Table of Contents
Safety Information ...................................................................................................................... I
Introduction ............................................................................................................................ 1-1
Functional Description and Specifications ............................................................................ 2-1
Functional Descriptions ............................................................................................................. 2-1
MULTITEST Torque Calibration System ............................................................................... 2-1
2000-610-02 Indicator ......................................................................................................... 2-3
Front Panel ................................................................................................................... 2-3
Rear Panel (Input/Output) ............................................................................................. 2-7
Torque/Force Transducers ............................................................................................. 2-9
Specifications .......................................................................................................................... 2-11
MULTITEST Torque Calibration System ...................................................................... 2-11
2000-610-02 Indicator .................................................................................................. 2-11
Torque/Force Transducers ............................................................................................ 2-13
2000-600-02 Manual Loader Specifications .................................................................. 6-10
Setup and Programming .......................................................................................................... 3-1
MULTITEST Torque Calibration System Setup .................................................................... 3-1
Setting Up the MULTITEST System .............................................................................. 3-2
2000-610-02 Indicator Controls ..............................................................................................3-3
Powering the Equipment ......................................................................................................3-4
4-in-1 Transducer Select ................................................................................................3-4
Programming Setup ..............................................................................................................3-5
Setting up Date and Time ..............................................................................................3-5
Setting Up High and Low Limits Alert ..............................................................................3-6
Programming AUTO CLEAR .......................................................................................... 3-7
DATA LIST Memory ........................................................................................................3-9
Setting Up Printer/PC Ports ................................................................................................ 3-11
Selecting Printer/PC Ports ............................................................................................ 3-11
Setting Up Serial Communications ................................................................................ 3-12
Encoders ............................................................................................................................ 3-13
Setting Up Angle Encoders .......................................................................................... 3-13
Setting Up Torque-Angle Measurement Modes .................................................................. 3-15
Setting Up the Torque/Angle Algorithm .......................................................................... 3-15
Setting Angle Only Measurements ................................................................................ 3-16
Using the MULTITEST System ................................................................................................4-1
Testing Torque Wrenches and Drivers ..................................................................................4-1
Selecting a Transducer ..................................................................................................4-1
Installing a Transducer ....................................................................................................4-1
Dial and Bending Beam Torque Wrenches and Screwdrivers ..........................................4-2
Adjustable or Preset “Click” Wrenches and Screwdrivers ................................................4-3
Testing Power Tools ..............................................................................................................4-5
Non-Impact Tools ............................................................................................................4-5
Measuring Force, Compression and Tension ..................................................................4-7
Displaying Statistical Analysis ..............................................................................................4-8
Displaying Statistical Analysis on LCD ............................................................................ 4-9
Printing Statistical Analysis .......................................................................................... 4-10
Displaying or Downloading Data List ............................................................................ 4-11
Displaying Data List on LCD ........................................................................................ 4-11
i
Table of Contents
Downloading Data List to Printer .................................................................................. 4-11
Downloading Data List to Personal Computer .............................................................. 4-12
How to Use Analog Output (Rear Panel BNC Connector) .............................................. 4-13
Measuring Torque and Angle .............................................................................................. 4-14
Torque Only .................................................................................................................. 4-14
Angle Only .................................................................................................................... 4-15
Torque-Angle Algorithm ................................................................................................ 4-16
Calibration ................................................................................................................................ 5-1
Calibration Equipment .......................................................................................................... 5-1
Mounting Details ............................................................................................................5-2
Quick Check ........................................................................................................................ 5-5
Torque/Force Calibrations ....................................................................................................5-8
Torque/Force Transducer Calibration ..............................................................................5-8
2000-610-02 Indicator Torque/Force Calibration ............................................................ 5-11
Gravitational Effects ............................................................................................................ 5-13
Correction Factors on Test Weights .............................................................................. 5-13
Gravitational Charts ...................................................................................................... 5-13
2000-600-02 Motorized Loader ................................................................................................ 6-1
Application ............................................................................................................................6-1
Functional Description .......................................................................................................... 6-2
Torque Tester/Calibrator ..................................................................................................6-3
2000-600-02 Manual Loader ............................................................................................6-3
Loader Rear Panel Controls ............................................................................................6-6
Ball Handle Adaptor ........................................................................................................6-7
4-in-1 Transducer (Accessory) ........................................................................................6-8
Extension Arm (Accessory) ............................................................................................ 6-9
Types of Loader Testing ...................................................................................................... 6-13
Torque Driver Testing .................................................................................................... 6-13
Torque Multiplier Testing .............................................................................................. 6-13
Force Testing ..................................................................................................................... 6-14
Accessories ..............................................................................................................................A-1
MULTITEST System Components and Inventory Control ......................................................A-2
Optional Transducers and Accessories ................................................................................A-3
Calibration Accessories ........................................................................................................ A-5
ii
Table of Illustrations
Functional Description and Specifications ............................................................................ 2-1
Figure 2-1: MULTITEST Torque Calibration Torque Tester/Calibrator ............................. 2-1
Figure 2-2: Roll Cabinet Drawer Layout ............................................................................. 2-2
Figure 2-3: 2000-610-02 Front Panel ................................................................................. 2-3
Figure 2-4: Maximum Range Display ................................................................................. 2-4
Figure 2-5: 2000-610-02 Rear Panel ................................................................................. 2-7
Setup and Programming .......................................................................................................... 3-1
Figure 3-1: MULTITEST Torque Calibration System Set-up ................................................. 3-1
Figure 3-2: Indicator Controls ..............................................................................................3-3
Figure 3-3: Date and Time Display ......................................................................................3-5
Figure 3-4: AUTO CLEAR, STORE, SEND Display ..............................................................3-7
Figure 3-5: RECALL Data Display ........................................................................................3-9
Figure 3-6: RECALL Data Display ........................................................................................3-9
Figure 3-7: Encoder Count Display .................................................................................... 3-14
Figure 3-8: Clamping Torque Display ................................................................................ 3-15
Figure 3-9: Edit Angle Display .......................................................................................... 3-16
Using the
Figure
Figure
Figure
Figure
Figure
Figure
MULTITEST System ................................................................................................. 4-1
4-1: Power Tool Test Setup ......................................................................................4-6
4-2: Statistical Analysis Display ................................................................................4-9
4-3: Value Display ....................................................................................................4-9
4-4: Sample Statistical Data Printout ...................................................................... 4-10
4-5: Data Download Display .................................................................................... 4-11
4-6: Angle Mode Display ........................................................................................ 4-15
Calibration ................................................................................................................................ 5-1
Figure 5-1: 2000-610-02 Indicator Calibration Fixture ..........................................................5-1
Figure 5-2: Single Low Torque Transducer Mounting Detail ................................................5-2
Figure 5-3: Single High Torque Transducer Mounting Detail ................................................5-3
Figure 5-4: 4-in-1 Transducer Mounting Detail ....................................................................5-4
2000-600-02 Manual Loader ..................................................................................................... 6-1
Figure 6-1: 2000-600-02 Manual Loader ............................................................................... 6-3
Figure 6-2: 2000-600-02 Manual Loader, Exploded View ...................................................... 6-4
Figure 6-3: 2000-600-02 Manual Loader Rear Panel Controls ............................................ 6-6
Figure 6-4: Ball Handle Adaptor ......................................................................................... 6-7
Figure 6-5: 4-in-1 Transducer on 2000-600-02 Manual Loader ........................................... 6-8
Figure 6-6: 2000-600-02 Manual Loader Extension Arm .................................................... 6-9
Accessories ..............................................................................................................................A-1
Figure A-1: Roll Cabinet Drawer Arrangement ....................................................................A-1
iii
iv
Using this Manual
This manual contains instructions for use and setup of the
MULTITEST Torque Calibration System. A table of contents and a
table of illustrations are provided to make this manual easy to
use.
Some of the information shown in text or illustrations is obtained
using optional equipment.
Conventions
This section contains a list of conventions used in text.
Check Note
A check note provides additional information about the subject
in the preceding paragraph.
Example:
System capabilities include, data storage, retrieval,
statistical analysis and automatic downloading to a
printer or computer.
Chapter References
Additional information in text is referenced by chapter number
and section name.
Example :
For testing procedures refer to Chapter 4—Using the
MULTITEST System.
Equipment Damage
The possibility of damage to vehicle or equipment is introduced
by a signal word indicating this condition.
Example :
IMPORTANT
The connector on single transducer cables contains
the EEPROM calibration memory chip. Never
attempt to remove the connector from the
transducer. It is installed with a permanent
adhesive. Or covered with shrink tubing.
v
Using This Manual
Safety Messages
Safety messages are provided to help prevent personal injury
and equipment damage. All safety messages are introduced by
a signal word indicating the hazard level. The types of safety
messages are:
! DANGER
▲
Indicates an imminently hazardous situation which,
if not avoided, will result in death or serious injury
to the operator or to bystanders.
! WARNING
▲
Indicates a potential hazard which, if not avoided,
could result in death or serious injury to the
operator or to bystanders.
! CAUTION
▲
Indicates a potential hazard which, if not avoided,
may result in minor or moderate injury to the
operator or to bystanders.
The three-part message panel, used with safety messages,
uses three different type styles to further define the potential
hazard:
• Normal type states the hazard,
• Bold type states how to avoid the hazard, and
• Italic type states the possible consequences of not avoiding
the hazard.
Some safety messages contain visual symbols with signal
words.
Example:
WARNING
Flying particles can discharge when applying torque.
• Users and bystanders must wear safety goggles.
• Always wear safety goggles when applying torque.
Flying particles can cause injury.
vi
Safety Information
IMPORTANT SAFETY INSTRUCTIONS
This manual contains important safety and operating
instructions for CDI MULTITEST Torque calibration system.
Refer to the information in this manual often for safe operation.
Read All Instructions
Read, understand and follow all safety messages and
instructions in this manual and on the test equipment. Safety
messages in this section of the manual contain a signal word, a
three-part message, and, in some instances, an icon.
The signal word indicates the level of hazard in a situation:
• Danger indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury to the
operator or bystanders.
• Warning indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury to the
operator or bystanders.
• Caution indicates a potentially hazardous situation which, if
not avoided, may result in moderate or minor injury to the
operator or bystanders.
The three-part message uses three different type styles to
further define the potential hazard.
• Normal type states the hazard.
• Bold type states how to avoid the hazard.
• Italic type states the possible consequences of not avoiding
the hazard.
An icon, when present, gives a graphical description of the
potential hazard.
SAVE THESE INSTRUCTIONS
I
Safety Information
WARNING
Risk of electric shock and fire.
• For indoor use only. Do not expose charger to
rain or snow. Do not use in damp locations.
• Replace defective cord immediately. Return to
qualified service center for replacement.
Electric shock or fire can cause injury.
WARNING
Flying particles can discharge when applying torque.
• Users and bystanders must wear safety goggles.
• Always wear safety goggles when applying torque.
• Do not use this equipment with the power off.
Always turn on the indicator and loader so the
torque and load values are indicated on the
display. The safety relays only work when the
power is on.
Flying particles can cause injury.
WARNING
Risk of entanglement.
• When starting power tools, check for obstacles
near your hand and anticipate the reaction force
by gripping the tool firmly.
• Do not wear loose clothing and jewelry while
operating a power tool. Loose clothes and jewelry
can be caught in moving parts.
• Keep body parts away from rotating parts.
• Wear a protective hair covering to contain long
hair and prevent contact with moving parts.
• Do not overreach. Keep proper footing and
balance at all times.
Entanglement can cause injury.
WARNING
Improper use can cause breakage.
• Read instructions before operating.
• Follow manufacturer’s instructions, safety
precautions, and specifications when operating
tools.
Broken equipment can cause injury.
II
Safety Information
WARNING
• Make sure all components, including, adaptors,
extensions, drivers and sockets are rated to
match or exceed the torque or load being applied.
• Be sure the capacity of the MULTITEST system
matches or exceeds each application before
performing a procedure.
• Do not use the MULTITEST system if it makes
unusual noises, has loose parts, or shows any
other sign of damage. Have repairs performed at
an Authorized Service Center before use.
• Do not use chipped, cracked, or damaged sockets
and accessories.
• Do not remove any labels. Replace any damaged
label.
• Follow good, professional tool practices:
— Pull on a wrench handle—do not push—and
adjust stance to prevent a possible fall.
— Do not use extensions, such as a pipe, on a
wrench handle.
• When using ratchets, make sure the direction
lever is fully engaged in the correct position.
• Never attempt to test an impact tool on this
instrument.
• Always position the 40" arm over the front of the
stand as shown. Never extend the test arm
behind the stand. The stand will tip over when
weights are applied.
• Always be alert to the potential for personal injury
that may be caused by excessive torque
applications, careless handling of heavy weights,
and out-of-balance or unsafe weight distribution.
III
Safety Information
IV
Introduction
1
The MULTITEST Indicator is a laboratory grade instrument that
provides TORQUE, FORCE and ANGLE of rotation
measurements and set-able alert functions. Although designed
as an integral component of the MULTITEST Torque Calibration
System, it can also be used independently in many laboratory
and industrial applications. The MULTITEST Indicator features
versatile date acquisition capabilities including measurement
storage, retrieval, statistical analysis and automatic
downloading to the built-in printer or external printer/computer.
A remote computer COM port is available for PC interfacing.
Used with precision torque/force transducers, the MULTITEST
Indicator provides high speed monitoring of static or dynamic
torque, force or angle inputs. Torque/force transducers,
purchased separately, are available in ranges from 15-200 in oz,
to 200-2000 ft lb, and provide system readings with an
accuracy of +/- 0.25% of indicated value, or better. A special
memory chip is built into each torque/force transducer that
identifies its range and maintains its calibration between any
other MULTITEST Indicator with an accuracy of +/- 0.5%. The
indicator and its transducers may be calibrated by using
accessory precision bars and certified weights.
The indicator features a bright red alpha-numeric LED display
for readout of torque in ft lb, in lb, in oz, Nm, dNm, cNm, mkg
and cmkg, or force in ounces, pounds, Newtons, decaNewtons,
kiloponds (kilograms) or grams, depending upon the transducer
in use.
Angle measurement, calibration, statistical analysis and set-up
functions are reported on a 2-line by 16-character 5x8 dot
matrix, backlighted LCD, display. A Torque-Angle mode can be
set up for precision fastener installation monitoring. The
MULTITEST Indicator uses X4 quadrature logic that takes
advantage of maximum resolution from industry standard
bidirectional rotary encoders.
