Table Of Contents 1. Introduction
Contents
1. 1 Turn ON OFF switch on the controller assembly to ON position 2 Press on DECREASE button of the touchpad overlay on the controller assembly until the set torque value displayed 15 at the lowest setting value stops changing 3 Set the tool in Forward direction and depress the trigger Let the tool stop automatically and make sure that the Pass light illuminates without the fail light Record the value displayed on the transducer s display 4 Set the tool in REVERSE and depress the trigger for a few seconds Repeat previous step After the second reading record the average value of the 2 readings observed on the transducer s display 5 Press on INCREASE button to increase the set torque value and repeat previous step for all torque settings in 100 increments until the maximum torque is reached set torque value does not change 6 Record the averages in a table such as the one depicted below A blank table can be found in Appendix A Make copies of the sheet and use as needed Calibration Values Torque Test Calibration Check Motor Torque Set Transducer Areas to Value Value Value Recalibra te 3 0 0 0 40 960 600 575 40 Good _ 10 12 900 _ 899 70 Good 1300 134 4 1400 19 ____ o 1500 150 4 po 1600 1594 Do amo 173 1 1800 1900 196 NENNEN 200 13 7 Adjust values t2. 60 J 000 90 OH 806 100 806 905 100 906 _____ 109 J 1200 1000 Lo 100 p Lo S 10 p Lo ASO p p Lo 1 1800 0 Lo OO vq Lo A BO _____ 20 po 2300 Eo 2800 200 Lo _______2700 SU M O O 290 S a ____ 18 New World Technologies Inc 30580 Progressive Way E RAD 2000 Abbotsford British Columbia V2T 642 Tel 604 852 0405 Certificate Fax 604 852 0269 Issue 1 Certificate Of Calibration Model E RAD 2000 Customer Serial Number Capacity 2000 Temp 72 deg Voltage 115VAC Humidity 52 Accuracy 3 of Digital Setting Procedure NW T0007 Calibration Date 4 Apr 07 Units FT LB Calibration Due Date 4 Apr 08 Calibration Technician Chris denBraber Torque Calibration Chart Torque Vs Dial Setting 2500 2000 1500 ra 1000 500 0 10 20 30 40 50 60 70 80 90 100 Dial Setting Test Equipment Torque Transducer Model Number ITF 5000 Torque Transducer Serial Number 2858 1 Calibration Due Date 8 Jul 07 Capacity 5000 Units ft lbs Stated Accuracy 5 of Full Scale Calibration Stanadard Number MI 09 04 8041 Appendix Selector Switch Option Selector switch provides the ability to p
3. A orc aes cin OR Figure 12 Connected Screen Click on Download Data Data Logger Software opens Excel sheet and places all the data in a table Data may be manipulated in Excel by the customer according the customer needs Save the file in the desired location as and xls file with a name that is meaningful to you such as jobsite date xls or date time xls or any other combination e From the File menu at the top left corner of the window select Save As e Click on the tab next to the Save as type and select Microsoft Excel Workbook Inthe File field type the name of the file you wish to save e Click on the tab next to the Save in label and choose the location in which the file is saved e Click on Save 10 Data Logger automatically disconnects the communication with the 11 controller assembly and a red background Disconnected message appears Controller Assembly memory is automatically cleared at the end of the download operation On Data Logger main screen click of the X at the top right corner of the screen or choose file at the top left of the screen and select Exit 17 Appendix A Calibration Test Table Calibration Values Calibration Check Motor Torque Transducer Areas to Recalibrate EEE Ye 10 o 10 e __20 e So o 40 60 409 50 70 HT 6 80
4. a torque sensor Using the calibration software ten calibration output settings are selected on the tool Torque 15 applied to the calibration jig using these settings and the resulting torque values as measured by the torque sensor are recorded The ten torque readings are then entered into the calibration software and the calibration data is downloaded to the tool 6 4 Calibration Software This is standard windows based software and is included with every shipped tool 6 4 1 Installation To install E RADCal software 6 4 2 Place the E RADCal software CD in the CD Rom drive If installation does not start automatically select my computer and double click open on the CD ROM drive Select and double click the setup file this will launch the installation program Software is installed in the default folder used by the installation program If prompt to select the users allowed to use this software you may want to use everyone so all users have access to the calibration software Select Next Select Install Select Finish Installation is completed with a placement of a short cut in the Start Menu Uninstalling E RADCal program If for any reason you desire to remove the calibration software follow these steps 6 5 Click on Start Menu Select Control Panel Select Add Remove Programs Find and select E RADCal in the program list and click on the Remove Button to remove the softwa
