Ingersoll Rand 4575759 - Manuals

Page 3 - User Manual

SENSOR I ® Expert User Manual 04575759 Form 7266 Version 005, 08/04

Page 7 - Application Guidelines for Accurate Use of the Expert Wrench

Sensor I ® Expert User Manual Application Guidelines for Accurate Use of the Expert Wrench To all Expert wrench users February 15, 1999 What distinguishes the Expert wrench from dial wrenches or other digitaltorque wrenches is one very significant feature: angle. The anglemeasurement allows users to...

Page 13 - TABLE OF CONTENTS

Page 15 - Sensor I® Expert User Manual

i Sensor I® Expert User Manual TABLE OF CONTENTS CHAPTER 1: INTRODUCTION ........................................................... 1CHAPTER 2: TOOL DESCRIPTION ..................................................... 3 Functions of Components CHAPTER 3: WRENCH OPERATION INSTRUCTIONS ....................

Page 17 - CHAPTER 1; Introduction

Sensor I ® Expert User Manual CHAPTER 1 Introduction

Page 19 - INTRODUCTION; The SENSOR 1

1 Sensor I ® Expert User Manual INTRODUCTION The SENSOR 1 ® EXPERT WRENCH is a hand-operated portable tightening system with a battery-powered microprocessor control system. In additionto standard torque and angle control tightening capabilities, it provides aYield Control mode of tightening and Dyn...

Page 21 - CHAPTER 2; Tool Description

Sensor I ® Expert User Manual CHAPTER 2 Tool Description

Page 23 - TOOL DESCRIPTION

3 Sensor I ® Expert User Manual TOOL DESCRIPTION Technical Data 40 125 250 400 Length: 13.5” (343 mm) 26” (665 mm) 42.5” (1080 mm) 48.5” (1232 mm) Square Drive: 3/8” (9.5 mm) 1/2” (12.5 mm) 3/4” (19mm) 3/4” (19 mm) Weight:Tool 2.4 lb (1.1 Kg) 5 lb (2.3 Kg) 12 lb (5.5 Kg) 13.8 lb (6.3 Kg) Control Uni...

Page 25 - Wrench Housing; indexed position and angle accuracies

5 Sensor I ® Expert User Manual Functions of Components Expert 125, 250 and 400 Models Wrench Housing Incorporates all the electronics and digital display. Wrench Handle Houses the charger/data port connector for battery charging and serial port communications. Wrench Head Contains the angle referen...

Page 26 - Handheld Tool

6 Sensor I ® Expert User Manual Functions of Components Expert 40 Handheld Tool Consists of the ratchet head, reset switch, cable and the angle measurement device. The head cannot be indexed relative to the handle. The plug at the end of the tool cable connects to the receptacle on the lower portion...

Page 27 - Control System Status Lights; These lights are used to signal operating status:

7 Sensor I ® Expert User Manual 1. Control System Status Lights These lights are used to signal operating status: RUN The control system is ready to begin a cycle. SNUG The torque applied to the fastener has reached the snug torque setting. OK The fastener has been tightened correctly in the selecte...

Page 28 - Mode Selector Switch; button is held in, the top; Parameter Adjustment Knob; When the; Reset; button is held in, this knob adjusts the value of the

8 Sensor I ® Expert User Manual 2. Mode Selector Switch Selects the particular tightening mode: Torque Control, Dynamic Audit,Yield Control and Angle Control. This switch also allows you to selectthe Setup mode to adjust communications parameters, setup andrestore custom modes, and perform diagnosti...

Page 29 - Provides a digital readout of parameters selected:

9 Sensor I ® Expert User Manual 5. Digital Display Provides a digital readout of parameters selected: A) These segments show the item being displayed on the main display: Pk is peak torque An is angle Ld not used Tq is dynamic torque B) These segments indicate limits: LT is low torque limit HT is hi...

Page 31 - button and then press the membrane key.

11 Sensor I ® Expert User Manual 6. Membrane Keys Each membrane key has two functions. To access the lower function,simply press the key. The upper function can be accessed by holdingin the Reset button and then press the membrane key. xCp When this key is pressed (with the Reset button held in), th...