1-1
Introduction
Set-up and calibration programming is entered on front panel
membrane keys. HIGH and LOW torque limits are adjustable to
give an audible alert. The user selects TRACK mode to display
torque values as they are applied, PEAK HOLD or POWER
TOOL modes to display the highest torque value applied, or
FIRST PEAK mode which captures the torque output at the
“click” of a set-able wrench or driver. CLEAR, STORE and
PRINT functions can be set up for automatic or manual
operation.
The indicator stores and recalls up to 3000 torque/force
readings and does statistical analysis on them for downloading
to printer or computer. The statistical report (print out) includes
a simple histogram for process monitoring. True RS-232 serial
printer and separate RS-232 computer COM ports are at the
back of the unit.
The MULTITEST Indicator operates from the AC power line and
is switch selectable for either 120VAC or 220 VAC, 50–60 Hz.
Its integral switching power supply is UL listed. A hard-wired
lithium battery keeps the internal memory and date-time clock
operating for up to 10 years.
The information in this manual is general. Operational features,
procedures and specifications may change without notice. CDI
makes no claims as to the suitability of this information for
diverse user applications.
1-2
Functional
Description and
Specifications
2
The MULTITEST Torque Calibration System is comprised of an
Indicator, Mechanical Loader, Roll Cabinet, Transducers and a
variety of optional equipment specified by the user.
Functional Descriptions
MULTITEST Torque Calibration System
A
B
C
D
Figure 2-1 MULTITEST Torque Calibration System
A — Indicator
The MULTITEST Indicator monitors and displays the torque
applied.
2-1
Functional Description and Specifications
B — Transducer (Accessory)
The loader accepts all MULTITEST series single transducers
directly. Use a 2000-500-02 adaptor kit to mount the optional
2000-400-02 4-in-1 transducer. For additional information refer
to Appendix A–Accessories.
C — Loader
Use the 2000-600-02 Manual Loader for testing and calibrating
all torque wrenches, drivers, torque multipliers, non-impact
pneumatic and electric nut runners. It can also be mounted
on a fixture for testing and calibrating cable tensiometers and
compression or tension gauges. Loader components are:
• Indicator Stand
• Safety Shield
• Hand Crank
• Transducer Mounting
D — Roll Cabinet
The roll cabinet features nine heavy duty drawers with ball
bearing slides, locking wheels and drawer locks. MULTITEST
accessories are stored in the roll cabinet which is fitted with
foam inserts for easy inventory control. The nine drawers are
assigned and arranged as shown in Figure 2-2 .
Figure 2-2: Roll Cabinet Drawer Layout
2-2
Functional Description and Specifications
MULTITEST Indicator
This section describes the major hardware components of the
MULTITEST Indicator, including:
• Front Panel
• Rear Panel (Input/Output)
• MULTITEST Torque/Force Transducers
Front Panel
B
A
C D
G
F
E
Figure 2-3: 2000-610-02 Front Panel
A — MULTITEST Torque/Force Display
TORQUE or FORCE displays on a bright red alphanumeric
LED, with 0.55" high characters in selected engineering UNITs.
• (+) = Clockwise torque or force
• (-) = Counter clockwise torque or force
B — Range LED Torque or Force Limit Indicators
• Red—OVER (Input exceeds 110% of transducer range)
• Green—WITHIN (Input is within transducer range)
• Yellow—UNDER (Input is below transducer range)
C — Power Switch
D — Mode Select LEDs
• Red—TORQUE
• Green—FORCE
E — MODE Function LEDs
•
•
•
•
•
Green—TRACK
Red—PEAK HOLD
Yellow—POWER TOOL
Red—FIRST PEAK
Green—ANGLE
2-3
Functional Description and Specifications
F — Maximum Range Display
Figure 2-4: Maximum Range Display
Two line by 16 character 5x8 dot-matrix LCD display that
shows:
• Maximum transducer range in the selected UNITS of measure
on the upper line,
• Statistical mean of all measurements in memory on the lower
line, left, and
• The number of the present data memory location on the lower
line, right.
This display also is used to indicate:
• ANGLE, in degrees, CW=(+), CCW=(-) of rotation,
• Prompt CALibration mode,
• Programming of angle encoder,
• Printer protocol,
• RECALL display of data list and STATistical analysis, and
• Set up for:
— DATE/TIME clock,
— AUTO/MANUAL CLEAR, STORE and SEND, and
— HIGH and LOW torque/force limits.
2-4
Functional Description and Specifications
G — Front Panel Membrane Function Keys
SELECT
Toggles between TORQUE and FORCE measurement modes.
MODE
Selects TRACK, PEAK HOLD, POWER TOOL, FIRST PEAK
and ANGLE modes.
UNIT
ANGLE
RESET
ZERO
TARE
DIGIT
DIGIT
ENTER
VALUE
VALUE
Selects following units on LCD display:
Torque units in: Nm, dNm, cNm, mkg, cmkg, lb ft, in lb, in oz,
or
Force units in: N, dN, kp, gf, lbf, oz
Manually resets ANGLE display on LCD at any time.
Manually resets ZERO TARE.
Selects LED or LCD digit to right (blinking) for setup and
programming. Shift for printer and angle encoder programming.
Selects LED or LCD digit to left (blinking) for setup and
programming. Shift for printer and angle encoder programming.
Terminates calibration and program modes. Returns to 4-in-1
transducer scan.
Increments selected digit during calibration and program modes.
Scrolls statistical analysis display.
Decrements selected digit during calibration and program
modes. Scrolls statistical analysis display.
2-5
Functional Description and Specifications
CAL
Opens and terminates calibration mode.
DATE
TIME
Edits DATE/TIME programming function.
SET
HIGH
Sets up high torque/force limit preset. Set up angle preset in
torque-angle mode.
SET
LOW
Sets up low torque/force limit preset. Set up clamping torque
preset in torque-angle mode.
STORE
DATA
RECALL
DATA
STAT
SEND
AUTO
SEND
AUTO
CLEAR
MANUAL
CLEAR
2-6
Stores present measurement to memory.
Recalls memory data to display.
Sends all memory data, statistical analysis and histogram to
printer/port.
Sends data list with or without date-time stamp to computer
printer. Sets up serial protocol function.
Sets up CLEAR, STORE, and SEND modes function.
Manually clears display in PEAK, FIRST PEAK, POWER TOOL
and ANGLE modes. Sets up memory clear options in RECALL
mode.
Functional Description and Specifications
Rear Panel (Input/Output)
The MULTITEST Indicator rear panel is shown in Figure 2-5.
G
VOLTAGE
SELECT
C
A
B
SOLENOID
CONTROL
ANALOG
OUTPUT
PRINTER SELECTOR
INTERNAL
EXTERNAL
TRANSDUCER INPUT
OPTIONAL
PRINTER PORT
F
E
D
FUSE
3.15 A
Figure 2-5: 2000-610-02 Rear Panel
12
11
A — SOLENOID CONTROL (Hirose RM15TRD-12S)
PIN FUNCTION
10
10
11
12
Loader Relay Common
Loader Relay CCW Limit
Loader Relay CW Limit
B — ANALOG OUTPUT (BNC)
Analog output provides a voltage level output that is directly
proportional to transducer input, from -1.8V (full scale counter
clockwise) to +1.8V (full scale clockwise). Zero offset +/-100
mV. Linearity +/-1% of reading. Maximum load = 5 Ma.
When using the 4-in-1 transducer, zero output
fluctuates until one of the transducers is scan selected
by applying 5% of full scale torque.
C — PRINTER SELECTOR
The INTERNAL/EXTERNAL switch disables the built-in printer.
2-7
Functional Description and Specifications
5
9
5
9
1
D — PRINTER PORT (DB-9P)
PIN
2
3
5
6
1
FUNCTION
Receive
Transmit
Ground
E — OPTIONAL (DB-9P)
PIN
2
3
5
6
19
1
37
20
FUNCTION
Receive
Transmit
Ground
F — TRANSDUCER INPUT (DB-37S)
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
FUNCTION
not used
ground
smart chip - bit 2
smart chip - bit 0
single xducer (-) signal
single xducer (+) signal
ground
4-in-1 xducer (-) signal 2
4-in-1 xducer (+) signal 2
ground
4-in-1 xducer (-) signal 4
4-in-1 xducer (+) signal 4
4-in-1 xducer LED 2
4-in-1 xducer LED 4
loader relay CW limit
rotary encoder signal A
rotary encoder signal B
ground
bridge excitation (+3V)
not used
smart chip - bit 3
smart chip - bit 1
ground
ground
4-in-1 xducer (-) signal 1
4-in-1 xducer (+) signal 1
ground
4-in-1 xducer (-) signal 3
4-in-1 xducer (+) signal 3
no transducer
4-in-1 xducer LED 1
4-in-1 xducer LED 3
loader relay CCW limit
loader relay common
Vcc (+5V@100 ma. max)
ground
bridge excitation (+3V)
G — VOLTAGE SELECT
Switch for selecting either 120VAC or 220VAC, 50-60 Hz.
2-8
Functional Description and Specifications
MULTITEST Torque/Force Transducers
MULTITEST torque/force transducers provide industry standard
internal square drives. They feature a full bridge strain-gauge
@ 350 Ohms nominal. Full range output is 1500 µE, 9mV,
(3mV/V @ 3.0V excitation).
Torque/force transducers use a built-in EEPROM memory chip
that stores range identification and calibration factors.
Calibration of transducers is accomplished using precision
torque bars and certified weights. For additional information,
refer to Chapter 5—Calibration .
After a transducer is calibrated, it provides +/-0.5% system
accuracy with any MULTITEST Indicator. If the transducer and
indicator are calibrated together, the system accuracy increases
to +/-0.25%.
Transducer Dimensions/Transducer Indicator Torque Range
and Force Range
Torque
Stock No. Range
Drive
Force
Range
2000-5-02
15-200 in oz
1/4" Ext.
3.9 in
3.0 in
1.5 lb
2000-6-02
4-50 in lb
1/4" Ext.
3.9 in
3.0 in
1.5 lb
Height
Diameter Weight
2000-65-02 15-150 in lb
1/4" Ext.
3.9 in
3.0 in
1.5 lb
2000-7-02
30-400 in lb
3/8" Ext.
33.3 lbf
4.1 in
3.0 in
3.0 lb
2000-8-02
80-1000 in lb
3/8" Ext.
83.3 lbf
4.1 in
3.0 in
3 lb
1/2" Ext.
125 lbf
4.25 in
4.0 in
5 lb
2000-11-02 20-250 ft lb
1/2" Ext.
250 lbf
4.25 in
4.0 in
5 lb
2000-12-02 60-600 ft lb
3/4" Ext.
600 lbf
4.25 in
4.0 in
5 lb
2000-13-02 100-1000 ft lb
1" Internal 1000 lbf
5.5 in
6.1 in
24 lb
2000-14-02 200-2000 ft lb
1" Internal 2000 lbf
5.5 in
6.1 in
24 lb
2000-400-02 4-50 in lb
1/4" Ext.
(4-in-1)
30-400 in lb
3/8" Ext.
80-1000 in lb
3/8" Ext.
20-250 ft lb
1/2" Ext.
2000-10-02 10-125 ft lb
H2.6-W5.0-L10.0 in
6 lb
Calibration also results in a specified display resolution on the
MULTITEST Indicator. Display resolution is dependent on the
type of transducer being used. The following table shows
display resolutions for the specified transducer with the force
arm.
2-9
Functional Description and Specifications
Display Resolution for Transducers in Force Mode
N
dN
lbf
ozf
kp
gf
2000-7-02
.03
.3
.007
.1
.003
3
2000-8-02
.08
.8
.02
.3
.008
8
2000-10-02
.1
1
.02
.4
.01
10
2000-11-02
.2
2
.05
.8
.02
n/a
2000-12-02
.5
5
.12
2
.05
n/a
2000-13-02
.9
9
.2
3
.1
n/a
2000-14-02
1.8
18
.4
6
.2
n/a
Display Resolution for Transducers in Torque Mode
mkg
cmkg
ft lb
in lb
in oz
Nm
dNm cNm
2000-5-02 .00003 .003
.0002
.002
.04
.0003
.003
.03
2000-6-02
.0001
.01
.0008
.01
.2
.001
.03
.3
2000-65-02 .0003
.03
.002
.03
.5
.003
.03
.3
2000-7-02
.001
.1
.006
.08
1.2
.009
.09
.9
2000-8-02
.002
.2
.016
.2
3.2
.02
.2
2
2000-10-02
.004
.4
.03
.3
5
.03
.3
3
2000-11-02
.007
.7
.05
.6
10
.07
.7
7
.12
1.4
n/a
.16
1.6
16
.2
3
n/a
.3
2.7
n/a
2000-12-02
.0161 1.6
2000-13-02
.03
3
2000-14-02
.05
5
.4
5
n/a
.5
5
n/a
2000-400-02 .0001 .01
.0008
.01
.2
.001
.03
.3
(4-in-1)
.001
.1
.006
.08
1.2
.009
.09
.9
.002
.2
.016
.2
3.2
.02
.2
2
.007
.7
.05
.6
10
.07
.7
7
MULTITEST torque/force transducers can withstand an overload
of 110% of full range. The MULTITEST Indicator alarms, (audible
beep and display "OVER" red LED) at 110% of rated capacity.
To protect the tool under MULTITEST Indicator or serve as a
fastener installation, torque preset alert, the MULTITEST
produces a constant audible tone when the input torque/force
exceeds the SET LOW limit. It then produces a pulsating tone
when the input torque/force exceeds the SET HIGH limit.
The MULTITEST Indicator ignores inputs less than 0.1% of full
range in TRACK mode, 2% in PEAK HOLD mode, 7% in FIRST
PEAK and POWER TOOL modes. With the 4-in-1 transducer,
the MULTITEST System ignores inputs less than 2% of full
range after scan select.
2-10
Functional Description and Specifications
Specifications
MULTITEST Torque Calibration System
System Accuracy
±0.25% of reading @ 25°C
(Indicator and transducer calibrated together)
MULTITEST Transducers used with, but not calibrated
to, another MULTITEST Indicator provide a system
accuracy of ±0.5% of reading @ 25°C.
Temperature Drift
+0.03%/°C (+0.017%/°F)
Angle Precision
Bi-directional rotary encoder pulses/revolution X4
2000-610-02 Indicator
Display Accuracy
±0.05% of reading @ 25°C
Temperature
Operating Temperature
10 to 32°C (50 to 90°F)
Storage
-20 to 50°C (-2 to 122°F)
Humidity
Up to 90%, Non-condensing
Temperature Drift
+0.011%/°C, (+0.006%/°F)
Dimensions
Weight
Width
16.5"
Height
6.25"
Depth*
14.5"
*Includes handle, feet, printer and connectors
13.5 lbs
Power Supply
UL approved, 120VAC/220VAC, 50-60 Hz
Amperage, 3.15 amps
2-11
Functional Description and Specifications
Data Storage/Recall w/Date Time Stamp
3,000 measurements
Statistical Analysis
Max, Min, Range, Mean, Sigma N, Sigma, Cp, Cpk
%Error, -NoGo, +NoGo.