5. sets up to 8 of torque with angle setting These settings need to be specified by the customer when ordering a tool A second option allows the programming of multiple sets up to 7 of torque with angle setting The 8 available setting is preprogrammed in the factory to angle 0 21 allowing the tool to operate as a standard ERAD tool with no angle This 15 not a standard option and requires the customer to place a request for upgrading to this option when ordering 22 Appendix E Contact Information New World Technologies Inc 30580 Progressive Way Abbotsford B C Canada 2 622 Tel 604 852 0405 Toll Free 1 800 983 0044 Fax 604 852 0269 Email info radtorque com www radtorque com 23
6. 0 to 470 2 1 ratio 1 e to increase actual torque by about 40 Ft Lb reduce calibration value by 20 Controller assembly disconnected from the PC and its power cycled Torque calibration 15 tested again for the values close to the changed range and adjustment is repeated if necessary 14 7 Data Retrieval E RAD torque system stores the record of up to 750 successful bolt torque operations It does not store failed to reach torque since the user re torques any failed attempts The Software CD contains a program to retrieve the stored data Minimum Requirements 1 Windows based with Windows NT Windows 2000 or Windows XP 2 E RAD Calibration software already installed on the same PC 3 CD ROM drive 4 Microsoft Excel installed on the same The software does not require installation but the following setup must be performed 1 Insert E RAD Calibration Software CD in to the CD ROM drive 2 Select my computer and double click open on the CD ROM drive Select E RAD Data Logger In the Edit drop menu top left of the window opened select 3 Navigate to the folder you want to place the software in choosing the same folder in which the calibration software was installed or on the Desktop 15 recommended 4 Connect a Serial communication cable between the PC and the controller assembly 7 1 Data Retrieval Operation Check to which com port you are connected on the PC and that there 1s no other pro
7. 7 Once connected calibration values under the percentage intervals are displayed Screen displays Connected at the top of the screen and the New World Technologies Globe rotates Figure 8 El FRaDCal m Port Connected wew wort C a li b Fa i or Part Com SBOD 8 N 2 Node 2 Open TECHNOLOGIES 30 Torque 1205 Actual Lb Ft 3603 Actual Lb Ft Set Current 75 Press ta connect to the controller Rev 6912 12 35 Figure 8 Main Calibration Screen 8 To enter calibration mode click on the Green Enter Calibrate Mode button Button color changes to Red and displays exit calibration mode Center Top screen displays In Calibration Mode Figure 9 9 To begin calibration click the percentage intervals in a sequential order according to the motor power percentage desired Tab background changes from blue to purple Figure 9 11 ERaDCal 5 BY In Calibrate Mode NEW WORLD 3 Port Com1 3600 8 N 2 Node 2 Open TECHNOLOGIES Torque 1205 Actual Lb Ft Torque i o 1982 Actual Lb Ft Set Current 30 Rev 912 12 3 Figure 9 Start Calibration Screen Attention Under Current Motor Load Setting 3 5 7 are used in special applications These values must read 0 in the calibration page and saved as 0 to the E RAD 10 Select 10 motor load to limit motor power output to 10 and so on 11 Make sure dire
8. ERAD as described in the above mentioned paragraphs Torque Angle Activation 1 Tool needs to be in standard ERAD operation mode 2 Simultaneously press on INCREASE and DECREASE buttons on the 3 Button Touch Pad Overlay 3 Verify on the LCD display that the torque changed to the proper pre torque setting and ANGLE is displayed with the proper desired angle setting Operation Pressing on the On Off trigger on the tool will start to torque the bolt Releasing the trigger any time prior to reaching the set pre torque will illuminate the fail light Once pre torque 15 reached the fail light and pass light illuminate on the tool Pass light to indicate pre torque 1s reached and fail to indicate cycle 1n incomplete angle not reached Once pre torque setting 1s reached the tool pauses for a brief moment before continuing to the angle cycle IMPORTANT NOTE The tool cannot be stopped once it enters the angle cycle Tool will complete the full angle setting before stopping to achieve the best accurate result in reaching the angle Torque Angle Deactivation 4 Tool needs to be in Torque Angle operation mode 5 Simultaneously press on INCREASE and DECREASE buttons on the 3 Button Touch Pad Overlay 6 Verify on the LCD display that the torque changed to the proper torque setting and ANGLE 15 not displayed Additional Options Addition of a selector switch in a torque angle tool only allows the programming of multiple
