Benutzeranleitung / Produktwartung 4575759 des Produzenten Ingersoll-Rand
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Sensor I® Expert Electr onic W r enches USER MANU AL.
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SENSOR I ® Expert User Manual 04575759 F orm 7266 V ersion 005, 08/04.
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Sensor I ® Expert User Manual NOTE The wrench should only be used f or its intended purpose , i.e ., for tightening, loosening and auditing purposes. It should be oper ated using a smooth steady pull at mode rate speed on the wr ench handle with both feet f irmly placed on fl oor .
Sensor I ® Expert User Manual NOTE If the wrench f ails to operate using the r ecommended procedur es described in this manual, the cause o f malfunctio n should be corr ected by an author ized Inger soll-Rand tec hnician. For a list o f authorized Ingersoll-Rand technician.
Sensor I ® Expert User Manual Applicati on Gui delin es for A ccurate U se of th e Expert Wren ch T o all Expert wrench users February 15, 1999 What d istingu ishes th e Expert wr ench fr om di al wren ches or oth er di g ital torque wr ench es is one very si gnif ican t feature: an gle .
Sensor I ® Expert User Manual Dynamic Audit: The Dyn am ic A ud it featur e o f the Expert wr ench au di ts resi du al tor que curren tly on the f astener after r ela xation an d oth er effects have taken place . On a very har d joint that is au di ted soon after tigh tenin g, this will consisten tly equ ate to installati on to r que .
Sensor I ® Expert User Manual 1. Set the sn ug tor que to appro xim at ely 50% of th e e xpected fin al torque read in g. 2. Set the captur e angle (see chart). 3. The oper ator m ust then pull th e wren ch appro xim ately 30° over a per iod of no mo re t h an 2 s e c o nds.
Sensor I ® Expert User Manual T o Tighten to a T o rque Set the tor que value to your targ et to r que , and set hi gh and low tor que and angle li mi ts if d esire d. Sn ug is set automati cally to a def ault value . This is the poin t from whi ch the an gle is activated.
Sensor I ® Expert User Manual seconds f or mod el 40, <5° per second f or mor e than 5 secon ds for all oth er mod els), th e wren ch will sign al an er ror by soun din g sever al short beeps . NOTE When using EVS-models, av oid ratch eting when the tor que is in the vicinity o f the snug torq ue and between snug and the y ield point.
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Sensor I ® Expert User Manual T ABLE OF CONTENTS.
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i Sensor I® Expert User Manual T ABLE OF CONTENTS CHAPTER 1: INTRODUCTION ............................................... ............ 1 CHAPTER 2: TOOL DESCRIPTI ON ....................... .............................. 3 Functions of Components CHAPTER 3: WRENCH OPERATION INSTRUCTIONS .
ii Sensor I® Expert User Manual TORQUE MULTIPLIER FUNC TION .................. .................... 40 Setup of a Torque Multiplier Use of a Torque Multiplier LEFT HAND FASTENERS ............................. .................... 42 RESET ADJUSTMENT (EVS-mode ls only) .
Sensor I ® Expert User Manual CHAPTER 1 Intr oduct ion.
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1 Sensor I ® Expert User Manual INTRODUCTION The SENSOR 1 ® EXPERT WRENCH is a han d -opera ted portable tigh tenin g system with a battery-power ed m icr opr ocessor con trol system.
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Sensor I ® Expert User Manual CHAPTER 2 T ool Descr ipt ion.
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3 Sensor I ® Expert User Manual T OOL DESCRIPTION T echn ical Data 40 125 250 400 Length: 13.5” (343 mm) 26” (665 mm) 42.5” (1080 mm) 48.5” (1232 mm) Squar e Drive: 3/8” (9.5 mm) 1/2” (12.5 mm) 3/4” (19mm) 3/4” (19 mm) We ig ht : T ool 2.
4 Sensor I ® Expert User Manual NOTE These specifications apply to the wrench and its contr ol sy stem only (without additional appar atus). A ccu racies cannot be specif ied when the wrench is used w ith torq ue mul tipliers or if the wrench is oper ated incorrectly .