Histogram: Lower Set Limit, Upper Set Limit, 10 Divisions
Printer/Computer Serial Output Port
Serial Communications
RS-232 (true)
300—19.2K Baud
8 data bits
1 stop bit
no parity
Computer Serial COM Port
RS-232 (True)
300—19.2K Baud
OPTIONAL
Analog Output
+(CW)/-(CCW) 1.8V at transducer full range linearity
±1% of reading
Loader Control Relays
Two, normally open, Form A, rated 12VDC @ 1/2A close contact
at 110% CW or CCW of torque/force transducer range.
For additional information refer to Transducer and
System specifications.
Display Capacity
(16 bit A/D), 8 digits, ±32,000 counts
Units of Measurement
Torque
ft lb, in lb, in oz, Nm, dNm, cNm, mkg and cmkg
Force
lbf, ozf, N, dN, kp, and gf
Angle
degrees
Torque/Force Resolution
Refer to transducer-indicator range and display resolution tables
in Functional Description of this chapter.
Angle Resolution
Bi-directional, X4 quadrature logic
2-12
Functional Description and Specificatons
Torque/Force Transducers
Accuracy
±0.2% of reading @ 25°C, within specified range, when used as
prescribed with the 2000-610-02 Loader.
Range and Resolution
Refer to transducer-indicator range and display resolution tables
in Functional Description of this chapter.
Temperature
Operating Temperature
10 to 32°C (50 to 90°F)
Storage
-20 to 50°C (-2 to 122°F)
Humidity
Up to 90% non-condensing
Temperature Drift
+0.02%/°C (+.011%/°F)
MULTITEST Manual Loader Specifications
Input Torque (Hand Crank)
8 ft lb maximum
Output Torque
2000 ft lb ±20 degrees rotation maximum
Power Requirements (Safety solenoids)
115/230VAC ±10%, @ 50-60 Hz
Physical Dimensions
Width
45"
Height
50"
Depth
24"
Weight (including 2000-100-02 roll cab)
1500 lbs
Optional Calibration Fixturing (Load bars and weights)
±0.05% accuracy
2-13
Functional Description and Specifications
2-14
Setup and
Programming
3
MULTITEST Torque Calibration System Setup
Figure 3-1: MULTITEST Torque Tester/Calibrator/Loader Setup
A
B
C
D
E
F
G
H
I
J
K
L
M
N
–
–
–
–
–
–
–
–
–
–
–
–
–
–
Internal printer
Internal/External printer selector switch
MULTITEST Indicator rear panel
Power cables (110/220 VAC)
Printer cable
External printer
Transducer cable
Personal computer cable
Smart 4-in-1 transducer
Analog device
Personal computer
Solenoid control cable
Smart single transducer
MULTITEST Manual Loader
3-1
Setup and Programming
Setting up the MULTITEST Torque Calibration System
1. Position the roll cabinet on a level floor and lock the
wheels.
2. Mount the indicator stand, part number 2000-111-0, to
the Loader.
3. Mount the MULTITEST 2000-610-02 Indicator to the
stand.
4. Connect the solenoid control cable between the Indicator
and Loader.
5. Install the appropriate MULTITEST transducer to the
Loader drive.
6. Install two (2) quick release pins, part number 2000-9513.
7. Connect the transducer cable, part number 2000-116,
between the Indicator and transducer.
8. Select the appropriate AC voltage input at the rear of the
Indicator and Loader. Connect the AC power cables to
the Indicator and the Loader. For additional information
refer to Chapter 6—Loader Rear Panel Controls.
9. Install the safety shield to the front of the Loader.
10. Install the reaction pins part number S/2000-173-1 and
S/2000-173-2 into the reaction slide on the Loader.
11. Install two linear bearings, part number S/2000-173-11.
For testing procedures refer to Chapter 4—Using
the Torque Tester.
Various fixtures, cables and adaptors are available for testing
the most common compression or tension gauges.
3-2
Setup and Programming
MULTITEST Indicator Controls
Refer to the illustration below when performing the power-up
and programming procedures.
B
A
C D
E
G
F
Figure 3-2: Indicator Controls
A
B
C
D
E
F
G
–
–
–
–
–
–
–
MULTITEST Torque/Force Display
Range LED Torque or Force Limit Indicators
Power Switch
Load Select LEDs
MODE Function LEDs
Maximum Range Display
Front Panel Membrane Function Keys
3-3
Setup and Programming
Powering the Equipment
To power the equipment, press the power button on the front of
the MULTITEST Indicator.
• At POWER ON, the LED displays :
CDI
SELFTEST... MEM O.K.
EE O.K.
• Then the following banners display:
SOLENOID TEST . . . .
TEST CW
TEST CCW
SELFTEST O.K.
and the LCD reads:
Firmware version datacode
• With no transducer installed, the LED display reads:
NO INPUT
and the LCD reads:
No transducer
connected
• When applying power with the transducer connected, or when
connecting a transducer while the power is on, the LED
displays:
READ BOX
BOX O.K.
ZERO TARE
+zero
The UNDER, TORQUE and TRACK indicators light. The LCD
displays:
Max=transducer range and units - upper line
x=average and memory location - lower line
4-in-1 Transducer Select
If the 4-in-1 transducer is installed at power on, the LCD display
reads:
Select Transducer
All four transducers are scanned as indicated by their
associated red LED indicators. To select one of the
transducers, apply at least 5% of its full range torque. To return
to the scan mode, press ENTER.
3-4
Setup and Programming
Programming Setup
Setting up Date and Time
1. Press DATE/TIME. The LCD display reads
Date dd/month/yy - upper line
Time hh:mm:ss - lower line, with the seconds flashing
Figure 3-3: Date and Time Display
2. Push left or right DIGIT to select the date/time element
being changed.
3. Increment or decrement the date/time element by
repeatedly pushing up or down VALUE.
Push and hold up or down VALUE to change the
display quickly. Incrementing/decrementing the day
rolls over to the next or previous month; likewise
month to year, seconds to minutes, and minutes to
hours.
4. Press ENTER to update date and time and then return to
measurements mode.
3-5
Setup and Programming
Setting Up High and Low Limits Alert
Torque/Force Mode
Use SET HIGH and SET LOW to protect the tool under test or
serve as a fastener installation torque or force preset alert. The
2000-610-02 produces a constant audible limits alert tone when
the input torque/force exceeds the SET LOW limit. It then
produces a pulsating limits alert tone when the input
torque/force exceeds the SET HIGH limit.
It is important to program these limits if statistical
analysis is to draw a histogram which includes
reporting out-of-limit parameters.
Changing transducers does not automatically change
SET HIGH and SET LOW limits.
Angle Mode
In the ANGLE mode, use SET LOW to program a clamping
torque limit and use SET HIGH to program an angle
measurement. For additional information refer to Torque-Angle
Measurement Modes in this chapter.
Setting Low Torque/Force Limit
1. Press SET LOW.
— The LED display reads:
last SET LOW value , with one digit flashing
— The LCD display reads:
Edit low limit - upper line
[units] - lower line
Change units of measure by pushing UNITS.
2. Select an LED digit to change (flashing) by pushing left
or right DIGIT.
3. Increment or decrement the selected digit by pushing up
or down VALUE. Push and hold up or down VALUE to
change the display quickly.
A decimal point "." appears between "9" and "0"
numerals. Maximum resolution is selected
automatically, regardless of decimal point position,
upon pushing ENTER. The program value is
absolute, for both ± readings.
4. Select and change the next LED digit using left and right
DIGIT and up and down VALUE. Continue until all digits
are set.
5. Press ENTER to return to measurements mode.
3-6
Setup and Programming
Setting High Torque/Force Limit
1. Press SET HIGH.
— The LED display reads:
last SET HIGH value , with one digit flashing
— The LCD display reads:
Edit high limit - upper line
[units] - lower line
Change units of measure by pushing UNITS.
2. Select an LED digit to change (flashing) by pushing left
or right DIGIT.
3. Increment or decrement the selected digit by pushing up
or down VALUE. Push and hold up or down VALUE to
change the display quickly.
A decimal point "." appears between "9" and "0"
numerals. Maximum resolution is selected
automatically regardless of decimal point position
upon pushing ENTER. The program value is
absolute, for both ± readings.
4. Select and change the next LED digit using left and right
DIGIT and up and down VALUE. Continue until all digits
are set.
5. Press ENTER to return to measurements mode.
Programming AUTO CLEAR
Use AUTO CLEAR to program the CLEAR, STORE and SEND
functions for automatic or manual operation. Use these
functions in PEAK HOLD, POWER TOOL and FIRST PEAK
modes to STORE torque or force measurements to memory,
CLEAR the display, and SEND the last measurement captured
on the LED display to the printer or PC. Auto STORE and
SEND are initiated at either AUTO or delayed CLEAR
operations.
Use the manual modes to:
• Store the present reading by pushing STORE DATA,
• Clear a captured display by pushing MANUAL CLEAR, or
• Send a measurement to the printer/port by pushing
SEND/AUTO SEND.
Use the automatic modes to:
• Store the last measurement, and/or
• Send the last measurement to the printer/port by initiating the
auto or delayed CLEAR function.
3-7
Setup and Programming
AUTO CLEAR can be programmed with a 1 to 9 second delay.
Use this feature to visually note the reading before the display
clears. AUTO CLEAR with no delay stores, prints and/or clears
with no delay at the initiation of the next torque or force input.
STORE DATA must be pressed to save the last
reading that displays on the LCD after a test.
AUTO CLEAR must be selected to use AUTO
STORE and AUTO SEND.
To use the AUTO CLEAR, STORE, or SEND:
1. Press AUTO CLEAR. LCD display reads:
Figure 3-4: AUTO CLEAR, STORE, SEND Display
2. Use right and left DIGIT to position the flashing (*)
character under the function being changed. To
program:
— CLEAR, press up or down VALUE to select "man"
(manual clear), "auto" (automatic), or (delayed
automatic) from "1Sec" to "9Sec" seconds.
— STORE, press up or down VALUE to select "man"
(manual) or "auto" (automatic).
— SEND, press up or down VALUE to select "man"
(manual) or "aut" (automatic).
3. Press ENTER to return to measurements mode.
3-8
Setup and Programming
DATA LIST Memory
When changing sensors, or when creating a new statistical data
list, the data list memory must be cleared. The entire memory
list or any single memory location may be selectively cleared.
Clearing from the top of the list decrements the total number of
memory locations. Clearing from inside the list shifts all
subsequently taken readings down from that location and
decrements the total number of memory locations.
Clear Last Memory Location
Use the procedure in this section to clear the last memory
location.
1. Press RECALL DATA. The LCD displays as shown in
Figure 3-5. The present memory location is at the upper
left, the total number of memory locations to its right and
the time the data was stored at the far right.
— The LED display shows the measurement value of
that memory location.
— The LCD displays its engineering units at the lower
right.
Figure 3-5: RECALL Data Display
2. Press MANUAL CLEAR. LCD display shows "CLEAR"
and the present (left) and total (right) memory locations
on the upper line, as shown in Figure 3-6.
Figure 3-6: RECALL Data Display
3. Press right DIGIT to select "Single" on the lower LCD
line.
3-9
Setup and Programming
4. Press ENTER to clear the last memory location. The
number of total memory locations decrements by one.
Pushing ENTER repeatedly continues to clear readings
from the top of the list down.
5. Press left DIGIT to select "None".
6. Press ENTER to return to RECALL mode.
7. Press ENTER again to return to measurements mode.
Clear Single Memory Location
Use the procedure in this section to clear a single memory
location.
1. Press RECALL DATA.
— The LCD display reads as shown in Figure 3-5. The
present memory location at the upper left, total
number of memory locations to the right and time
data was stored at far right.
— The LED display shows the measurement value of
that memory location while the LCD displays its
engineering units at the lower right.
2. Press up or down VALUE to select the particular memory
location to clear.
3. Press MANUAL CLEAR. The LCD display shows
"CLEAR" and the present (left) and total (right) memory
locations on the upper line, as shown in Figure 3-6.
4. Press right DIGIT to select "Single" on the lower LCD
line.
5. Press ENTER to clear the present memory location. The
number of total memory locations decrements by one
and all subsequent measurements move down one
location.
Push ENTER repeatedly to continually clear
readings until all subsequent and then prior
locations clear.
6. Press left DIGIT to select "None".
7. Press ENTER to return to RECALL mode.
8. Press ENTER again to return to measurements mode.
3-10
Setup and Programming
Clear All Memory Locations
Use the procedure in this section to clear all memory locations.
1. Press RECALL DATA.
— LCD displays as shown in Figure 3-5. The present
memory location at the upper left, the total number
of memory locations to the right and the time data
was stored at far right.
— LED display shows the measurement value of that
memory location while the LCD displays its
engineering units at the lower right.
2. Press MANUAL CLEAR.
— LCD display shows "CLEAR" and the present (left)
and total (right) memory locations on the upper line,
as shown in Figure 3-6.
3. Press right DIGIT twice to select "All" on the lower LCD
line.
4. Press ENTER to clear the entire data memory. LED
display reads:
NO DATA
The audible alarm sounds momentarily. The 2000-61002 automatically returns to measurements mode.
Setting Up Printer/PC Ports
The MULTITEST Indicator is equipped with two RS-232 serial
communications ports for use with an external printer or
personal computer. The transfer rate is programmable from 300
to 19.2K baud rate with 8 data bits, 1 stop bit and no parity.
• Select "PRINTER" to enable the printer port.
The built-in printer is connected to the PRINTER port.
To disable the built-in printer, use the
INTERNAL/EXTERNAL switch on the back of the 2000610-02 Indicator.
• Select "PC" to enable the OPTIONAL COM port.
Selecting Printer/PC Ports
1. Press CAL to enter calibration mode.
— LED display reads the following with the least
significant digit (LSD) flashing:
CODE0000
2. Use left and right DIGIT to select the appropriate digits
and up and down VALUE to increment or decrement
each digit between "0" and hexidecimal "F," program the
number "2000" into the LED display.
3-11
Setup and Programming
3. Press ENTER.
— The LED display reads:
PRINTER or PC
— The LCD display reads:
Download: - upper line
Port - lower line
4. Press up VALUE to toggle between "PRINTER" port or
optional “PC”.