9. Table Of Contents Me IBI a O 1 SPEEA O A 2 3 System Component Description 3 Jk Controller ASSembly EA ties 4 32 4 Sos P WEDGNOC ontroL aADIES 5 oue s enabeomrmiunmcaton C ADC ae OTO Oy 5 BO oun Circ PD re eee 5 20 5 Calibration Cerica eaea a WZ 5 ho a a s EINN 6 5 Operation 7 6 Calibration Procedure 9 6 1 Calibration er aee A dzo 9 62 opi O da 9 05 ACAKDEANODOVENYE Jada 9 65 Caulbraton SOW ale coded entm ddd 10 6 4 1 DVS Fal W koko 10 6 4 2 Uninstalling E RADCal program sees 10 63 Calibration Software Operation aree rore tet etiara adit e pee tu aoo pa AL 10 6 5 oos oed ettet aat bebo as tutte A 13 Calibration Adjustinent EXarmple 2 02 os eU M seats 14 T UIDES 15 Jab ao i nei 15 Appendix A Calibration Test 18 Appendix B Sample Calibration Certificate 19 Appendix Selector Sw
10. ction switch on the tool is in Forward position REVERSE does not appear on the controller assembly display and depress the trigger on the tool to torque Do not let the trigger go until the tool stops automatically 12 If the tool is stopped and the green Pass light on the tool 15 not illuminated or the Fail red light is illuminated place the direction switch in REVERSE and depress the trigger for a coupe of seconds Repeat step 12 13 Record the reading on the transducer s display take a couple more readings to make sure that the readings are in the same value range and take the average of the values 14 the Calibration Torque table place the cursor in the text box to the right of the label value of 10 and type the average value calculated in the previous step Press Enter Attention Enter must be pressed after every entry otherwise the value will not be recorded 15 Repeat steps 11 to 15 for the other settings of 20 100 load 16 Click on Save Settings A busy message appears above the buttons This means that the controller communicated the calibration values to the computer and the values are saved 17 Turn ON OFF switch on the controller assembly to OFF position 18 Disconnect Serial Cable from the controller assembly 12 6 6 Calibration Testing After calibrating the tool it is recommended to perform a calibration test to verify the tool s accuracy and validity of the calibration values
11. e reaction arm has a proper and safe point of reaction o Depress the ON OFF trigger and keep it pressed until the hand held tool stop rotating and the Pass light illuminates The hand held tool operates until the torque reaches the preset value Pass indicator Illuminated and then stops automatically If the Trigger is released before the set torque is reached or the tool fails to reach the required torque the Failed indicator light is illuminated o To clear an error or a failed indicator illumination set the direction switch to REVERSE bottom line of LCD displays REVERSE Any error or failed indicator illumination is cleared Holding the Trigger depressed causes the tool to operate in the reverse direction as long as the Trigger 15 depressed o If the tool is unable to reach the correct torque switch the Direction switch to reverse and back the bolt off for a couple of seconds then repeat the torque operation IMPORTANT NOTE If the tool 15 running for more than 20 seconds and the correct torque 15 not reached the tool stops and the Red Failed indicator illuminates on the handgrip o Once the set torque is reached and the green Pass light is illuminated the tool reverses direction for a short pulse motion to release the chuck from the bolt Upon completion of the bolting job or at the end of the day power down the controller assembly by turning the ON OFF switch to OFF It is not necessary to disconnect the cables fr
12. gram running that may use the serial port for communication 1 Turn the ON OFF switch on the controller assembly to ON position 2 Ifrunning the program for the first time the following port setup screen may appear Figure 10 COMM PORT SETUP Comm Fort Baud Aate Com 1 Com 2 Com 3 Com 4 Com 5 2400 4800 3600 19200 38400 57600 Hode 1 Mode 2 Node 3 SAVE SETTINGS CANCEL Figure 10 Comm Port Setup 15 3 Select the Com port you are connected to and set Baud Rate to 9600 and Drive Node to Node 2 as depicted above Click on SAVE SETINGS 4 Main Screen appears Figure 11 m Data Collection Wizard JEJEJ File Setup m RLD RAD TESHNOLOGIES ER 2000 www Operator ID mmi Job Number IEEE Job Location Completion Date m4 Completion Time IEEE Download Date 2570972006 Download Time 04 38AM 0 Figure 11 Data Retrieval Main Screen Fill in the following information IMPORTANT NOTE Download Date and Download Time are automatically retrieved from the computer Make sure that the time set on your PC is correct Operator ID Job Number Job Location Completion Date Completion Time 5 Click on Setup in the drop menu at the top of the page and select Connect Red background Disconnected message changes to green background Connected message Figure 12 16 A miar E RAD MODEL ER 2000