Page 35 - CHAPTER 3; Operation

Sensor I ® Expert User Manual CHAPTER 3 Operation Instructions

Page 37 - WRENCH OPERATION INSTRUCTIONS; technician. For a list of authorized; Ensure the Power Switch is in the ON position and press the; Primary Operation Modes; Display

15 Sensor I ® Expert User Manual WRENCH OPERATION INSTRUCTIONS General Information NOTE Exceeding maximum torque rating may cause damage to wrench or lossof calibration. The wrench should only be used for its intended purpose, i.e., fortightening, loosening and auditing procedures. It should be oper...

Page 39 - the; button to choose between Metric or English units.; Torque Control Tightening Procedure; Press and release the; button to power up the wrench. If the; Units; key to select the desired Torque units. See graphic below.

17 Sensor I ® Expert User Manual 6. Release the Reset button. The units choice is now saved. 7. Move the Mode Selection switch to one of the tightening modes and use the Units button to choose between Metric or English units. Torque Control Tightening Procedure 1. Press and release the Reset button ...

Page 44 - button. If the FAULT; until; Commence tightening with moderate speed

22 Sensor I ® Expert User Manual NOTE When using EVS-models, avoid ratcheting when the torque is in thevicinity of the snug torque and between snug and the yield point. 8. Release the Reset button. If the FAULT light is lit, then press and hold the Reset button again while holding the wrench steady....

Page 45 - button to power; button held in, use the

23 Sensor I ® Expert User Manual Angle Control 1. Press and release the Reset button to power up the wrench. 2. Move the Mode Selection switch to Angle Control. 3. Attach the angle reference arm (EA-models) to the wrench, and place the magnet on a magnetic surface. 4. Press and hold in the Reset but...

Page 47 - CYCLE COUNTER; button is pressed after a tightening. A tightening cycle is; Resetting the Cycle Counter; The cycle counter can be reset by either; button and pressing the; Clear; key

25 Sensor I ® Expert User Manual CYCLE COUNTER The cycle counter is displayed in the upper right-hand corner of the digitaldisplay (see Functions of Components). The counter indicates the number ofcompleted tightenings stored in memory. The cycle counter will incrementonce the Reset button is presse...

Page 48 - QUALITY CONTROL LIMITS AND STATISTICS; Setup and Viewing Quality Control Limits

26 Sensor I ® Expert User Manual QUALITY CONTROL LIMITS AND STATISTICS Setup and Viewing Quality Control Limits 1. Press and release the Reset button on the side of the wrench. 2. Move the Mode Selection switch to the tightening mode required. 3. Press the Window key. You will see "--.-" on ...

Page 49 - Deleting Quality Control Limits

27 Sensor I ® Expert User Manual Deleting Quality Control Limits 1. Press and release the Reset button to power the wrench. 2. Move the Mode Selection switch to the tightening mode required. 3. Press the Window key. You will see "--.-" on the display along with "LT" flashing in the t...

Page 50 - Exceptions for angle low and high limits:; While in Angle Control:; • To delete high and low angle settings, HA and LA must be adjusted to; Use of Quality Control Limits; button is pressed any limits that have been set will be

28 Sensor I ® Expert User Manual Exceptions for angle low and high limits: NOTE While in Angle Control: • To delete high and low angle settings, HA and LA must be adjusted to the target angle. • To delete high and low torque settings, HT and LT must be adjusted to the snug torque. Use of Quality Con...

Page 51 - Statistics; The statistics can be viewed as follows:; button, press the x key. The display will show

29 Sensor I ® Expert User Manual Statistics The following statistical information is available for each custom andprimary tightening mode: NOTE Cp and CpK are not available for angle in Dynamic Torque Audit mode asthe control limits for low angle (LA) and high angle (HA) are not used. The statistica...

Page 52 - CUSTOM TIGHTENING MODES; Setup and Storage of Custom Tightening Modes

30 Sensor I ® Expert User Manual 4. To read the standard deviation, σ , and process capability, CpK, repeat the above procedure, but press the σ key in place of the x key. The stan- dard deviation and CpK will be displayed for torque (Pk), and angle (An). CUSTOM TIGHTENING MODES The Sensor I ® Exper...

Page 53 - Retrieving Custom Tightening Modes; Identifying Custom Tightening Modes

31 Sensor I ® Expert User Manual Retrieving Custom Tightening Modes 1. Move the Mode Selection switch to the Setup position. 2. Hold in the Reset button until mode appears in the upper right-hand corner of the digital display. 3. With the Reset button still held in, use the Parameter Adjustment Knob...