5 Sensor I ® Expert User Manual Functions of Components Expert 125, 250 and 400 Models Wr ench Housing Incorpor ates all the electr on ics and d ig i tal display . Wr ench Handle Houses th e char ger/d ata port connect or f or battery charg ing an d seri al port commun icati on s.
6 Sensor I ® Expert User Manual Functions o f Components Expert 40 Handheld T ool Consists o f the r atchet h ead, r eset switch, cable an d the an gle meas urem ent d evice . The head cann ot be in de xed r elative to the h andle . The plug at th e en d of th e tool cable connects to th e receptacle on th e lower portion o f the Con trol U n it.
7 Sensor I ® Expert User Manual 1. Control Sy stem Status Lights These li gh ts are used to si gnal oper ating status: RUN The con trol system is ready to beg in a cycle. SNUG The tor que applied to th e fastener has r eached the sn ug torque settin g.
8 Sensor I ® Expert User Manual 2. Mode Selector Sw itch Selects the parti cular ti ghten ing m ode: T orque Con trol, Dyn am ic A ud it, Yiel d Contr ol and An gle Cont rol. This swi tch also allows you to sel ect the Setup m ode to adjust commun i cati ons par ameters , setup and restor e custom m odes , and perf orm di agnosti cs 3.
9 Sensor I ® Expert User Manual 5. Digital Display Provi des a d ig ital r ead out of par ameters selected: A) These segm ents sh ow th e item bein g displa yed on the m ain display: Pk is peak tor q.
10 Sensor I ® Expert User Manual G) This segmen t will ligh t when th e wren ch is in calibration m ode f or torque or angle . H) This segmen t ind ica ted that degr ees of an gle are bein g displayed on th e screen. I) These segm ents in dicate th e cycle n umber for the ti ghten ing or th e mod e num b e r w he n i n s e t u p mode.
11 Sensor I ® Expert User Manual 6. Membr ane Ke ys Each membr an e key has two functi o ns . T o access the lower fun ction, simply pr ess th e key . The upper fun ction can be accessed by h oldin g in the Reset button and then pr ess th e membr ane k ey .
12 Sensor I ® Expert User Manual 7. A udible Alarm Sign als the completi on of a ti ghten in g proced ure by con tinu ous tone and si gnals a f ault by an interm i tte nt ton e . The au dible alarm will only sound while tor que is bein g a pplied to th e wrench han dle .
13 Sensor I ® Expert User Manual 12. [ITEM NO LONGER IN USE] 13. Contr ol Unit Pivot (model 40 only) The pivot separ ates the upper porti on of th e Con trol U ni t from th e lower portion an d allows th e upper portion to be pivoted back f or belt-moun ted mobile use an d pivo ted forw ard f or ben ch top use .
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Sensor I ® Expert User Manual CHAPTER 3 Oper at ion Instruct ions.
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15 Sensor I ® Expert User Manual WRENCH OPERA TION INSTRUCTIONS Gener al Information NOTE Exceeding maximum tor que r ating ma y cause damage to wrench or loss of calibr ation. The wr en ch should only be used f or its in tend ed purpose , i .e ., for tigh ten ing, loosen ing an d aud itin g proced ures .
16 Sensor I ® Expert User Manual At th e top r igh t-hand secti on of th e scr een is the cycle coun t ind i cator . It displays th e n umber of completed ti ghteni ngs f or that mod e (up to 999 tigh ten ings). Th e counter in crem ents by on e at the en d o f each tigh tenin g once th e Reset button has been pressed .
17 Sensor I ® Expert User Manual 6. Release th e Reset button. The uni ts choi ce is now s aved . 7. M ove the M ode Selecti on swi tch to one o f the ti ghten ing m odes an d use th e Units button to choose between M etri c or En glish uni ts. T orque Contr ol Tightening Procedur e 1.
18 Sensor I ® Expert User Manual 4. Press and h old in the Reset button. (In iti ally the sn ug torque will be shown, th en after a few secon ds the tar get toque will be sh own). See graphi c below . Note th e snug tor que in T o rq u e C on tro l mo de i s no t adjustable and set to th e m ini mum sn ug allowable as a d efa ult.
19 Sensor I ® Expert User Manual Dynamic Audit 1. Press an d re lease the Reset button to power up the wr en ch (if the wr ench is left i dle for one m inute th e wren ch will turn o ff to save battery power). 2. Move th e M ode Selecti on switch to Dyn ami c Audit.