13. hat are not in the accepted tolerance goal 15 3 as follows IMPORTANT NOTE If calibration values are increased actual torque applied decreases If calibration values are decreased actual torque applied increases 6 7 a Adjust the calibration value closest to the actual torque value you want to change Proceed to the next value to be changed if you require adjustment on a subsequent calibration value even if the next value is farther than the one previously changed b In general the farther away from the calibration value the change is made the less it will affect the actual torque value being changed c A general rule for adjusting the calibration value is a ratio of 2 1 between calibration value and applied torque For example to make a change of 20 ft lb to the actual applied torque reduce the calibration value by 10 Calibration Adjustment Example The table in section 6 8 shows the value of 20 motor power to be outside the accepted tolerance of 3 Actual torque reading is 360 Ft Lb whereas the value on the controller assembly is set to 400 Ft Lb error of 10 To correct the calibration value the following procedure 15 executed Controller assembly is turned off Controller assembly connected to a PC with calibration software installed and running Connect is selected and calibration software actively connected to the controller Calibration value adjacent to the 20 label is changed from 49
14. itch Option 20 Appendix D Torque Angle Option 21 Appendix E Contact Information 23 IMPORTANT DO NOT OPERATE THE TOOL BEFORE READING THIS USER MANUAL IF BREAKDOWN MALFUNCTION OR DAMAGE OCCURS DO NOT ATTEMPT TO REPAIR CONTACT NEW WORLD TECHNOLOGIES INC OR YOUR LOCAL DISTRIBUTOR IMMEDIATELY IMPORTANT WHEN USING A POWER PLUG ADAPTER MAKE SURE THE EARTH GROUND PIN IS PRESENT AND CONNECTED IN THE ADAPTER NEW WORLD TECHNOLOGIES INC DOES NOT RECOMMEND REAPLCING THE SUPPLIED POWER CORD IN THE EVENT THE POWER CORD IS REPLACED MAKE SURE THE NEW POWER CORD HAS AN EARTH GROUND PIN 1 Introduction The E RAD electric torque wrench tool 15 a highly accurate and repeatable bolt torque system The E RAD is self contained portable and operates with the use of a standard 115V or 220V AC power source Its rugged splash proof design makes it fully capable of operating in harsh industrial environments E RAD 1s also offered in an upright heavy duty steel case Torque value is set via two buttons on the touch pad mounted on the main unit Torque is applied when the trigger on the hand tool 15 pressed Both torque set and achieved torque are displayed on the LCD display in a variety of user selectable units The E RAD Torque Wrench 1s available in several torque ranges from 700 950 lb ft Nm to 3000 4050 Ib ft Nm Custom t
15. leted and passed the System Ready light on the hand held tool is illuminated The display will flash model and firmware revision for 2 seconds then displays on the top row last used torque setting and on the bottom row the actual torque reading Readings are in the recently used units of measurement e To increase torque setting press on the INCREASE arrow If maximum value of torque setting 15 reached the displayed value does not change If the buttons are pressed briefly the torque changes by a single count If the buttons are held down for 3 seconds the torque will start to change in single counts then in increments of 10 counts and finally in increments 100 counts e To decrease torque setting press on the DECREASE arrow If minimum value of torque setting is reached the displayed value does not change If the buttons are pressed briefly the torque changes by a single count If the buttons are held down for 3 seconds the torque will start to change in single counts then in increments of 10 counts and finally in increments 100 counts To change units of measurements press on UNITS The units will cycle between Ft Lb Nm and Kg F Set the torque to the setting required for your application To perform a torque operation Make sure the torque setting is correct Couple the hand held tool to the bolt Make sure the direction switch 15 set to forward verify display does not show REVERSE on the bottom row Make sur