5. Press ENTER to return to measurements mode.
Setting Up Serial Communications
1. Press CAL to enter calibration mode.
— LED display reads the following with the least
significant digit (LSD) flashing:
CODE0000
2. Use left and right DIGIT to select the appropriate digits
and up and down VALUE to increment or decrement
each digit between "0" and hexidecimal "F," program the
number "2000" into the LED display.
3. Press ENTER.
— The LED display reads:
PRINTER or PC
— The LCD display reads:
Download: - upper line
Port - lower line
4. Press right DIGIT.
— LED display shows the previously programmed baud
rate for the printer with the LSD flashing.
— LCD display reads:
Baudrate Com1
5. Using up and down VALUE and left and right DIGIT,
program the baud rate matching the printer being used.
The built-in printer operates at 09600 baud.
6. Press right DIGIT until LCD display reads:
Baudrate Com2
— LED display shows the previously programmed baud
rate for the optional PC port with the LSD flashing.
7. Using up and down VALUE and left and right program
the desired baud rate that matches the PC being used.
The recommended default is 09600 baud.
3-12
Setup and Programming
8. Press right DIGIT.
— LED display indicates:
YES or NO
— LCD display reads:
Download: - upper line
Send Init yes/no - lower line
9. Press up or down VALUE to select "YES" to initialize the
ports for reverse characters (on some external printers)
or "NO" for standard characters.
10. Press ENTER to return to measurements mode.
Encoders
The MULTITEST Indicator uses X4 quadrature logic for
maximum resolution with any bi-directional incremental rotary
encoder. Encoder output is mathematically converted and
displays in degrees (°) of rotation, regardless of encoder count.
Example:
—
—
A 90 count encoder measures 90 X 4 = 360
increments, (whole degrees).
A 360 count encoder measures 360 X 4 = 1440
increments, (1/4 degrees), etc. Clockwise (CW)
rotation is signified by (+) and counterclockwise
(CCW) rotation is signified by (-).
Setting Up Angle Encoders
1. Press CAL.
— LED display reads the following with the least
significant digit (LSD) flashing:
CODE0000
2. Using up and down VALUE and left and right DIGIT,
program the hexadecimal code "000E" into the display.
3. Press ENTER.
— LED display reads:
SELECT
— LCD display reads:
Encoder: Measure Resolut
To determine the resolution of an unknown encoder:
A . Press ENTER.
— The LED display reads:
COUNTING
— The LCD display reads:
Count[0]= 000000 - upper line
Count[1]= 000000 - lower line
3-13
Setup and Programming
B . Rotate the encoder shaft exactly one complete turn
(360 degrees). The upper right LCD display reads
the total number of counts for the encoder.
C. Push ENTER then CAL to return to the previous
mode.
To enter the resolution of a known encoder:
A . Press up VALUE to select "Encoder: Enter
Resolution" on the LCD display.
B . Press ENTER and, using up and down VALUE and
left and right DIGIT, enter the counts resolution of
the encoder.
C. Push ENTER then CAL to return the previous
mode.
4. Check the encoder count to degrees of rotation
conversion by pressing up VALUE to select "Encoder:
Check Resolution" on the LCD display.
5. Press ENTER and rotate the encoder shaft exactly one
complete turn.
— The LCD display reads:
Angle[0]= 0360.0
Figure 3-7: Encoder Count Display
6. Press ENTER.
7. Press CAL to return to measurements mode.
"Count[1]" and "Angle[1]" in the LCD display are future
options for use with a second encoder channel.
3-14
Setup and Programming
Setting Up Torque-Angle Measurement Modes
In using the torque-angle or "turn-of-the-nut" algorithm, a
fastener is run down to a specified clamping torque and then
rotated an additional number of angular degrees regardless of
the torque necessary to turn it. A typical fastener specification
might read: "15 ft lb & 50° rotation." For additional information,
refer to the Torque-Angle Tutorial Quick Reference card that
accompanies this manual.
When setting up torque-angle measurement modes:
• Angle measurements are not stored and cannot be printed.
• CLEAR, STORE and SEND must be set to MANUAL in the
ANGLE mode. For additional information, refer to
Programming AUTO CLEAR in this chapter.
• Torque SET HIGH must be set above the maximum torque
expected. For additional information, refer to Setting Up High
and Low Limits Alert in this chapter.
Setting Up the Torque/Angle Algorithm
When in the ANGLE mode, use SET LOW to preset the
MULTITEST Indicator to a clamping torque. At torque preset
coincidence (when the input torque matches the SET LOW
preset value), the MULTITEST Indicator momentarily sounds an
alert and automatically switches to measure angle from zero
degrees. Preset the maximum angle using the SET HIGH
function. A pulsating alert sounds at angle preset coincidence
(when the measured angle matches the SET HIGH maximum
angle preset value). SET HIGH torque preset also is active in
the angle mode to protect the wrench from over-torque.
Set Up Torque-Angle Algorithm
Use the following procedure to set up the torque-angle
algorithm.
1. Select ANGLE mode using MODE.
2. Press SET LOW.
— The LED display shows the previously programmed
clamping torque preset value.
— The LCD display reads:
Clamping torque - upper line
[units] - lower line
Figure 3-8: Clamping Torque Display
3-15
Setup and Programming
3. Using up and down VALUE and left and right DIGIT,
enter the clamping torque from the fastener torque-angle
specification onto the LED display.
4. Press ENTER.
5. Press SET HIGH.
— LED display shows the previously programmed
degrees of rotation preset value.
— LCD display reads:
Edit max. angle
Figure 3-9: Edit Angle Display
6. Using up and down VALUE and left and right DIGIT,
enter the degrees of rotation from the fastener torqueangle specification onto the LED display.
7. Press ENTER to return to measurements mode.
Setting Angle Only Measurements
Certain fastener procedures involve multiple nuts or bolts to be
installed in a particular pattern. Using torque-angle
engineering, all fasteners are sequentially installed to a
specified clamping torque (sometimes two separate torques)
and then sequentially rotated a specified number of angular
degrees.
To measure angle only, use the following procedure to set SET
LOW to zero in the ANGLE mode.
1. Select ANGLE mode using MODE.
2. Press SET LOW.
— The LED displays the previously programmed
clamping torque preset value.
— The LCD display reads:
Clamping torque - upper line
[units] - lower line
3. Using up and down VALUE and left and right DIGIT,
enter zero onto the LED display.
4. Press ENTER.
3-16
Setup and Programming
5. Press SET HIGH.
— The LED display shows the previously programmed
degrees of rotation preset value.
— The LCD display reads:
Edit max. angle
6. Using up and down VALUE and left and right DIGIT,
enter the degrees of rotation from the fastener torqueangle specification onto the LED display.
7. Press ENTER to return to measurements mode.
3-17
Setup and Programming
3-18
Using the Multitest
4
Torque Calibration System
The 2000-610-02 Indicator is designed to work specifically with
the MULTITEST series of smart transducers for measuring
torque. The MULTITEST series transducers contain a memory
chip that identifies the transducer range and calibration
parameters to the Indicator.
This chapter contains information on how to test, measure, and
use the MULTITEST Torque Calibration System.
Testing Torque Wrenches and Drivers
To use the MULTITEST Torque Calibration System for torque
wrench testing, a transducer of the appropriate range is fitted to
the 2000-600-02 Manual Loader. The Loader provides a stop
that holds the torque wrench handle fixed and rotates the
transducer under the wrench drive. The system applies a
precise, monitored torque to the wrench. For additional
information refer to Chapter 6 –2000-600-02 Manual Loader.
Selecting a Transducer
When selecting a transducer, choose a single transducer that
covers the low to high end capacity of the torque wrench.
Although possible, it is best not to change transducers between
calibration check points. For example: to test or calibrate a 20
to 100 ft lb wrench, use the 2000-10-02 transducer, which
covers the range between 10 and 125 ft lb.
Installing a Transducer
Install the transducer by lining up the red mark with the
“TORQUE” label on the loader. For additional information refer
to 2000-600-02 Loader.
• Before changing or replacing transducers, adjust SET HIGH
and SET LOW limits to remain within the capacity of the tool
under test. For additional information refer to Chapter
3–Setting Up High and Low Limits Alert.
• If you must retain the statistical analysis, do not change SET
HIGH and SET LOW limits after changing the transducers
and be careful not to exceed the wrench capacity.
The procedures provided are general. You may use or establish
your own testing procedures, techniques or standards.
4-1
Using the MULTITEST Toque Calbration System
Dial and Bending Beam Torque Wrenches and
Screwdrivers
Be sure the MULTITEST transducer is capable of handling the
intended torque to avoid damaging the transducer. Always
operate the system with the 2000-600-02 Loader power on.
WARNING
Do not use this equipment with the power off.
Always turn on the indicator and loader so the
torque and load values are indicated on the display.
The safety relays only work when the power is on.
1. To program the 2000-610-02 Indicator refer to Chapter
3–Set Up and Programming. Use SET HIGH and SET
LOW limit alert, data STORE, display CLEAR, printer
SEND and STATistical analysis features.
2. Press UNIT to select the desired engineering unit of
measure as displayed on the LCD display. It is easiest
to match that of the tool under test.
3. Press MODE to select TRACK mode.
— The green TRACK lamp lights.
4. Install the tool onto the torque transducer-loader. Slowly
apply clockwise (CW) torque using the Loader crank
handle until the indicator displays the full scale torque for
the tool. Release the torque and repeat twice again to
exercise the tool and the transducer.
When applying torque by hand, make sure to hold the
drive end of the tool perfectly in line with the transducer
drive to minimize side loading errors.
5. Remove tool from the transducer-loader and wait
approximately 30 seconds then press ZERO TARE. Set
the dial indicator on the tool to zero, if possible.
6. Press MODE to select PEAK HOLD mode.
— The red PEAK HOLD lamp lights.
7. Reinstall the tool and apply CW torque to the first check
point or calibration point recommended by the
manufacturer. If the point is not specified, use the
desired working torque or about 70% of full scale.
8. Read the tool display. The percentage difference
between the indicator and tool readings should not be
greater than the sum of their respective accuracies.
4-2
Using the MULTITEST Toque Calbration System
Example:
When tool accuracy is 4% and MULTITEST Indicator /
Transducer System accuracy is 0.25%, readings should
be within ±4.25%.
9. Release the torque, CLEAR the indicator display, and
reapply torque for each of the remaining check points
recommended by the tool manufacturer. If no
recommendation is available, check at 20%, 40%, 60%,
80% and 100% of the tool full scale.
10. Repeat steps 4 through 9 in the counter clockwise
(CCW) direction.
Adjustable or Preset “Click” Wrenches and
Screwdrivers
Be sure the MULTITEST transducer is capable of handling the
intended torque to avoid damaging transducer. Always operate
the system with the power on.
WARNING
Do not use this equipment with the power off.
Always turn on the indicator and loader so the
torque and load values are indicated on the display.
The safety relays only work when the power is on.
1. To program the MULTITEST Indicator refer to Chapter
3–Set Up and Programming. Use SET HIGH and SET
LOW limit alert, data STORE, display CLEAR, printer
SEND and STATistical analysis features.
2. Press UNIT to select the desired engineering unit of
measure as displayed on the LCD display. It is easiest
to match that of the tool under test.
3. Press MODE to select TRACK mode. The green TRACK
lamp lights.
4. Adjust the tool for maximum “click” setting. Install the
tool on the torque transducer-loader. Slowly apply torque
using the loader crank handle until the tool clicks or the
Indicator displays 100% of the full scale capacity for the
tool. Release the torque and repeat twice again to
exercise the tool and the transducer.
When applying torque by hand, make sure to hold the
drive end of the tool perfectly in line with the transducer
drive to minimize side loading errors.
4-3
Using the MULTITEST Toque Calbration System
5. Remove the tool from the transducer-loader and wait
approximately 30 seconds then press ZERO TARE.
6. Press MODE to select FIRST PEAK mode. The red
FIRST PEAK lamp lights.
When testing “click” screwdrivers, it may be easier to
use the PEAK HOLD mode on the MULTITEST
Indicator to capture the maximum applied torque
reading.
7. If featured, adjust the micrometer or preset knob on the
tool to one of the following:
• The first check point recommended by the
manufacturer, or
• The desired working torque, or
• Approximately 70% of its full scale torque.
8. Reinstall tool and apply torque until the wrench “clicks.”
9. Release the torque and note the FIRST PEAK or PEAK
HOLD reading. The percentage difference between the
Indicator reading and tool setting should not be greater
than the sum of their respective accuracies.
Example:
When the tool accuracy is 4%, and the MULTITEST
Indicator accuracy is 0.25%, then readings should be
within ±4.25%.)
10. CLEAR the Indicator display.
11. Repeat steps 4 through 10 in the opposite direction, if
required.
4-4
Using the MULTITEST Torque Calbration System
Testing Power Tools
The dynamic torque characteristic of a power tool and the static
torque applied when using a wrench usually result in different
torque readings. Spinning electric and pneumatic motor
armatures contain inertia that produces a higher torque reading
than what is actually absorbed by a practical fastener. The
difference is also due to individual fastener installation
characteristics that exhibit anywhere from a gradually increasing
run-down torque, (soft-joint) to a free speed, sudden dead stop,
(hard-joint). The way in which a particular operator responds to
the tool’s reaction forces can also be reflected in the resulting
torque measurements.
A joint rate simulator is required when testing a power tool to
allow start-up rotation of the tool’s armature. The simulator is
experimentally adjusted to replicate the average joint hardness
of the intended work. Joint rate simulators that may be used
with transducers ranging from 50 in lb to 1000 in lb are:
• 50 in lb max, 1/4" internal square drive for use on 2000-6-02
transducer, part number 900-0,
• 400 in lb max, for use on 2000-7-02 transducer, part number
900-2-0, or
• 1000 in lb max, for use on 2000-8-02 transducer, part number
900-3-0.
Be sure to operate any pneumatic or electrical power
tool according to the manufacturer’s recommendations.
Non-Impact Tools
Be sure the MULTITEST transducer is capable of handling the
intended torque to avoid damaging transducer. Always operate
the system with the power on.
WARNING
Do not use this equipment with the power off.
Always turn on the indicator and loader so the
torque and load values are indicated on the display.
The safety relays only work when the power is on.
1. To program the MULTITEST Indicator, refer to Chapter
3–Set Up and Programming in this manual. Use SET
HIGH and SET LOW limit alert, data STORE, display
CLEAR, printer SEND and STATistical analysis features.
2. Press UNIT to select the desired engineering unit of
measure as displayed on the LCD display. It is easiest
to match that of the tool under test.