20 Sensor I ® Expert User Manual 8. Press and h old in the Reset button. Th e snug tor que will be displayed . 9. With th e Reset button held in, use th e P ara meter A djustmen t Knob to adjust th e snug tor que to the d esi red value (appr ox. 50% of e xpected tor que).
21 Sensor I ® Expert User Manual Yield Control 1. Press an d release th e Reset button to power up the wr ench. 2. Move th e M ode Selecti on switch to Yi eld Cont rol.
22 Sensor I ® Expert User Manual NOTE When using EVS-models , avoid r atch eting when the torque is in the vicinity o f the snug torque and betw een snug and the yield point. 8. Release the Reset button. If the F AUL T ligh t is li t, then pr ess and h old the Reset button again while hold ing th e wr ench steady .
23 Sensor I ® Expert User Manual Angle Contro l 1. Press an d re lease the Reset button to power up th e wren ch. 2. Move th e M ode Selecti on switch to An gle Cont rol. 3. Attach th e an gle refer ence arm (EA -mod els) to the wr en ch, and place th e magn et on a magn etic surf ace .
24 Sensor I ® Expert User Manual 6. Press th e Display k ey until "Pk" is di splayed on the lower left-han d si de o f the scr een. 7. Press in the Reset button. Th e snug tor que will be displayed . 8. With th e Reset button held in, use th e P ara meter A djustmen t Knob to adjust th e snug tor que to the d esi red value .
25 Sensor I ® Expert User Manual CYCLE COUNTER The cycle coun ter is d isplayed in the upper r igh t-hand corn er of th e d ig ital display (see Fun ction s of Compon en ts). The coun ter ind icates th e number o f completed tigh tenin gs stored in m em ory .
26 Sensor I ® Expert User Manual QU ALITY CONTROL LIMITS AND ST A TISTICS Setup and Vie wing Quality Contr ol Limits 1. Press an d re lease the Reset button on th e sid e of th e wren ch. 2. Move th e Mod e Selection swi tch to the ti ghten in g mod e requ ir ed.
27 Sensor I ® Expert User Manual Deleting Quality Control Limits 1. Press an d release th e Reset button to power the wren ch. 2. Move th e M ode Selecti on switch to th e tigh tenin g mod e requ ir ed. 3. Press th e Window k ey . Y ou will see "--.
28 Sensor I ® Expert User Manual Exceptions f or angle lo w and high limits: NOTE While in Angle Contro l: • T o delete hi gh and low an gle settings , HA and LA m ust be adjusted to the tar get an gle . • T o delete hi gh and low tor que setting s , HT and L T must be adjusted to the sn ug tor que.
29 Sensor I ® Expert User Manual Statistics The f ollowing statisti cal inform ation is available f or each custom and pri m ary tigh tenin g mod e: NOTE Cp and CpK are not av ailable for angle in Dynamic T or que Audit mode as the contr ol limits for lo w angle (LA) and high angle (HA) are not used.
30 Sensor I ® Expert User Manual 4. T o r ead the stand ard d eviati on, σ , an d process capabili ty , CpK, repeat the above pr ocedur e , but press th e σ key in place o f the x k ey . The stan- dar d de viati on and CpK will be d ispla yed for tor que (Pk), and an gle (An).
31 Sensor I ® Expert User Manual Retrie v ing Custom Tightening Modes 1. Move th e M ode Selecti on sw it c h t o the S e t u p p o s it io n. 2. Hold in th e Reset button until m od e appears in the upper r igh t-hand c or ne r of t he digit a l di s p l ay .
32 Sensor I ® Expert User Manual The f i rst number in di cated the sn ug torq ue value (50% of the e xpected torq ue), the last n umber is the captur e angle in d egrees . If only on e number is d isplayed on the scr een and th e "Pk" segm ent is li t, the Cu stom Mod e is a Yield Con tr ol st r ategy .
33 Sensor I ® Expert User Manual D A T A ST ORAGE AND RETRIEV AL The char ge r/data port (i tem 8 in Ch apter 2: T ool Descr iption) has an integr al RS232 seri al port. This an be connected to a PC, and wi th th e InterLink so ftwar e or a termin al progr am, th e data can be upload ed to the computer .