16. nterface e Hand Held Tool Power and Control Connectors 3 military style connector provide interface between the Controller Assembly and the Hand Held Tool 120 Tts 60 HZ Comm Port EL New We rhnologies Inc e Figure 3 Controller Assembly Connections User Interface Figure 4 1s provided by e 3 Button Touch Pad Overlay 1 provides the user the ability to increase decrease and change the units of measurement of the torque setting CD Display 2 visual feedback of the torque setting torque achieved and direction of rotation e On Off main power switch 3 connects disconnects main power 115V AC or 220V AC depending on the unit Green Light Lens 4 lights on when power is connected and turned on Figure 4 User Interface 3 2 Hand Held Tool The tool provides 2 user control switches and 3 visual status feedback Figure 5 e On Off Trigger switch 1 hand tool activation Forward Reverse switch 2 controls direction of rotation FORWARD REVERSE CW CCW System Ready light 3 Green light when the tool 15 ready for use Fail light 4 Red light when the tool fails e Pass light 5 Green light when the tool completes torque operation a L Figure 5 Hand Held Tool 3 3 Power and Control Cables Both power and control cables are hard wired in the factory to the hand tool Each cable 1s secured with a spring strain relief to pr
17. om the controller assembly Download the torque records to a Personal Computer windows based if desired recommended at the end of a job See section 8 6 Calibration Procedure E RAD systems leaving New World Technologies Inc are calibrated in the Lab prior to shipping A Calibration Certificate see appendix B is issued for each tool and shipped with each tool 6 1 Calibration Equipment Basic requirements e Personal Computer with CD ROM and a serial port or a USB port with a USB SERIAL adapter e Windows NT Windows 2000 or Windows XP Torque measuring equipment display transducer ETC 6 2 Calibration Period New World Technologies Inc recommends that the system be calibrated once a year according to the date specified on the Calibration Certificate The calibration period complies with industry standards for precision measuring devices Customers may wish to perform calibration in their facility at different intervals within the period listed above for various reasons e Tool was exposed to extreme temperatures e Rough handling or significant shock to the system e Tool seems to be exceeding the accepted torque error or tolerance margin 6 3 Calibration overview To perform E RAD calibration the controller assembly must be connected to a PC via a serial cable The PC must have the E RADCal calibration software installed prior to calibration The hand held tool must be coupled to a suitable test jig fitted with
18. on the cables or drag the Controller Assembly by pulling on the cables Failure to comply may result in damage to equipment e Align control cable notch to the notch in the controller Assembly Push the connector in forward and turn clock wise at least 14 turn until the plug locks into the connector on the case e Align power cable notch to the notch in the controller Assembly Push the connector in forward and turn clock wise at least 74 turn until the plug locks into the connector on the case Connect main AC power plug to an appropriate AC power source 115V AC or 220V AC according to the model e Make sure serial communication cable is disconnected 5 Operation Instructions This section details the operation of the E RAD system A Caution Make sure that all connectors are secured prior to turning the power switch ON Failure to comply may result in equipment failure and or equipment damage When the tool is in operation the Reaction Arm rotates in the opposite direction to the Output Square Drive and must be allowed to rest securely against a solid object or surface adjacent to the bolt to be tightened Figure 6 Warning Keep hands clear of the reaction arm when the tool is in use Failure to comply may result in serious injury Ek os Figure 6 Reaction Arm e Turn main power switch to ON position Green ON light on the controller Assembly is illuminated e Once internal self test is comp
19. orque ranges are available upon request You may order your E RAD Digital Torque Control Consoles in two different configurations Figure 1 E RAD System 2 Specifications Torque Range Units Supported Power Source Stated Accuracy Cables Length Control Assembly 300 700 Ib ft 300 1200 Ib ft 500 2000 Ib ft 500 3000 Ib ft Or Or Or Or 400 950 Nm 400 1600 Nm 675 2700 Nm 675 4050 Nm Custom torque ranges are available up upon request Lb Ft Nm Kg F 115V 10A or 220V 3 15 ft 4m 18 ft 6m or custom length Yellow hard plastic or steel case 3 System Component Description E RAD System Figure 2 includes the following Controller Assembly yellow hard plastic or steel case Hand Held Torque Tool Power and Control Cables attached to hand held tool Reaction Arm Serial Communication Cable Calibration and Data Retrieval software CD Calibration Certificate User Manual 4 3 m D f x f I 1 2 D 3 1 Controller Assembly The Controller Assembly contains a motor power source and motor drive controller for the hand held tool Four connectors on the side of the unit Figure 3 provide interface to the Controller Assembly e Main Power Connector 1 115V AC or 220V AC depending on the unit main power input e Serial Communication Connector 2 standard PC serial communication i