Page 54 - Clearing Custom Tightening Modes

32 Sensor I ® Expert User Manual The first number indicated the snug torque value (50% of the expectedtorque), the last number is the capture angle in degrees. If only one number is displayed on the screen and the "Pk" segment is lit,the Custom Mode is a Yield Control strategy. The number di...

Page 55 - DATA STORAGE AND RETRIEVAL; Setup of Wrench for Data Upload; Setup parameters in a computer terminal program.; button to turn on the wrench.; button held in, use the Parameter Adjustment Knob to

33 Sensor I ® Expert User Manual DATA STORAGE AND RETRIEVAL The charger/data port (item 8 in Chapter 2: Tool Description) has anintegral RS232 serial port. This an be connected to a PC, and with theInterLink software or a terminal program, the data can be uploaded to thecomputer. Examples of all out...

Page 56 - Data Out During Tightening

34 Sensor I ® Expert User Manual 7. Press in the Reset button and adjust the baud rate to the desired value (valid baud rates are 19200, 9600, 4800, 2400, 1200 & 600). NOTE The last two numerals are not shown on the wrench display. 8. Move the Mode Selection switch to Setup. 9. Press in the Rese...

Page 57 - Data Out at End of Tightening

35 Sensor I ® Expert User Manual 6. While holding the Reset button, press the Units key to select the option. The display will show "ON". To deselect this option press the Joint key deselects it. 7. Rotate the Mode Select switch back to the Setup position. The display should now show "--...

Page 58 - Parameter Dump

36 Sensor I ® Expert User Manual 8. Holding in the Reset button, adjust the Custom Setup Mode number below 20. 9. Release the Reset button and move the Mode Selection switch to the desired tightening mode. Parameter Dump Once initiated the parameter dump function will dump out settings for aparticul...

Page 59 - End of Tightening Data Dump

37 Sensor I ® Expert User Manual 6. With the Reset button held in, use the Parameter Adjustment Knob to select the desired tightening mode. Select from: 7. Release the Reset button once the tightening mode has been selected. 8. Press the Display button and the tightening parameters will be transmit-...

Page 60 - Tightening Curve Storage

38 Sensor I ® Expert User Manual 5. Move the mode selection switch to Torque Control. 6. With the Reset button held in, use the Parameter Adjustment Knob to select the tightening mode for which the end of tightening data is to be transmitted over the serial interface. Select from: 7. Release the Res...

Page 61 - Tightening Curve Data Dump

39 Sensor I ® Expert User Manual 1. Complete a tightening. 2. Hold in the Reset button. 3. With the Reset button held in press the Store key. 4. Starting at zero, the screen will then indicate the storage position where the curve will be stored. 5. Release the Reset button. Tightening Curve Data Dum...

Page 62 - Rotate the Mode Select switch back to the Setup position.; button, adjust the Custom Setup Mode number; TORQUE MULTIPLIER FUNCTION; The Sensor I; Setup of a Torque Multiplier; Window

40 Sensor I ® Expert User Manual samples have been sent, the display reverts to showing the selected curve number. 9. Rotate the Mode Select switch back to the Setup position. 10. Holding in the Reset button, adjust the Custom Setup Mode number below 20. TORQUE MULTIPLIER FUNCTION The Sensor I ® Exp...

Page 64 - button and rotate the Mode switch to the tightening; Use of a Torque Multiplier; Joint; LEFT HAND FASTENERS

42 Sensor I ® Expert User Manual 8. Release the Reset button and rotate the Mode switch to the tightening mode position for which the multiplier was enabled. The multiplier is now enabled for that primary tightening mode. NOTE It is only possible to have one programmable multiplier value inoperation...

Page 69 - CHAPTER 4; Battery Charging

Sensor I ® Expert User Manual CHAPTER 4 Battery Charging

Page 71 - BATTERY CHARGING; Remove the protective cap from the wrench handle (models 125, 250

51 Sensor I ® Expert User Manual BATTERY CHARGING The battery must be recharged as soon as "LO BAT" appears on the display.The charger connects to the charger/data port (item 8 in Chapter 2: ToolDescription). 1. Remove the protective cap from the wrench handle (models 125, 250 and 400 only)....