4-5
Using the MULTITEST Toque Calbration System
3. Press MODE to select TRACK mode. The green TRACK
lamp lights.
4. Adjust the power tool to the desired torque output, if
possible.
5. Adjust the appropriate joint rate simulator assembly for
the desired soft-hard configuration.
6. Install the joint rate simulator onto the MULTITEST
transducer, as shown in Figure 4-1. Secure the
transducer set screw, if provided. Loosen the simulator
load screw using the appropriate hex or box wrench.
Figure 4-1: Power Tool Test Setup
A – Power Tool
B – Joint Rate Simulator
C – Transducer
7. Couple the power tool to the joint rate simulator using
the appropriate accessory adaptor and bit.
8. While holding the power tool drive perfectly in-line with
the transducer drive, energize the tool until its motor
stalls or, if featured, the tool clutch slips.
9. Remove the power tool. Loosen the joint rate simulator
load screw.
10. Repeat steps 7 through 9 twice again to exercise the
tool-simulator assembly and the MULTITEST transducer.
11. Remove the power tool from the loader-transducer and
wait approximately 30 seconds then press ZERO TARE.
12. Press MODE to select POWER TOOL mode. The yellow
POWER TOOL lamp lights.
4-6
Using the MULTITEST Toque Calbration System
13. While holding the power tool drive perfectly in-line with
the transducer drive, reinstall the tool onto the simulator
and energize the tool until its motor stalls or, if featured,
the tool clutch slips. Be careful not to add torque by
turning the tool by hand.
14. Release the torque and note the Indicator POWER TOOL
reading.
15. CLEAR the display.
16. Repeat steps 4 through 15 in the opposite direction, if
required.
Given the variables typical of power tools and fastener
joint dynamics, a number of readings should be taken
and averaged to best determine the accuracy and
repeatability for each tool.
Measuring Force, Compression and Tension
The MULTITEST Torque Calibration system can be configured
to measure compression or tension force using MULTITEST
series torque transducers. A reaction arm is used on the
transducer to mathematically cancel the length portion of the
torque measurement leaving only the force portion for display.
Example:
The 250 ft lb transducer provides a display of up to 250
lbf (pounds force) if fixed with a one-foot long reaction
arm.
Special reaction arm and mounting fixture kits are available for
testing and calibrating the most common tension/compression
gauges and cable tensiometers.
• To avoid damage to the MULTITEST transducer, be sure it is
capable of handling the force you intend to apply.
• Only single transducers of 400 in lb and higher range are
recognized by the MULTITEST Indicator for force
measurement.
• Install the transducer by lining up the red mark with the
"FORCE" label on the loader. Refer to the 2000-600-02
Loader section of this manual.
Never attempt to use the 4-in-1 transducer for force
measurement.
4-7
Using the MULTITEST Toque Calbration System
Use the following procedure to make force measurements.
1. To program the MULTITEST Indicator, refer to Chapter
3—Set Up and Programming in this manual. Use SET
HIGH and SET LOW limit alert, data STORE, display
CLEAR, printer SEND and STATistical analysis features.
2. Install the compression or tension fixture according to the
manufacturer’s instructions.
3. Press SELECT to select FORCE measurement.
4. Press MODE to select TRACK mode. The green TRACK
lamp lights.
5. Press UNIT to select the desired engineering unit of
measure as displayed on the LCD display. It is easiest
to match that of the gauge being tested.
6. Apply load by turning the loader handle CW for tension
or CCW for compression. This may be reversed
depending on the fixture.
7. Release and reapply load twice again to exercise the
transducer and gauge.
8. With the load released, wait approximately 30 seconds
then press ZERO TARE.
9. Apply load according to one of the following:
• The check points recommended by the gauge
manufacturer, if specified, or
• The desired working force, or
• Approximately 70% of its full scale capacity.
Note or adjust the gauge reading to match that of the
MULTITEST LED display.
Displaying Statistical Analysis
The MULTITEST Indicator accumulates torque/force
measurements in a data list. The list is created with each
AUTO or MANUAL data store entry. Statistical analysis is
calculated on the list, and if SET HIGH and SET LOW limits are
established, draws a simple histogram of the results. These
features are very useful in statistical process control (SPC)
management. Statistical analysis can be previewed on the LCD
display or sent directly to a printer/computer port. For
additional information on setting up printer or PC ports, refer to
Chapter 3—Set Up and Programming in this manual.
4-8
Using the MULTITEST Toque Calbration System
Displaying Statistical Analysis on LCD
1. Press STAT.
— The LED display reads:
** STAT**
— The LCD displays reads:
HIT SEND = PRINT - upper line
= LIST STAT - lower line
Figure 4-2: Statistical Analysis Display
2. Repeatedly press up or down VALUE to scroll through
the LCD display as shown in Figure 4-3.
Figure 4-3: Value Display
3. Press ENTER to return to measurements mode.
4-9
Using the MULTITEST Toque Calbration System
Printing Statistical Analysis
1. Press STAT.
— The LED display reads:
**STAT**
— The LCD display reads:
HIT SEND = PRINT - upper line
= LIST STAT - lower line
2. Press SEND to print out the entire statistical analysis.
LED display reads:
SENDING
Refer to the sample printout in Figure 4-4. As
indicated on the LCD display, use MANUAL CLEAR
to cancel printing.
3. Press ENTER to return to measurements mode.
Figure 4-4: Sample Statistical Data Printout
4-10
Using the MULTITEST Toque Calbration System
Displaying or Downloading Data List
Torque measurements stored in the data list also include a date
and time stamp. For additional information on setting up printer
or PC ports, refer to Chapter 3—Set Up and Programming in
this manual.
Displaying Data List on LCD
1
Press RECALL DATA.
— The LCD display reads:
RECALL
The present memory location is at the upper left,
the total number of memory locations to its right
and the time the data was stored at the far right.
—
The LED display shows the measurement value of
that memory location while the LCD displays its
engineering units at the lower right.
2. Use up and down VALUE to view the data list.
3. Press ENTER to return to measurements mode.
Downloading Data List to Printer
1. Press RECALL DATA.
2. Press SEND/AUTO SEND.
— The LCD display reads:
Download - upper line
+DateTime Raw - lower line, with the plus sign flashing
Figure 4-5: Data Download Display
3. To download the data list plus date-time stamp, press
ENTER. The LED display reads:
SENDING
4. To download the raw data list, use right DIGIT to select
“Raw” on the LCD display.
4-11
Using the MULTITEST Toque Calbration System
5. Press ENTER to download the raw data list. The LED
display reads:
SENDING
6. Press ENTER again to return to measurements mode.
Downloading Data List to Personal Computer
1. Connect the accessory 2000-50-1 cable between the
MULTITEST OPTIONAL port and the computer COM
port. For additional information on setting up printer or
PC ports, refer to Chapter 3—Set Up and Programming
.
2. Set up your computer to receive serial communication.
Example:
If using an IBM compatible and Windows 95:
— Click on START—RUN to open the Terminal
program.
— Type TERMINAL.
— Press <Enter>.
3. Press RECALL DATA.
4. Press SEND/AUTO SEND. As shown in Figure 4-5, the
LCD display reads:
Download - upper line
+Date Time Raw - lower line, with the plus sign flashing
—
To download the data list plus date-time stamp,
press ENTER. The LED display reads:
SENDING
—
To download the raw data list, use right DIGIT to
select “Raw” on the LCD display. Then press
ENTER to download. The LED display reads:
SENDING
5. Press ENTER again to return to measurements mode.
6. Copy the data list to your chosen software.
Example:
If using an IBM compatible and Windows 95:
— Select EDIT —SELECT ALL, and then EDIT—COPY.
— Open the spreadsheet or data program being used.
— Select EDIT—PASTE in the program being used.
4-12
Using the MULTITEST Toque Calbration System
How to Use Analog Output (Rear Panel BNC
Connector)
Analog Output on the MULTITEST Indicator provides a real time
voltage level that is directly proportional to the torque/force
measurement applied to the transducer. It is useful for direct
driving equipment such as analog plotters and chart recorders,
or interfacing to a computer/controller with analog to digital
(A/D) data acquisition capability. Maximum output loading must
be less than 5 mA.
The output varies between approximately +1.8 volts, full
clockwise (CW) torque/force applied and approximately -1.8
volts, full counter clockwise (CCW) torque/force applied. Zero
offset is within ±100 mv. Linearity is better than ±1% of
reading.
When used with the 4-in-1 transducer, zero output
varies with the scan of the four transducers. Select
one of the four by applying at least 5% of its full range
torque to it. Press ENTER to return to scanning.
1. To program the MULTITEST Indicator, refer to Chapter
3—Set Up and Programming. Use SET HIGH and SET
LOW limit alert, data STORE, display CLEAR, printer
SEND and STATistical analysis features.
2. Press MODE to select the TRACK mode.
3. Connect the recording or monitoring equipment to the
ANALOG OUTPUT port using a BNC coaxial connector.
4. With no torque applied, measure the ANALOG OUTPUT
voltage and adjust or program your equipment for zero.
5. Apply full range torque to the transducer in the CW
direction as shown on the MULTITEST Indicator LED
display.
6. Measure the ANALOG OUTPUT voltage and adjust or
program your equipment to display the full range torque
value.
7. Apply full range torque to the transducer in the CCW
direction as shown on the MULTITEST Indicator LED
display.
8. Measure the ANALOG OUTPUT voltage and adjust or
program your equipment to display the full range torque
value.
4-13
Using the MULTITEST Toque Calbration System
Measuring Torque and Angle
Although measuring torque and angle is not a torque testing
feature, transducers and the MULTITEST Indicator may be used
to monitor torque during fastener installation. The Indicator can
also be set up to monitor "turn-of-the-nut" or angle of rotation
using common bi-directional incremental rotary encoders for
critical fastener installations. Typically, a torque-angle algorithm
is used where the joint is clamped using a preload torque. The
fastener is then rotated a specific number of degrees regardless
of the torque necessary to turn it.
Torque Only
When using the instructions in this section refer to the TorqueAngle Tutorial Quick Reference Card that accompanies this
manual.
1. For additional information on setting SET HIGH and LOW
limits alert, Data STORE, display CLEAR, printer SEND
and STATistical analysis features, refer to Chapter
3—Set Up and Programming.
2. Press UNIT to select the desired engineering unit of
measure as displayed on the LCD display.
3. Press MODE to select TRACK or PEAK HOLD mode.
4. Install the transducer between the fastener and the
wrench or tool.
5. Apply increasing torque until the audible tone indicates
that measured torque matches or exceeds the SET LOW
torque limit. If you match or exceed the SET HIGH
torque limit, the alert sounds a pulsating tone.
4-14
Using the MULTITEST Toque Calbration System
Angle Only
The MULTITEST accepts input from common bi-directional
incremental rotary encoders. The Indicator interfaces to any
encoder resolution (counts per revolution) and can be
programmed to display angle in degrees of rotation.
For additional information on setting up angle encoders and
measurement modes, refer to Chapter 3—Set Up and
Programming in this manual.
1. Press MODE to select ANGLE.
— LED displays torque.
— LCD displays degrees of rotation at the lower left.
Figure 4-6: Angle Mode Display
2. Install the angle encoder between the fastener and an
appropriate wrench or breaker bar. Fix the encoder
reference arm, strap, clamp or magnet to the work.
3. Press ANGLE RESET to zero the angle display.
4. Rotate the fastener while monitoring the angle on the
LCD display. The SET HIGH limit momentarily sounds
an audible tone at angle preset coincidence (when the
measured angle matches the SET LOW angle).
5. Press ANGLE RESET to clear the angle display.
4-15
Using the MULTITEST Toque Calbration System
Torque-Angle Algorithm
In addition to MULTITEST series torque transducers, the
MULTITEST Indicator accepts input from common bi-directional
incremental rotary encoders. The Indicator features a special
Torque-Angle measurement mode where a clamping torque is
first applied and measured, then at torque preset coincidence,
(when the input torque matches the SET LOW limit), the
Indicator automatically switches to measuring angle in degrees
of rotation.
The operator continues to rotate the fastener until angle preset
coincidence (angle matches the SET HIGH limit). With this, the
specified torque and angle parameters are accomplished in one
wrenching operation.
For additional information on setting up angle encoders,
programming a particular angle and measurement modes, refer
to Chapter 3—Set Up and Programming in this manual.
1. Press MODE to select ANGLE.
— The LED display reads:
0
—
The LCD angle display is blank at the lower left, as
shown in Figure 4-6.
2. Install the angle encoder and torque transducer between
the fastener and an appropriate wrench or breaker bar.
3. With the encoder reference arm, strap, clamp or magnet
fixed to the work, rotate fastener while monitoring torque
on the LED display. At torque preset coincidence, (when
the torque measurement matches the SET LOW torque
limit) the Indicator sounds a momentary tone and initiates
display of degrees of rotation on the LCD.
4. Continue rotating the fastener until angle preset
coincidence (when the angle measurement matches the
SET HIGH angle limit). The Indicator sounds a pulsating
tone. The LED display holds the peak torque applied
and reads:
A+torque (angle plus torque)
5. Press MANUAL CLEAR to zero the torque and angle
displays.
4-16
Calibration
5
The MULTITEST Torque Calibration system is factory calibrated
using precision torque test arms, certified weights and laboratory
grade equipment. MULTITEST series transducers must be
positioned vertically, with torque applied within ±15 degrees of
horizontal.
This chapter contains calibration instructions and information for
the MULTITEST Torque Calibration System.
Annual calibration is recommended. Calibration by the
user is recorded in memory and voids factory
certification. Contact your authorized CDI sales
representative for calibration and repair services.
If extreme calibration precision is required, refer to
Correction Factors on Test Weights in this chapter.
Calibration Equipment
Equipment Required
• Precision test arms and certified calibration weights,
• Test stand,
Figure 5-1: 4 in 1, wheel, butterfly, hook and hanger
5-1
Calibration
Mounting Details
Single Transducer Mounting Detail for Calibration
Single transducer calibration requires the use of a reaction
stand and transducer calibration block.
As shown in Figure 5-2, the transducer is secured to the
calibration block with two quick release pins.
• Both pins must be installed for safety and stability of the
mount.
• The white mark on the transducer is aligned in the up
position.
Figure 5-2: Single Low Torque Transducer Mounting Detail
Torque Under 250 ft lb
Mount the calibration block at the center of the stand with two
1/2-13 socket head cap screws with test bars that are 10" or
shorter. Install these screws using the supplied torque wrench
and 3/8-3/8 socket driver adapter. Use this configuration for up
to 250 ft lb of applied torque.