20. ovide durability and flexibility The length of the cables is normally 15 18 in length but can be custom ordered to any length specified by the customer Cables are terminated with turn lock military style metal connectors and provide secure and solid connection to the Controller Assembly 3 4 Serial Communication Cable This cable enables serial communication interface between the Controller Assembly via standard RS232 3 5 Software CD E RAD software CD contains 2 custom made windows based programs for the RAD system E RAD Calibration software enables Lab Field calibration of the hand held tool e E RAD Data Retrieval Software enables the retrieval of up to 750 successful torque operations 3 6 Calibration Certificate Each unit is calibrated with compliance to ISO 10012 using equipment that is calibrated according to known industry accepted standards traceable via NIST standards See appendix A for a Calibration Certificate Sample 4 System Setup A Caution Before plugging in main power cord or Hand Held Tool cables make sure main power switch 15 in the OFF position Failure to comply may result in equipment failure or equipment damage Before powering up the unit perform the following steps Ah Caution Do not force the connectors onto the Controller Assembly Failure to comply may result in damage to the connectors Caution Never lift the tool by the cables Do not pull excessively
21. re from your computer Calibration Software Operation Before launching the calibration software make sure the calibration system is set up as follows Serial Cable is connected between the computer and the controller assembly Use the supplied USB to Serial adapter provided with the tool if you are using a computer that has only USB ports and no Serial port Control assembly in connected to main power source Hand held tool is coupled to the calibration fixture with a transducer in place Turn ON OFF switch on the controller assembly to ON position Wait until the System ready green light is illuminated on the tool On the Computer 1 2 3 Click on Start Menu Select all programs Find and select RAD then select Rad Calibration 10 4 Click the PORT tab top left corner of the screen Communication screen appears and display available ports 5 Select the serial port COM port you are connected to chose 9600 baud rate and node 2 as in figure 7 Communications Setup SAUE 19200 5 600 Select the Baud and Made or select Search MOTE Ports that are missing the above list may allocated to another application System reset may required to free them Search Okay Cancel Figure 7 Communication Port Setup 6 Select Okay Screen displays that Mint found at these settings If no mint drive found message appears then the settings selected are incorrect
22. rogram up to 8 torque settings 1 per switch position These settings are usually the most common settings used and allow a fast switch between torque settings instead of dialing up down the torque each time a different torque is required This option includes a lockout key switch which enables disables torque changes via the keypad and switch position programming Programming a switch position 1 2 Turn the key to the right in this position key removal in not allowed 3 4 1f more position are required to be programmed turn the switch know to the next 5 6 Place the switch knob to the position to be programmed Press increase or decrease to reach the torque setting required position and repeat step 3 After the last position programming turn the key left and remove the key Positions are now programmed and ready to use Note when the key 15 removed the keypad 15 disabled pressing on any of the buttons will have no effect 20 Appendix D Torque Angle Option Basic ERAD torque angle option allows for one set of torque and angle values The values initial torque and estimated final torque after the completion of the angle motion for the torque angle option must be specified by the customer when placing an order for an angle tool Customer should include the following information as well Bolt TPI joint configuration and joint stiffness 1f possible When the angle option 1s not activated the tool acts as a standard
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