34 Sensor I ® Expert User Manual 7. Press in the Reset button an d adjust th e baud r ate to th e desi red value (valid bau d r ates are 19200, 9600, 4800, 2400, 1200 & 600). NOTE The last two numer als ar e not sh own on the wr ench display . 8.
35 Sensor I ® Expert User Manual 6. While hold in g the Reset button, pr ess the U ni ts key to select th e optio n. The d isplay will sh ow "ON". T o d eselect this option pr ess the Joint ke y deselects i t. 7. Rotate the M ode Select swi tch ba ck to the Setup posi tion.
36 Sensor I ® Expert User Manual 8. H oldin g in the Reset button, adjust th e Custom Setup Mod e number below 20. 9. Release the Reset button and m ove the M ode Selecti on swi tch to the de si red t ig ht e ni ng mo de.
37 Sensor I ® Expert User Manual 6. With th e Reset button held in, use th e P aram eter Adjustm ent Kn ob to select the d esir ed ti ghten ing m ode . Select from: 7. Release th e Reset button once the ti ghten ing mode has been se lected. 8. Press th e Display button an d the ti ghten ing par ameters will be tr ansm i t- ted .
38 Sensor I ® Expert User Manual 5. Move th e mod e selection swi tch to T orque Con trol. 6. With th e Reset button held in, use th e P aram eter A djustmen t Knob to select the ti gh tenin g mod e for whi ch th e en d of ti ghten ing d ata is to be tran smi tted over the ser ial in terf ace .
39 Sensor I ® Expert User Manual 1. Complete a tigh ten ing. 2. Hold in th e Reset button. 3. With th e Reset button held in pr ess the Stor e ke y . 4. Starting at zer o, the screen will then in di cate the stor age posi tion wh ere the curve will be stor ed.
40 Sensor I ® Expert User Manual samples have been sen t, the d ispla y reverts to sh owing th e selected curve number . 9. Rotate the M ode Select sw i tch back to the Setup posi tion. 10. H oldin g in the Reset button, adjust th e Custom Setup Mod e number below 20.
41 Sensor I ® Expert User Manual If while in a pri m ary or custom tigh te nin g mod e , th e MUL symbol is on but the user is un sur e of th e multipli er value , it can be ch ecke d by followin g the proced ure d escr ibed in steps 2 and 3.
42 Sensor I ® Expert User Manual 8. Release the Reset button and rotate th e Mod e switch to th e tigh ten ing mod e positi on for whi ch the multipli er was enabled . The multipli er is now en abled f or that pri mary ti ghten ing m od e. NOTE It is only possible to have one pr ogrammable multiplier v alue in operation at an y time .
43 Sensor I ® Expert User Manual 2. Press th e Reset to power up the wr ench. 3. Move th e M ode Selecti on switch to Setup. 4. With th e Reset button held in, use th e P aram eter Adjustm ent Kn ob to select Custom setup M ode #103. NO TE : The m ain d isplay shows an in te- ger fr om 0 to 9.
44 Sensor I ® Expert User Manual and s tillness o f th e wren ch when i t is reset. Th e sh orter the ti ghten in g peri od, th e sm aller the err or will be . The mor e stable the wr ench is at reset, the sm aller the err or . See th e Application Guidelines at th e fron t of this man u al for ad di ti onal gu id elin es.
45 Sensor I ® Expert User Manual 8. Repeat until th e an gl e accuracy an d reset o f the wr ench ar e sui table to t he a p p lic a t io n . NOTE The default r eset adjustment v a lue for models 125, 250 and 400 is 4. The default r eset adjustment value f o r model 40 is 6.
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Sensor I ® Expert User Manual CHAPTER 4 Battery Char ging.
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51 Sensor I ® Expert User Manual BA T T E R Y C H AR G I N G The battery m ust be r echarge d as soon as "LO BA T" appears on the d isplay . The char g er connects to the char g er/ data port (item 8 in Chapter 2: T ool Descripti on). 1. Rem ove the pr otective cap from th e wren ch handle (m odels 125, 250 and 400 only).