A 1/2" to 3/8" reducer is required when mounting the
10" arm to transducers having 3/8" drives.
5-2
Calibration
Torque Over 250 ft lb
For torque calibration above 250 ft lb, the calibration block is
moved to the left for CCW loading and to the right for CW
loading. The torque arm is always extended over the front of
the reaction bracket for both CW and CCW torque applications.
In this configuration, useful up to 2000 ft lb, the calibration block
is secured to the stand using four 3/8-16 socket head cap
screws, each torqued to 45 ft lb. For additional information
refer to Figure 5-3 .
Figure 5-3: Single High Torque Transducer Mounting Detail
The 2000-12-02, 600 ft lb transducer, requires the 1-1/4" to 3/4"
drive reducer, supplied, to couple to the 40" test bar.
WARNING
Always position the 40" arm over the front of the
stand as shown. Never extend the test arm behind
the stand. The stand will tip over when weights are
applied.
The 40" test arm is coupled to the 2000-13-03, 1000 ft lb, and
2000-14-03, 2000 ft lb transducers using a 1-1/4" drive adaptor
plate.
1. Remove the internal drive adaptor plate and bottom plate
from the transducer using the torque wrench, ratchet
head and 3/8-3/8 hex bit or 3/4" open end adaptor
supplied.
5-3
Calibration
2. Remove separated adaptor from calibration block.
3. Attach transducer to the calibration block so that red
mark on transducer lines up with white dot in left bottom
corner on calibration block. Tighten six 1/2"-13 hex head
bolts to 75 ft lb torque.
NOTE:
Transducers the with four bolt flange, tighten the
four 3/8”-16 hex bolt to 45 ft lb.
4. Attach the 1-1/4" drive adaptor plate using six 1/2"x13
hex head bolts, each torqued to 75 ft lb using the torque
wrench, and 3/4” open end adaptor, supplied.
5. After calibration, re-install the internal drive plate and
bottom plate using appropriate 1/2"x13 screws, torquing
them to 75 ft lb. Also re-install the separated adaptor to
the calibration block.
Appropriate hangers and weights are listed in the calibration
check point table in this chapter. Notice that the weight of the
hanger is included in all measurements. The hanger must be
removed to set ZERO TARE on the Indicator.
4-in-1 Transducer Mounting Detail for Calibration
The 4-in-1 transducer mounts upright with integral transducers
in the vertical position. This transducer may be mounted to
a:
• Wall using four 1/4" bolts torqued to 10 ft lb, or
• Sturdy table using a right angle bracket. Refer to Figure 5-4.
Figure 5-4: 4-in-1 Transducer Mounting Detail
The 4-in-1 transducer may also be mounted to the calibration
stand, shown in Figure 5-2, using the fixture multiple
transducers P/N 2500-500-02. For this mounting configuration
the two slide knobs must be loosened and four 5/16-18 bolts
attached to secure the 4-in-1 transducer to the bracket
assembly.
5-4
Amendment for User’s Manual: December 08, 2006.
Calibration
Quick Check
WARNING
Always be alert to the potential for personal injury
that may be caused by excessive torque
applications, careless handling of heavy weights,
and out-of-balance or unsafe weight distribution.
1. With the MULTITEST Indicator ON, select TORQUE
measurement, TRACK mode, and select the UNITs of
measure appropriate to the transducer as specified in the
calibration check point table in this chapter.
2. Install the transducer to be checked and allow a 5 minute
warm up period to stabilize the electronic circuits and
transducer elements.
3. Transducers are mounted vertically for calibration as
instructed in Mounting Details in this chapter. Mount the
4-in-1 transducer to a sturdy bench using the bracket
provided. Mount single transducers vertically using
the accessory stand and block. Attach the specified
torque test bar, wheel or butterfly, secured with its drive
retention screw, and install the specified hanger for
clockwise (CW) torque application.
4. Apply and remove the full range torque for the transducer
three times.
5. Remove the weights and hanger, but leave the arm
attached, and wait approximately 30 seconds then press
ZERO TARE.
6. At each of the check points specified for the transducer
in the calibration check point table (in this chapter), apply
torque in the CW direction and verify the display
readings are within 0.25% of applied torque. If any
reading is out of specification, proceed to Calibrating
MULTITEST Torque/Force Transducers in this chapter.
7. Repeat Steps 3 through 6 in the counter clockwise
(CCW) direction.
When using the 2-1/2" or 5" test wheel, a small “S”
hook is supplied to provide a positive zero bias in the
direction (CW or CCW) that the calibration is
performed. Do not remove the “S” hook P/N 2000-151-4
when setting zero tare.
5-5
Calibration
Suggested Transducer Calibration Check Points, Bars, Hangers and Weights
(Sheet 1 of 2)
Part
No.
Bar
Hanger Calibration
Length Weight Points
Check
Points
Weights to Add
(n) = more than 1
Total
2000-4-02
5-50 in oz
(0.5% accuracy)
2.5"
2.5"
2.5"
2.5"
2.5"
none
1/2 lb
1/2 lb
1/2 lb
1/2 lb
1
2
3
4
5
5.0 in oz
20.0 in oz
30.0 in oz
40.0 in oz
50.0 in oz
5 in oz
20 in oz
30 in oz
40 in oz
50 in oz
2 oz
none
4 oz
8 oz
4 oz, 8 oz
2
8
12
16
20
2000-5-02
15-200 in oz
(0.25% accuracy)
2.5"
2.5"
2.5"
2.5"
2.5"
2.5"
none
1/2 lb
1/2 lb
1/2 lb
1/2 lb
1/2 lb
1
2
3
4
5
20.0 in oz
40.0 in oz
80.0 in oz
120.0 in oz
200.0 in oz
15.0 in oz
20.0 in oz
40.0 in oz
80.0 in oz
120.0 in oz
200.0 in oz
2 oz, 4 oz
none
1/2 lb
1/2 lb, 1 lb
1/2 lb, (2) 1 lb
1/2 lb, (2) 2 lb
6 oz
1/2 lb
1 lb
2 lb
3 lb
5 lb
2000-6-02
4-50 in lb
(0.25% accuracy)
5.0"
5.0"
5.0"
5.0"
5.0"
5.0"
1/2
1/2
1/2
1/2
1/2
1/2
lb
lb
lb
lb
lb
lb
1
2
3
4
5
5.0 in lb
10.0 in lb
20.0 in lb
30.0 in lb
50.0 in lb
4.0 in lb
5.0 in lb
10.0 in lb
20.0 in lb
30.0 in lb
50.0 in lb
0.3
1/2
1/2
1/2
1/2
1/2
oz, 0.5 oz, 4 oz
lb
lb, 1 lb
lb, 1 lb, 2 lb
lb, 1 lb, (2) 2 lb
lb, 1 lb, (4) 2 lb
0.8 lb
1 lb
2 lb
4 lb
6 lb
10 lb
2000-65-02
15-150 in lb
(0.25% accuracy)
5.0"
5.0"
5.0"
5.0"
5.0"
1/2
1/2
1/2
1/2
1/2
lb
lb
lb
lb
lb
1
2
3
4
5
15.0 in lb
30.0 in lb
60.0 in lb
90.0 in lb
150.0 in lb
15.0 in lb
30.0 in lb
60.0 in lb
90.0 in lb
150.0 in lb
1/2
1/2
1/2
1/2
1/2
lb,
lb,
lb,
lb,
lb,
2 lb
1 lb, (2) 2 lb
1 lb, (2) 5 lb
2 lb, (3) 5 lb
(2) 2 lb, (5) 5 lb
3 lb
6 lb
12 lb
18 lb
30 lb
2000-7-02
30-400 in lb
(0.25% accuracy)
10.0"
10.0"
10.0"
10.0"
10.0"
10.0"
1/2
1/2
1/2
1/2
1/2
1/2
lb
lb
lb
lb
lb
lb
1
2
3
4
5
40.0 in lb
80.0 in lb
160.0 in lb
240.0 in lb
400.0 in lb
30.0 in lb
40.0 in lb
80.0 in lb
160.0 in lb
240.0 in lb
400.0 in lb
1/2
1/2
1/2
1/2
1/2
1/2
lb,
lb,
lb,
lb,
lb,
lb,
2lb
1 lb, 2 lb
2 lb, 5 lb
(3) 5 lb
1 lb, 2 lb, (4) 5 lb
1 lb, (4) 2 lb, (6) 5 lb
3 lb
4 lb
8 lb
16 lb
24 lb
40 lb
2000-8-02
80-1000 in lb
(0.25% accuracy)
10.0"
10.0"
10.0"
10.0"
10.0"
10.0"
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
1
2
3
4
5
100.0 in lb
200.0 in lb
400.0 in lb
600.0 in lb
1000 in lb
80.0 in lb
100.0 in lb
200.0 in lb
400.0 in lb
600.0 in lb
1000 in lb
1/2
1/2
1/2
1/2
1/2
1/2
lb
lb,
lb,
lb,
lb,
lb,
2
2
2
2
2
2000-10-02
10-125 ft lb
(0.25% accuracy)
10.0"
10.0"
10.0"
10.0"
10.0"
10.0"
7-1/2 lb
15 lb
1
15 lb
2
15 lb
3
15 lb
4
15 lb
5
12.5 ft lb
25.0 ft lb
50.0 ft lb
75.0 ft lb
125.0 ft lb
10 ft lb
12.5 ft lb
25.0 ft lb
50.0 ft lb
75.0 ft lb
125.0 ft lb
1/2 lb, (2) 2 lb
none
(3) 5 lb
5 lb, (2) 10 lb, 20 lb
(3) 5 lb, (2) 10 lb, (2) 20 lb
5 lb, 10 lb, 20 lb, (2) 50 lb
12
15
30
60
90
150
lb
lb
lb
lb
lb
lb
2000-11-02
20-250 ft lb
(0.25% accuracy)
10.0"
10.0"
10.0"
10.0"
10.0"
10.0"
15
15
15
15
15
15
25.0 ft lb
50.0 ft. lb
100.0 ft. lb
150.0 ft. lb
250.0 ft. lb
20.0 ft lb
25.0 ft lb
50.0 ft. lb
100.0 ft. lb
150.0 ft. lb
250.0 ft. lb
(2) 2 lb, 5 lb
5 lb, 10 lb
5 lb, (2) 20 lb
5 lb, (2) 50 lb
5 lb, (3) 20 lb, (2) 50 lb
5 lb, (4) 20 lb, (4) 50 lb
24
30
60
120
180
300
lb
lb
lb
lb
lb
lb
5-6
Range
lb
lb
lb
lb
lb
lb
lb
lb
lb
lb
lb
lb
1
2
3
4
5
lb
lb,
lb,
lb,
lb,
(2) 5 lb
(2) 5 lb, (2) 10 lb
(2) 5 lb, (4) 10 lb
(2) 5 lb, (4) 10 lb, (2) 20 lb
Weight
oz
oz
oz
oz
oz
8 lb
10 lb
20 lb
40 lb
60 lb
100 lb
Calibration
Suggested Transducer Calibration Check Points, Bars, Hangers and Weights
(Sheet 2 of 2)
Part
No.
Bar
Hanger Calibration
Length Weight Points
Check
Points
Weights to Add
(n) = more than 1
Total
2000-12-02
60-600 ft lb
(0.25% accuracy)
40"
40"
40"
40"
40"
15
15
15
15
15
lb
lb
lb
lb
lb
1
2
3
4
5
60.0 ft lb
120.0 ft lb
240.0 ft lb
360.0 ft lb
600.0 ft lb
60.0 ft lb
120.0 ft lb
240.0 ft lb
360.0 ft lb
600.0 ft lb
1
1
2
1
5
lb,
lb,
lb,
lb,
lb,
2 lb
(2) 10 lb
5 lb, 10 lb, (2) 20 lb
2 lb, 10 lb, (4) 20 lb
(3) 20 lb, (2) 50 lb
18
36
72
108
180
lb
lb
lb
lb
lb
2000-13-02
100-1000 ft lb
(0.25% accuracy)
40"
40"
40"
40"
40"
15
15
15
15
15
lb
lb
lb
lb
lb
1
2
3
4
5
100.0 ft lb
200.0 ft lb
400.0 ft lb
600.0 ft lb
1000.0 ft lb
100.0 ft lb
200.0 ft lb
400.0 ft lb
600.0 ft lb
1000.0 ft lb
5
5
5
5
5
lb,
lb,
lb,
lb,
lb,
10 lb
(2) 20
(5) 20
(2) 10
(4) 20
30
60
120
180
300
lb
lb
lb
lb
lb
2000-14-02
200-2000 ft lb
(0.25% accuracy)
40"
40"
40"
40"
40"
50
50
50
50
50
lb
lb
lb
lb
lb
1
2
3
4
5
200.0 ft lb
400.0 ft lb
800.0 ft lb
1200.0 ft lb
2000.0 ft lb
200.0 ft lb
400.0 ft lb
800.0 ft lb
1200.0 ft lb
2000.0 ft lb
(2) 5 lb
20 lb, 50 lb
(2) 5 lb, (4) 20 lb, (2) 50 lb
(2) 5 lb, (5) 20 lb (4) 50 lb
(2) 5 lb, (4) 10 lb, (5) 20 lb (8) 50 lb
60
120
240
360
600
lb
lb
lb
lb
lb
2000-400-02
(4-in-1)
4-50 in lb
(0.25% accuracy)
5"
5"
5"
5"
5"
5"
1/2
1/2
1/2
1/2
1/2
1/2
lb
lb
lb
lb
lb
lb
1
2
3
4
5
5.0 in lb
10.0 in lb
20.0 in lb
30.0 in lb
50.0 in lb
4.0 in lb
5.0 in lb
10.0 in lb
20.0 in lb
30.0 in lb
50.0 in lb
0.3
1/2
1/2
1/2
1/2
1/2
oz, 0.5 oz, 4 oz
lb
lb, 1 lb
lb, 1 lb, 2 lb
lb, 1 lb, (2) 2 lb
lb, 1 lb, (4) 2 lb
30-400 in lb
(0.25% accuracy)
10"
10"
10"
10"
10"
10"
1/2
1/2
1/2
1/2
1/2
1/2
lb
lb
lb
lb
lb
lb
1
2
3
4
5
40.0 in lb
80.0 in lb
160.0 in lb
240.0 in lb
400.0 in lb
30.0 in lb
40.0 in lb
80.0 in lb
160.0 in lb
240.0 in lb
400.0 in lb
1/2
1/2
1/2
1/2
1/2
1/2
lb, 2 lb
lb, 1 lb, 2 lb
lb, 1 lb, (3) 2 lb
lb, (3) 5 lb
lb,1 lb, 2 lb, (4) 5 lb
lb,1 lb (4) 2 lb, (6) 5 lb
80-1000 in lb
(0.25% accuracy)
10"
10"
10"
10"
10"
10"
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
1
2
3
4
5
100.0 in lb
200.0 in lb
400.0 in lb
600.0 in lb
1000 in lb
80.0 in lb
100.0 in lb
200.0 in lb
400.0 in lb
600.0 in lb
1000 in lb
1/2
1/2
1/2
1/2
1/2
1/2
lb
lb,
lb,
lb,
lb,
lb,
10"
10"
10"
10"
10"
10"
15
15
15
15
15
15
1
2
3
4
5
25.0 ft lb
50.0 ft. lb
100.0 ft. lb
150.0 ft. lb
250.0 ft. lb
20.0 ft lb
25.0 ft lb
50.0 ft. lb
100.0 ft. lb
150.0 ft. lb
250.0 ft. lb
(2) 2 lb, 5 lb
5 lb, 10 lb
5 lb, (2) 20 lb
5 lb, (2) 50 lb
5 lb, (3) 20 lb, (2) 50 lb
5 lb, (4) 20 lb, (4) 50 lb
Range
20-250 ft lb
(0.25% accuracy)
lb
lb
lb
lb
lb
lb
lb
lb
lb
lb
lb
lb
2
2
2
2
2
lb
lb,
lb,
lb,
lb,
lb
lb
lb, (2) 20, (2) 50 lb
lb, (4) 50 lb
(2) 5 lb
(2) 5 lb, (2) 10 lb
(2) 5 lb, (4) 10 lb
(2) 5 lb, (4) 10 lb, (2) 20
Weight
0.8 lb
1 lb
2 lb
4 lb
6 lb
10 lb
3
4
8
16
24
40
lb
lb
lb
lb
lb
lb
8 lb
10 lb
20 lb
40 lb
60 lb
100 lb
24
30
60
120
180
300
lb
lb
lb
lb
lb
lb
Note: For 2500-400-02, multiple transducer assembly, refer to
the Suggested Calibration Check Points for
2500-400-02 sheet that accompanies this manual.