Page 73 - CHAPTER 5; Diagnostics

Sensor I ® Expert User Manual CHAPTER 5 Diagnostics & Troubleshooting

Page 75 - DIAGNOSTICS AND TROUBLESHOOTING; service center shown in Appendix D.; Torque Channel A/D Display; The value displayed should be in the range 25-29 when no torque is; Angle Reference Arm Test Mode

49 Sensor I ® Expert User Manual DIAGNOSTICS AND TROUBLESHOOTING Introduction This chapter provides troubleshooting information using the built-indiagnostic test modes. Tests can be performed by selecting Custom SetupMode numbers between 200 and 212. When diagnostics are complete, rotatethe Mode Sel...

Page 76 - Service Center for adjustment.

50 Sensor I ® Expert User Manual at the low end is correct-the high end should follow. Model 40 should bereturned to an authorized Ingersoll-Rand Service Center for adjustment. Battery Level Test Mode (Custom Mode #204) The display value will be between 100 (fully charged) and zero (depleted). EZ An...

Page 79 - CHAPTER 6; Calibration

Sensor I ® Expert User Manual CHAPTER 6 Calibration

Page 81 - CALIBRATION; General Information; button and rotate the Parameter Adjustment

53 Sensor I ® Expert User Manual CALIBRATION General Information This section describes the calibration method for the torque/angle sensors.Calibration is accomplished by performing tightenings with the wrench andreferencing external measuring equipment to compare the results. TheParameter Adjustmen...

Page 84 - EZ Angle Calibration

56 Sensor I ® Expert User Manual Cal Mode and press Display to cancel. Number will cycle. To save Cal scale factor, select Setup, hold in Reset and adjust the Mode below 20. 21. Go to Setup Mode #103 and turn the Mode Select switch to Torque Con- trol. Press Reset and the Units key simultaneously to...

Page 87 - Appendix A; Sample of

Sensor I ® Expert User Manual Appendix A Sample of Data Reports

Page 89 - Sample Reports

62 Sensor I ® Expert User Manual Appendix A These reports are accessed by the methods noted in "Data Storage andRetrieval". The information provided by the optional InterLink software willhave a different format. Sample Reports Parameter Dump Tightening Configuration No : Torque Control Mode...

Page 91 - TORQUE; Cpk; EXTERNAL

64 Sensor I ® Expert User Manual End of Tightening Data Dump (cont.) TORQUE Mean : 0020.6 Sigma : 000.34 Cp : 004.60 Cpk : 004.02 ANGLE Mean : 0031.9 Sigma : 001.87 Cp : 001.84 Cpk : 001.50 EXTERNAL Mean : 0000.1 Sigma : 000000 Cp : N/A Cpk : N/A

Page 95 - Appendix B; List of

Sensor I ® Expert User Manual Appendix B List of Setup Modes

Page 97 - Custom Modes; Custom Mode

67 Sensor I ® Expert User Manual Appendix B Custom Modes Custom Modes 1 through 20 are the Custom Tightening modes. They arememory locations used to store tightening strategies for later recall. Custom Modes 100 through 120 are the Custom Setup Modes and are usedfor both advanced option selection pe...

Page 99 - Appendix C; Spare Parts List

Sensor I ® Expert User Manual Appendix C Spare Parts List

Page 101 - Spare Parts Listing - MODEL 40

69 Sensor I ® Expert User Manual Appendix C Spare Parts Listing - MODEL 40 Description Part # CPN *Wrench Assembly, EZ angle EZS40A-HHT 89934541 *Wrench Assembly, Auditor EA40A-HHT 89930952 Ratchet Head Replacement Kit E40HDKIT 89935159 Ratchet Head Assembly (EA-) EA40A-HD 89930978 Ratchet Head Asse...

Page 111 - Appendix D; Service Centers

Sensor I ® Expert User Manual Appendix D Service Centers

Page 113 - USA

77 Sensor I ® Expert User Manual Appendix D Service Centers USA Ingersoll-Rand CompanyAutomation and Integration Center1872 Enterprise Dr.Rochester Hills, MI 48309 Tel: +1 (248) 293-5700Fax: +1 (248) 293-5800 EUROPE Ingersoll-Rand CompanyFastener Tightening System DivisionSwan Lane, Hindley Green, N...

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