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Sensor I ® Expert User Manual CHAPTER 5 Diagnost ics & T r oubleshoot ing.
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49 Sensor I ® Expert User Manual DIA GNOSTICS AND TROUBLESHOOTING Introduct ion This chapter provi des tr oubleshootin g inf ormati on using th e built-in di agn ostic test m odes . T ests can be performed by selectin g Custom Setup Mod e n umbers between 200 and 212.
50 Sensor I ® Expert User Manual at the lo w end is corr ect-the hi gh en d should f ollow . M odel 40 sh ould be return ed to an author ized Ingersoll-Rand Servi ce Center f or adjustm ent. Battery Lev el T est Mode (Custom Mode #204) The d isplay value will be between 100 (fully char ged) an d zero (d epleted).
51 Sensor I ® Expert User Manual 2. Connect th e seri al cable to th e charg er/data port. In sert the test con- nector in to th e end o f the ser i al ca ble .
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Sensor I ® Expert User Manual CHAPTER 6 Calibr at ion.
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53 Sensor I ® Expert User Manual CALIBRA TION G e ne ra l I n fo r m a ti o n This sectio n descr ibes the calibr ation m ethod f or the tor que/angle sen sors . Calibrati on is accomplish ed by perform ing ti gh tenin gs with th e wren ch an d refer encin g extern al measur ing equ ipmen t to compare th e results .
54 Sensor I ® Expert User Manual T orque Calibr at ion T orque calibr ation pr ocedur e descr ibed is for th e 125 lb .ft. m odel wr ench. For other wr ench models , use the follo wing inf ormation for calibr ation: Model 40: 45-450 dNm Range , 170 dNm +/-1 dNm Calibr ation point Model 250: 115-330 Nm Range , 220 Nm +/-0.
55 Sensor I ® Expert User Manual 9. Apply torque to th e wren ch equ a l to appro xim ately 25Nm and ch eck that the tor que read in gs match w ithin specif ied toler ance . 10. After check in g the low en d and hi gh end tor que , use th e P aram eter Adjustm ent Kn ob to balan ce through out th e specifi ed torque r ang e (20 Nm-170 Nm).
56 Sensor I ® Expert User Manual Cal M ode and pr ess Display to cancel. N umber will cycle . T o save Cal scale factor , select Setup, hold in Reset and adjust th e M ode below 20. 21. Go to Setup Mod e #103 an d turn the M ode Select swi tch to T orque Con- trol.
57 Sensor I ® Expert User Manual on a flat surface , selecting An gle Contr ol and pr essin g the Reset button until th e fr ont pan el's FA UL T ligh t is extin guish ed and the gr een RUN ligh t appears .
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Sensor I ® Expert User Manual Appendix A Sample o f Dat a Reports.
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62 Sensor I ® Expert User Manual Appendix A These r eports are accessed by th e me thods n oted in "Data Storag e and Retri eval". The inf orm ation pr ovid ed by the opti on al InterLink so ftwar e will have a differ ent form at.
63 Sensor I ® Expert User Manual End of Tightening Dat a Dump Tigh tenin g Conf igur ation N o : T orque Con tr ol Mod e To r q u e U n i t s : N m Load Un its : kN External chann el : Load Cell An gle Tr ansd ucer : Non Con tact An gle Measur emen t Mul t ip l ier : 1 .
64 Sensor I ® Expert User Manual End of Tightening Dat a Dump (cont.) TO RQ U E Mean : 0020.6 Si gma : 000.34 Cp : 004.60 Cpk : 004.02 ANGLE Mean : 0031.
65 Sensor I ® Expert User Manual Tightening Curve Dat a Dump T orq u e Unit s : N m Load U ni ts: kN Mul t i pl ie r: 1 . 00 Ti ghten ing Di recti on: Clockwise Contr ol Strategy: An gle Contr ol T a.
66 Sensor I ® Expert User Manual Dat a Out at End o f Tightening T ,0020.5,-,A,0015,a,E,0000,- T ,0017.8,t,A,0010,a,E,0000,- T ,0013.8,t,A,0008,a,E,0000,- T ,0020.5,-,A,0013,a,E,0000,- T ,0027.0,-,A,0017,-,E,0000,- T ,0026.8,-,A,0018,-,E,0000,- T ,0030.