5-7
Calibration
Torque/Force Calibrations
MULTITEST Torque/Force Transducer Calibration
IMPORTANT
Improper calibration can result in torque
measurement errors. Follow these procedures
precisely. If an error is made in the procedure, turn
the indicator off and begin again. Users are
responsible for the results of their transducer
calibration.
MULTITEST series torque/force transducers can only be
calibrated using the MULTITEST Indicator. Calibration data is
calculated and then stored in the EEPROM memory chip of the
transducer by the microcontroller in the Indicator.
WARNING
Always be alert to the potential for personal injury
and equipment damage that may be caused by
excessive torque applications, careless handling of
heavy weights, and out-of-balance or unsafe weight
distribution.
Equipment
Procedure
•
•
Precision test arms and certified calibration weights.
Test stand.
1. With the MULTITEST Indicator ON, select TORQUE
measurement, TRACK mode, and select the UNITs of
measure appropriate to the transducer. Refer to the
calibration check point table in this chapter for the
transducer calibration check points, and specified arms,
hangers and weights.
2. Install the transducer being calibrated and allow a 5
minute warm up period to stabilize the electronic circuits
and transducer elements.
3. Mount the 4-in-1 transducer upright, drives vertical, as
shown in Figure 5-4, or mount single transducers
vertically using the accessory stand and block as
detailed in Figure 5-3. Attach the specified torque arm,
secured with the drive retention screw, and install the
specified hanger for clockwise (CW) torque application.
Use the “S” hook on the 2-1/2" or 5" bars.
4. Press CAL. LED display reads the following message
with least significant digit (LSD) flashing:
CODE0000
5-8
Calibration
5. Enter the following code into the display using the
DIGIT right and left keys and the up and down VALUE
keys:
CODE5222
6. Press ENTER.
— The LED display reads:
SELECT
—
The LCD display reads:
Calibrate CW
7. Press ENTER.
— The LED display reads a flashing number in the
LSD.
— The LCD display read:
Enter no. of transducers
8. Using the up and down VALUE keys, enter “1” for a
single transducer or “4” for the 4-in-1 transducer.
— If you enter "1" skip to step 11.
9. Press ENTER. The LED display reads a flashing number
in the LSD and the LCD display reads:
Select transducer
10. Using the up and down VALUE keys, enter the number of
the 4-in-1 transducer to calibrate. Possible values are:
1 = 50 in oz
2 = 400 in lb
3 = 1000 in lb
4 = 250 ft lb
11. Press ENTER.
— The LED display banners:
ENTER FS
followed by the last full scale calibration point for the
particular transducer installed or selected with its
MSD flashing.
—
The LCD display reads:
ENTER FS transducer
[units]
12. Using the up and down VALUE keys and the left and
right DIGIT keys, enter the full scale torque capacity of
the transducer in the engineering units selected.
13. Press ENTER.
— The LED display banners:
ZERO TARE
Four zeros follow shifting alternately across the
display.
— The LCD display reads:
CALIBRATION
<ZEROTARE> CONT.
5-9
Calibration
14. Apply and release full scale torque to the transducer
three times in the CW direction, then remove the weights
and hanger. Leave the torque arm installed. Wait
approximately 15 seconds before applying weight
hangers and weights.
15. Press ENTER.
— For single transducers, the LED display momentarily
reads:
ZEROTARE and then LOAD + + 1
with the two plus signs alternating
—
For 4-in-1 transducers, the LED display reads:
ZERO T1 through 4 as each transducer is scanned
—
The LCD display reads:
*CALIBRATION* - upper line
Load transducer - lower line
16. Apply torque using the precision arm, hanger or certified
weights listed as calibration point 1 in the calibration
check point table in this chapter.
17. When the reading is stable, push and hold the up and
down VALUE keys to enter the exact torque value into
the LED display.
18. Press ENTER. LED display momentarily reads
O-K and then LOAD ++ 2
Apply the next calibration point torque from the chart and
press ENTER. Repeat for all five calibration points.
—LED display banners:
O-K,
MAX NUMBER OF CAL POINTS REACHED
SAVING
CAL SAVED
SELECT
—
LCD display reads
Calibrate CW
19. Remove weight and remove the arm.
20. Select "Calibrate CCW” on the LCD display by pushing
the VALUE up key.
21. Repeat steps 7 through 18, applying all torque in the
counter clockwise (CCW) direction.
All readings show minus signs (-).
22. Press CAL to return to measurements mode.
5-10
Calibration
MULTITEST Indicator Torque/Force Calibration
IMPORTANT
Equipment
Improper calibration can result in torque
measurement errors. Follow these procedures
precisely. If an error is made in the procedure, turn
the indicator off and begin again. Users are
responsible for the results of their calibration.
•
•
Procedure
Laboratory grade millivolt meter for calibration measurements
capable of resolving 1/100 millivolts.
Calibration fixture as shown in Figure 5-1.
1. With the power off, plug the calibration fixture into the
TRANSDUCER INPUT connector at the back of the
MULTITEST Indicator.
2. Turn the power on. After initialization:
— LED display reads:
NO INPUT
—
LCD display reads:
No Transducer Connected
3. Press CAL. LED display reads with least significant digit
(LSD) flashing:
CODE0000
4. Using the DIGIT right and left keys and the up and down
VALUE keys enter the following code into the display:
CODE5111
5. Press ENTER.
— The LED display banners the message shown below
followed by the last excitation voltage programmed:
—
CALIBRATING VOLTAGE (mV)
3023.79 (example voltage)
The LCD display reads
Calibrate tester - upper line
STEP 1 Supply mv - lower line
6. Using a laboratory millivolt meter, measure the voltage
across pins 2 (ground) and 19 (gage excitation) of the
calibration fixture.
Example:
3023.79 millivolts
5-11
Calibration
7. Program the measured voltage (example provided in step
5 on the previous page) into the MULTITEST Indicator
using the up and down VALUE keys and the left and right
DIGIT keys.
8. Press ENTER.
— The LED display reads:
—
APPLY 0V
LCD display reads:
Calibrate tester - upper line
STEP 2 0V tare - lower line
9. Short pins 5 and 6 together on the calibration fixture.
10. Press ENTER.
— The LED display reads in millivolts input:
—
G+XX.XXX
The LCD display reads
Calibrate Tester - upper line
STEP 3 Adjust mV - lower line
11. Remove the short between pins 5 and 6 of the calibration
fixture.
12. Using a laboratory millivolt meter, measure the voltage
across pins 5 and 6.
Example:
08.262 mV
13. Program the measured voltage into the MULTITEST
Indicator as demonstrated in the example, “+08.262” by
pushing and holding the up or down VALUE keys.
14. Press ENTER. The LED display momentarily reads:
SAVING...
15. Turn the power to OFF. Remove the calibration fixture.
5-12
Calibration
Gravitational Effects
Correction Factors on Test Weights
Weights used in torque calibration are affected by their
acceleration due to:
• Altitude above or below sea level, and
• Latitude on earth between the equator and the poles.
Test bars are not affected by these conditions. The accuracy of
torque wrenches and testers does not change due to changes in
geographic location. Only when using weights must correction
factors be considered. After an analysis is made for a given
location, it is often found that the correction factor is
insignificant.
Two methods of correction are provided. They are:
• Correction factor for check point readings adjusts the
calibration readings without changing the applied weight.
• Correction factor for weights adjusts the weight applied
without changing check point readings. For additional
information refer to Gravitational Charts in this chapter.
Gravitational Charts
The charts in this section are taken from CRC Handbook of
Chemistry and Physics, 58th Edition. CRC Press, Inc., 18901
Cranswood Parkway. Cleveland, Ohio 44128.
Acceleration Due to Gravity for Sea Level at Various
Latitudes
Latitude
Degrees
0
5
10
15
20
25
30
32
34
36
38
40
42
44
Acceleration
cm/sec2
Latitude
Degrees
978.039
978.078
978.195
978.384
978.641
978.960
979.329
979.487
979.652
979.822
979.995
980.171
980.350
980.531
46
48
50
52
54
56
58
60
65
70
75
80
85
90
Acceleration
cm/sec2
980.711
980.892
981.071
981.247
981.422
981.592
981.757
981.918
982.288
982.608
982.868
983.059
983.178
983.217
5-13
Calibration
Free Air Correction for Altitude
Altitude
Meters
200
300
400
500
600
700
800
900
Correction
cm/sec2
-.0617
-.0926
-.1234
-.1543
-.1852
-.2160
-.2469
-.2777
Correction Factor for Check Point Readings
1. Determine latitude and altitude. Obtain information from
local geological survey office or library.
2. Find the acceleration due to gravity for sea level from its
chart.
3. Subtract the free air correction for altitude from its chart.
4. Divide the result calculated in step 3 by the standard
gravitational factor 980.665 cm/sec/sec.
5. Multiply the check point in the calibration charts by the
factor calculated in step 4 to obtain the corrected check
point readings while using the original weight.
Correction Factor for Weights
1. Determine latitude and altitude. Obtain information from
local geological survey office or library.
2. Find the acceleration due to gravity for sea level from its
chart.
3. Subtract the free air correction for altitude from its chart.
4. Divide the result, calculated in step 3, by the standard
gravitational factor 980.665 cm/sec/sec.
5. Calculate the inverse of the calculation in step 4 by
dividing it into 1.
6. Multiply the weight given for each check point in the
calibration charts by the inverse factor, calculated in step
5, and use this corrected weight with the original check
point readings.
5-14
2000-600-02
Manual Loader
6
The 2000-600-02 Manual Loader is designed as an integral
component of the CDI MULTITEST Torque Calibration System
providing a precision output torque of up to 2000 ft lb while
requiring only 8 ft lb input.
Application
Power
The loader is a laboratory grade instrument used for testing and
calibrating all torque wrenches, drivers, torque multipliers, nonimpact pneumatic and electric nut runners. This equipment also
can be mounted on a fixture for testing and calibrating cable
tensiometers and compression or tension gauges.
To activate the limit solenoids that protect the transducers from
overload, the loader requires AC power, 115/230VAC, 50 to 60
Hz, 3.15 amps.
WARNING
Do not use this equipment with the power off.
Always turn on the indicator and loader so the
torque and load values are indicated on the display.
The safety relays only work when the power is on.
Transducer Rotation
The manual hand crank provides up to 20° of transducer
rotation in both clockwise (CW) and counter clockwise (CCW)
directions.
MULTITEST Torque Calibration System
Components included in the 2000-600-02 System are:
• 2000-610-02 Indicator,
• 2000-600-02 Loader, and
• 2000-100-02 Roll Cabinet.
When the 2000-600-02 Manual Loader interfaces with the 2000610-02 Torque/Force Indicator and the MULTITEST series of
torque transducers, the MULTITEST Torque Calibration system
provides precision loading, monitoring and data acquisition of
torque, force and angle parameters within +/- 0.25% accuracy.
System capabilities include, data storage, retrieval, statistical
analysis and automatic downloading to a printer or computer.
6-1
2000-600-02 Motorized Loader
Torque/force transducers, purchased separately, are available in
ranges from 15-200 in oz, to 200-2000 ft lb. The MULTITEST
Torque Calibration system features accessory calibration
equipment including precision torque bars, certified weights,
calibration mounts and stands. Reaction arms, cables,
mounting plates and fixtures are also available for testing
tensiometers, compression and tension gauges, and torque
multipliers.
The 2000-600-02 includes a CDI roll cabinet, part number 2000100-02, with heavy duty casters and nine drawers with ball
bearing slides for transducer and calibration equipment storage.
An extendable swivel monitor stand accepts mounting of the
2000-610-02 Indicator for operator convenience.
Functional Description
This section describes major hardware components of the
torque tester, including the:
• Torque tester/calibrator,
• 2000-600-02 Manual Loader,
• Loader rear panel controls,
• Ball handle adaptor,
• 4-in-1 transducer (accessory), and
• Extension arm (accessory).
6-2
2000-600-02 Manual Loader
Torque Tester/Calibrator
The 2000-600-02 Manual Loader mounts on a CDI roll cabinet,
part number 2000-100-02. An indicator stand mounts onto the
loader.
2000-600-02 Manual Loader
Figure 6-1: 2000-600-02 Manual Loader
A
B
C
D
–
–
–
–
Indicator Stand
Safety Shield
Hand Crank
Transducer Mounting
6-3
2000-600-02 Manual Loader
Use the 2000-600-02 Manual Loader to test torque wrenches.
Refer to Figure 6-2 for an exploded view of the Loader and
components.
Figure 6-2: 2000-600-02 Manual Loader, Exploded View
A — Transducer Mounting
A transducer facilitates the low-to-high ranges of the wrench
under test. The transducer must be installed into the loader by
lining up the red mark with the "TORQUE" label on the loader
and securing it using two quick release pins.
IMPORTANT
The connector on single transducer cables contains
the EEPROM calibration memory chip. Never
attempt to remove the connector from the
transducer.
B — Hand Crank
Turn hand crank on the loader to apply torque. 2000 ft lbs of
torque are generated with only 8 ft lbs of manual torque applied.
6-4
2000-600-02 Manual Loader
C — Reaction Block
The reaction block is positioned so that the reaction pins
straddle the wrench handle at the hand hold position specified
on the wrench.
D — Linear Bearings
May be slipped over the reaction pins to reduce friction when
testing very small or high resolution electronic wrenches.
E — Reaction Pins
Hold the reaction block in place.
IMPORTANT
Adjustable stops on the reaction pins may be raised
or lowered to level the wrench prior to loading. Do
not place a second stop above the wrench handle. It
is normal for the wrench handle to rise as it levels
itself under load.
F — Drive Adaptor
A drive adaptor couples the wrench to the transducer. Low
torque MULTITEST series transducers use an internal-internal
drive adaptor and high torque MULTITEST transducers may use
an adaptor/reducer.
G — Transducer (Accessory)
The loader accepts all MULTITEST series single transducers
directly. An optional 2000-400-02 4-in-1 transducer can be
mounted using a 2000-500-02 adaptor kit. For more
information, refer to Appendix A–Accessories.
6-5
2000-600-02 Manual Loader
Loader Rear Panel Controls
The 2 0 0 0 - 6 0 0 - 0 2 M a n u a l Loader r e a r p a n e l i s s h o w n i n Figure
6-3.
Figure 6-3: 2000-600-02 Manual Loader Rear Panel Controls
A — Fuse
The loader power supply is protected with a 1 amp slo-blow
fuse.
B — Voltage Select
A selector switch allows the loader to use both 110VAC or
220VAC.
C — AC Power Input
The loader uses either 110VAC or 220VAC.
D — Solenoid Control
AC power is applied to the loader to operate a pair of safety
solenoids used to protect the transducers from overloading.
Should the applied torque exceed 110% of the transducer
capacity, in either CW or CCW directions, the indicator
energizes the solenoids to lock the hand crank.
The loader connects to the 2000-610-02 Indicator by the 2000117 cable.
6-6
2000-600-02 Manual Loader
Ball Handle Adaptor
Wrenches featuring a ball handle are fixtured using the ball
handle reaction adaptor shown in Figure 6-4. Install the adaptor
onto the reaction slide using both reaction pins. Fix the adaptor
height with the threaded knob.
Figure 6-4: Ball Handle Adaptor
6-7
2000-600-02 Manual Loader
4-in-1 Transducer (Accessory)
The 4-in-1 transducer is mounted to the loader using the
standoff fixture and bracket assembly as shown in Figure 6-5.
Figure 6-5: 4-in-1 Transducer on 2000-600-02 Manual Loader
A — Quick Release Pins
Four quick release pins must be installed. The first two secure
the standoff fixture to the loader and the second two lock the
adaptor to the transducer bracket.
B — Loader Standoff (under bracket)
The standoff and bracket must be installed into the loader by
lining up the holes of the standoff to the holes of the loader.
C & D — Bracket Knobs
Two knobs on the bracket are used to align the selected
transducer over the loader drive. Tighten the left knob (D) first,
then the top knob (C). The wrench or driver to be tested is then
coupled to the selected transducer using an internal-internal
adaptor.
E — 4-in-1 Adapter Bracket
Holds the 4-in-1 transducer horizontal to the loader.
6-8
2000-600-02 Manual Loader
Extension Arm (Accessory)
The 2000-600-02 Manual Loader accepts torque wrenches up to
80" in length. The extension arm is attached as shown in
Figure 6-6. A quick release pin is used at the end of the arm to
capture the reaction pin slide assembly.
Figure 6-6: 2000-600-02 Manual Loader Extension Arm
6-9
2000-600-02 Manual Loader
Types of Loader Testing
Torque Driver Testing
An accessory torque screwdriver testing kit, 2000-750-02, is
available for use in testing or calibrating most torque
screwdrivers and "T" handled drivers. In addition to providing
perfect driver-transducer alignment, it allows the use of the
2000-600-02 loader crank for precision torque application.
Certain torque screwdrivers, "T" handled drivers, electric or
pneumatic nut runners, and non-impact power tools must be
tested by hand. Double check to be sure that the transducer
you choose is capable of handling the maximum torque that you
will apply. Hold the tool exactly in line with the transducer drive
while testing. Off-axis side loading may compromise the test or
calibration of the tool.
Torque Multiplier Testing
The 2000-600-02 Manual Loader and MULTITEST series
transducers can be configured to test certain torque multipliers.
The MULTITEST Indicator also provides measurement, display,
storage and statistical analysis of multiplier output torque to
2,000 ft lbs.
In practice, the multiplier is attached to the loader using custom
fixturing. The operator provides input torque with an
appropriate wrench, breaker bar or the multiplier’s integral hand
crank.
Various mounting fixtures, adaptors, reaction stops and pins are
available for testing the most common torque multipliers. Ask
your CDI sales representative for design assistance.
6-10
2000-600-02 Manual Loader
Force Testing
The 2000-600-02 Manual Loader and MULTITEST series
transducers can be configured to deliver compression and
tension loads. The MULTITEST Indicator also provides
measurement, display, storage and statistical analysis of
FORCE inputs.
A 12" load arm attaches to the transducer drive which
mathematically cancels the length factor from the torque
measurement. For example, a 250 ft lb transducer translates
into 250 lbf (pounds force). The transducer is installed by lining
up its red locator line with the FORCE marker on the loader.
Only single transducers ranging above 400 in lb can be used to
measure force.
A cable attaches to the load arm. The cable pulls against a
tension gauge or closes a compression block mounted at the
right side of the loader.
Cable tensiometers are attached directly onto the cable itself.
The arm pulls against a block fixed at the right side of the
loader.
6-11
2000-600-02 Manual Loader
6-12
Appendix
Accessories
A
This appendix contains information on replacement parts and
accessories that are available from Consolidated Devices,
Inc.,1-800-525-6319.
Refer to Figure A-1, below, for drawer and cutout arrangement
information.
Figure A-1: Roll Cabinet Drawer Arrangement
A-1
Accessories
MULTITEST Torque Calibration System
Components and Inventory Control
Component
Description
Drawer-Cutout
2000-100-02
2000-100-2
2000-100-3
2000-100-4
2000-100-5
2000-100-7
2000-100-8
Roll cabinet
Foam insert
Foam insert
Foam insert
Foam insert
Foam insert
Foam insert
6
7
8
9
3
4
2000-600-02
2000-600-10
2000-560
2000-111-0
2000-173-1
2000-173-2
343-50-02
2000-173-11
2000-173-6
2
QC2I75
2
QJ024
2
QIJR50
2
FA12E
2000-114
2000-118
2000-119
2000-120
2000-195-12
Manual torque loader
Loader
Plexiglass safety shield
Indicator stand
Reaction pin assembly
Reaction pin assembly
Standoff fixture
(2) Linear ball bearing
Reaction ball handle adaptor
Torque wrench
3/4” Open end adaptor
3/8” Interchangeable ratchet head
3/8” x 3/8” Hex driver bit
110VAC Power cord
220VAC Power cord - Europe
220VAC Power cord - Australia
220VAC Power cord - Great Britain
Quick Release (2)
2000-610-02
2000-110-01
2000-114
2000-118
2000-119
2000-120
2000-116
2000-117
Digital torque/force/angle indicator kit
Indicator with printer
110VAC Power cord
3-F
220VAC Power cord - Europe
3-F
220VAC Power cord - Australia
3-F
220VAC Power cord - Great Britain 3-F
Cable, Indicator to transducers
3-B
Cable, Indicator to loader
3-E
1
A-2
8-C
8-C
9-A
8-B
7-D
7-B
7-C
7-C
3-D
8-I
1
The 2000-100-02 roll cabinet is fitted with 1" thick foam inserts for
storage and effective tool control. Storage space is also available
for calibration hangers, torque arms and small weights.
2
Used for calibration plate and internal drive plate installation on the
2000-13-02 and 2000-14-02 transducers. Item is not available from
Consolidated Devices, Inc.
Accessories
Optional Transducers and Accessories
Component
2000-5-02
1/4" ext. drive
342-40
2000-6-02
1/4" ext. drive
342-40
2000-65-02
1/4" ext. drive
342-40
2000-7-02
3/8" ext. drive
342-41-2
2000-8-02
3/8" ext. drive
342-41-2
2000-10-02
1/2" ext. drive
65-26-3
2000-11-02
1/2" ext. drive
65-26-3
2000-12-02
3/4" ext. drive
65-78-2
2000-13-02
1" int. drive
2000-226-2
2000-14-02
1" int. drive
2000-226-2
2000-400-02
343-4-1
342-40
342-41
342-41-2
65-26-3
343-25
2000-500-02
2000-195-13
S/343-500-0
Description
Drawer-Cutout
15-200 in oz transducer
1/4" internal adaptor
9-B
7-E
4-50 in lb transducer
1/4" internal adaptor
9-C
7-E
15-150 in lb transducer
1/4" internal adaptor
9-D
7-E
30-400 in lb transducer
3/8" internal adaptor
9-E
7-E
80-1000 in lb transducer
3/8" internal adaptor
9-F
7-E
10-125 ft lb transducer
1/2" internal adaptor
9-H
7-E
20-250 ft lb transducer
1/2" internal adaptor
9-I
7-E
60-600 ft lb transducer
3/4" internal adaptor
9-J
7-E
100-1000 ft lb transducer
1"-3/4" reducer
9-G or 4-A
7-E
200-2000 ft lb transducer
1"-3/4" reducer
9-K or 4-B
7-E
4-in-1 transducer kit
Multiple transducer
1/4" ext. drive, 4-50 in lb
3/8" ext. drive, 30-400 in lb
3/8" ext. drive, 80-1000 in lb
1/2" ext. drive, 20-250 ft lb
1/4" internal adaptor
1/4"–3/8" internal adaptor
3/8" internal adaptor
1/2" internal adaptor
Right angle mounting bracket
4-in-1 transducer adaptor kit
Quick release pin (2)
Bracket assembly
8-E
7-E
7-E
7-E
7-E
8-E
8-I
8-D
A-3
Accessories
A-4
Component
Description
Drawer-Cutout
2000-550-02
2000-550-108
2000-550-115
2000-195-1
Extension arm kit, for up to 80" wrenches
Arm
Reaction pin slide block assembly 8-F
Retention pin
8-I
2000-50-1
Cable, Indicator to PC
3-C
2000-50-2
Cable, Indicator to serial printer
3-A
2000-900-121
Cable, smart cable replacement
2000-750-02
Torque screwdriver testing kit
2000-260-0
Tensiometer testing kit
2000-261-0
Force (tension) gauge kit
2000-262-0
Force (compression) gauge kit
2000-263-02
Force arm kit
900-0
Joint rate simulator; 50 in lb max,
1/4" internal square drive for use
on 2000-6-02 transducer
900-2-0
Joint rate simulator; 400 in lb max,
for use on 2000-7-02 transducer
900-3-0
Joint rate simulator; 1000 in lb max,
for use on 2000-8-02 transducer
Accessories
Calibration Accessories
Calibration of the 2000-610-02 Indicator and MULTITEST series
transducers is recommended at least every 1 year.
Component
Description
Drawer-Cutout
2000-250-02
2000-250-0
2000-150-01
2000-152-3
2000-221-0
2000-154-8
Calibration stand kit
Stand
Transducer mounting block
3/8" Square drive adaptor
1-1/4" Square drive adaptor
1-1/4" - 3/4" Drive reducer
2000-320-0
200 in oz - 2000 ft lb Weight Kit
For This Kit Calibration Equipment
Hangers
2000-301
2000-304-0
2000-302-0
2000-303-0
1/2 lb Weight hanger
7.5 lb Weight tray
15 lb Weight tray
50 lb Weight tray
Torque Arms
2500-50-0
2000-151-0
2000-152-0
2000-154-0
2.5" Radius wheel
5" Radius wheel
10" Radius butterfly
40" Calibration arm
Weights
2500-310-1
2500-310-2
2000-310-2
2000-310-3
2000-300-2
2000-300-3
2000-300-4
2000-300-5
2000-300-6
2000-300-7
2000-300-8
0.3 oz Hook (1)
0.5 oz Hook (1)
2 oz Bob (1)
4 oz Bob (1)
1/2 lb Disk (1)
1 lb Disk (2)
2 lb Disk (4)
5 lb Disk (6)
10 lb Block (4)
20 lb Block (4)
50 lb Block (4)
2000-321-0
Hangers
2000-301
2000-304-0
2000-302-0
Torque Arms
2000-50-02
2000-151-0
2000-152-0
2000-151-4
7E
7E
7E
7-A
6
6
6
6
6
6
6
7
200 in oz - 250 ft lb Weight Kit
For This Kit Calibration Equipment
1/2 lb Weight hanger
7.5 lb Weight tray
15 lb Weight tray
2.5" Radius wheel
5" Radius wheel
10" Radius butterfly
“S” Hook
A-5
Accessories
Component
Weights
2500-310-1
2500-310-2
2000-310-2
2000-310-3
2000-300-2
2000-300-3
2000-300-4
2000-300-5
2000-300-6
2000-300-7
2000-300-8
2000-322-0
A-6
Description
0.3 oz Hook (1)
0.5 oz Hook (1)
2 oz Bob (1)
4 oz Bob (1)
1/2 lb Disk (1)
1 lb Disk (2)
2 lb Disk (4)
5 lb Disk (6)
10 lb Block (4)
20 lb Block (4)
50 lb Block (4)
Drawer-Cutout
6
6
6
6
6
6
6
7
600 in oz - 2000 ft lb Weight Kit
For This Kit Calibration Equipment
Hangers
2000-302-0
2000-303-0
15 lb Weight tray
50 lb Weight tray
Torque Arms
2000-154-0
40" Calibration arm
Weights
2000-300-3
2000-300-4
2000-300-5
2000-300-6
2000-300-7
2000-300-8
1 lb Disk (1)
2 lb Disk (1)
5 lb Disk (2)
10 lb Block (4)
20 lb Block (5)
50 lb Block (8)
6
6
7
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