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Sensor I ® Expert User Manual Appendix B List o f Setup Modes.
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67 Sensor I ® Expert User Manual Appendix B Cust om Modes Custom Mod es 1 through 20 ar e th e Cu stom Tigh tenin g mod es. Th ey ar e mem ory locations used to store tigh te ni ng s t ra t e gie s fo r l a t er re c a l l .
68 Sensor I ® Expert User Manual Custom M odes 200 thr ough 220 are the Custom Di agnosti c m odes an d are used for wr ench testin g. The Custom Di agn ostic m odes ar e: Custom Mode Function 200 Di.
Sensor I ® Expert User Manual Appendix C Spar e P arts List.
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69 Sensor I ® Expert User Manual Appendix C Spare P arts List ing - MODEL 40 Descript ion Part # CPN *Wren ch Assembly , EZ angle EZS40A -HHT 89934541 *Wren ch Assembly , Aud itor EA40A -HHT 89930952.
70 Sensor I ® Expert User Manual Spare P arts List ing - MODEL 40 (cont.) Descript ion Part # CPN Han dle decal - logo - Itali an 40HLGLBL-I 89935597 PCB Expert 40 Display T03710-69 04539516 PCB Expert 40 Con trol E40-PCB-MAIN 04705760 Ang le Ref.
71 Sensor I ® Expert User Manual Spare P arts List ing - MODEL 40 (cont.) Descript ion Part # CPN Rear Cont rol U ni t Decal - English E40-PR-LABEL 04705786 Rear Cont rol U ni t Decal - Fren ch E40-P.
72 Sensor I ® Expert User Manual Spar e Parts List ing - MODEL 125 Descript ion Part # CPN PCB Expert Display T03710-69 04539516 PCB Expert Con trol T03711-69 04539524 An gle Ref Arm (EA- m odels onl.
73 Sensor I ® Expert User Manual Spare P arts List ing - MODEL 125 (cont.) Descript ion P art # CPN Euro p lug 2.5M 95301-CORDE 89934277 Head In de xing Set Scr ew SETSCR-10 -24-395 04630059 Insulati.
74 Sensor I ® Expert User Manual Spar e Parts List ing - MODEL 250 Descript ion Part # CPN PCB Expert Display T03710-69 04539516 PCB Expert Con trol T03711-69 04539524 An gle Ref Arm (EA-m odels only.
75 Sensor I ® Expert User Manual Spare P arts List ing - MODEL 250 (cont.) Descript ion Part # CPN Bri tish 3-Cond uctor 2.5M Righ t Angle Plug 95301-CORDB 89934269 Euro plug 2.
76 Sensor I ® Expert User Manual Spar e Parts List ing - MODEL 400 Descript ion Part # CPN PCB Expert Display T03710-69 04539 516 PCB Expert Control T03711-69 04539524 An gle Ref Arm (EA- m odels onl.
77 Sensor I ® Expert User Manual Spare P arts List ing - MODEL 400 (cont.) Descript ion Part # CPN Bri tish 3-Cond uctor 2.5M Righ t Angle Plug 95301-CORDB 89934269 Euro plug 2.
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Sensor I ® Expert User Manual Appendix D Serv ice Centers.
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77 Sensor I ® Expert User Manual Appendix D Service Centers US A Ingersoll-Rand Compan y Automation and Integr ation Center 1872 Enterprise Dr . Rochester Hills, MI 48309 T el: +1 (248) 293-5700 Fax: +1 (248) 293-5800 EUROPE Ingersoll-Rand Compan y Fastener Tightening Sy stem Div ision Swan Lane , Hindley Green, Nr .
78 Sensor I ® Expert User Manual Ingersoll - Rand, Co. Swan Lane, Hindley Green, Wigan WN2 4EZ, U.K. EX-0000-EX-4999 EN792-1, EN26789, EN60204, EN60950, EN50081, EN50082 Sensor I Expert Electronic Wr.
79 Sensor I ® Expert User Manual NOTICE SA VE THESE INSTRUCTIONS. DO NOT DESTORY When the life of the tool has expir ed, it is recommended that the tool be disassembled, degreased and parts be separated by mate rial so that they can be rec ycled.
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