Ingersoll Rand Impact Driver 4575759 User Manual

Sensor I® Expert Electronic Wrenches  
USER MANUAL  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SENSOR I® Expert  
User Manual  
04575759  
Form 7266  
Version 005, 08/04  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
NOTE  
The wrench should only be used for its intended purpose, i.e., for  
tightening, loosening and auditing purposes. It should be operated  
using a smooth steady pull at moderate speed on the wrench handle  
with both feet firmly placed on floor. Specifications apply to the  
wrench only (without additional apparatus). Accuracies cannot be  
specified when the wrench is used with torque multipliers or if the  
wrench is operated incorrectly.  
NOTE  
The used of universal joints is not recommended. Use of such devices  
may cause inaccuracies in torque and/or angle measurements. The use  
of extensions to the handle, or application of force to other parts of the  
wrench may cause damage, result in personal injury, or may result in  
inaccurate tightenings.  
NOTE  
Exceeding the maximum torque noted on the wrench may cause damage  
to wrench or loss of calibration.  
NOTE  
Always make sure that the socket is fully engaged on the joint before  
tightening begins. Failure to do so may cause inaccuracies in torque  
and/or angle measurements.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
NOTE  
If the wrench fails to operate using the recommended procedures  
described in this manual, the cause of malfunction should be corrected  
by an authorized Ingersoll-Rand technician. For a list of authorized  
Ingersoll-Rand technician. For a list of authorized Ingersoll-Rand  
service centers, see Appendix D.  
NOTE  
If calibration equipment is not available, it is recommended that the  
wrench be returned to an authorized Ingersoll-Rand service center for  
an annual recalibration.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 digital  
torque wrenches is one very significant feature: angle. The angle  
measurement allows users to accurately audit torque dynamically and  
perform sophisticated tightening methods such as angle and yield control.  
The EZ Angle sensor is a major improvement over previous technology. The  
most obvious change is the removal of the external arm on the ratchet  
head-eliminating the space constraint. In addition, users no longer need to  
find a suitable place to attach the reference arm magnet.  
Although the Expert wrench is a rugged industrial tool, to achieve precision  
results, it needs to be treated as a precision instrument. The following  
outline summarizes the ideal method of use:  
Wrench Reset:  
The reset process sets the zero reference for both torque and angle. The  
wrench must be held steady with no torque applied to achieve a good reset.  
It will indicate a fault if excessive torque or angle is applied while resetting.  
For best results, attach the socket to the wrench and place it on the  
fastener or rest the ratchet head on a table. Hold in the Reset button until  
the green Run light illuminates and release. You can then move the wrench  
to the fastener, or begin tightening immediately. To achieve angle accuracy  
that is better than the documented performance specification place the  
entire wrench on a table and hold it completely still during reset. This will  
improve the angle accuracy to better than 2% of the final angle.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Dynamic Audit:  
The Dynamic Audit feature of the Expert wrench audits residual torque  
currently on the fastener after relaxation and other effects have taken  
place. On a very hard joint that is audited soon after tightening, this will  
consistently equate to installation torque. On a very soft joint or a joint  
audited long after the initial tightening, it may be considerably reduced.  
Standard methods are open to variance from operator influence. Experienced  
auditors try to overcome these difficulties by watching the socket very  
closely and moving very cautiously. Other operators may have a tendency to  
pull the wrench until the expected value is reached. Although that specific  
bolt may end up with the correct torque, it does not tell Quality Control  
about any possible problems that are occurring with the fastening  
equipment on line.  
The Expert wrench helps eliminate this operator influence by capturing the  
residual torque after a very small angle is turned regardless of how far or  
fast the wrench is pulled. In other words, all that is required is a quick pull  
and the processor takes a "snapshot" of the dynamic torque at the pre-set  
angle of turn.  
To Dynamically Audit Residual Torque:  
A table of audit angle values is provided for your convenience. The guiding  
principle is to set a sufficient angle of turn to ensure the bolt threads are  
moving when the torque snapshot occurs. The longer the fastener, the  
greater the required angle.  
To ensure that an accurate reading is received, the following procedure  
should be followed:  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
1. Set the snug torque to approximately 50% of the expected final torque  
reading.  
2. Set the capture angle (see chart).  
3. The operator must then pull the wrench approximately 30° over a period  
of no more than 2 seconds. Pulling the wrench past the desired audit  
angle will not have an adverse effect on the audit reading - it will be  
"captured" at the correct audit angle. The captured torque can be viewed  
when the parameter shown on the display is "Tq".  
Joint Grip Length* (d = bolt diameter)  
Joint Type  
2d - 5d  
5d - 10d  
>10d  
2d  
Hard/Medium  
Soft  
2°  
2°  
3°  
4°  
4°  
6°  
6°  
8°  
*The grip length is the total length of the bolt located within the assembly  
pieces. Keep in mind that adding socket extensions will also call for an  
increase in angle.  
This chart is offered as a guideline only. The optimum value for the capture  
angle will be influenced by the overall joints stiffness, joint configuration,  
and frictional conditions. Application testing is recommended to determine  
the most accurate value for the specific joint under audit.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
To Tighten to a Torque  
Set the torque value to your target torque, and set high and low torque and  
angle limits if desired. Snug is set automatically to a default value. This is  
the point from which the angle is activated. The default snug values for all  
models are listed in the TOLL DESCRIPTION Technical data table in Chapter  
2. Reset the wrench before tightening. The OK light will go on and an alarm  
will sound when the target is reached. If the wrench is pulled too slowly for  
a long period (<10° per second for model 40, <5° per second for more than  
5 seconds for all other models), the wrench will signal an error by sounding  
several short beeps.  
To Tighten to an Angle  
Set the snug torque and target angle as well as any high and low torque and  
angle limits. Reset the wrench before tightening. The Ok light will go on and  
an alarm will sound when the target is reached. If the wrench is pulled too  
slowly for a long period (<10° per second for 5 seconds for model 40, <5°  
per second for more than 5 seconds for all other models), the wrench will  
signal an error by sounding several short beeps.  
To Tighten to Yield  
Snug torque should be set to approximately 50% of the expected proof load  
torque of the bolt in use. Set any required torque or angle limits, and select  
your joint type-hard, normal or soft. Reset the wrench before tightening.  
The OK light will go on and an alarm will sound when the target is reached.  
If the wrench is pulled too slowly for a long period (<10° per second for 5  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
seconds for model 40, <5° per second for more than 5 seconds for all other  
models), the wrench will signal an error by sounding several short beeps.  
NOTE  
When using EVS-models, avoid ratcheting when the torque is in the  
vicinity of the snug torque and between snug and the yield point.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
TABLE OF CONTENTS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
TABLE OF CONTENTS  
i
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
ii  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
CHAPTER 1  
Introduction  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 addition  
to standard torque and angle control tightening capabilities, it provides a  
Yield Control mode of tightening and Dynamic Torque Auditing. It is suitable  
for laboratory, production, quality control, maintenance and field service.  
The control system is powered by a rechargeable NiMH battery located  
inside the wrench handle (model 125, 250 & 400) or in the lower portion of  
the control unit (model 40). The wrench has a toggle lever used to select  
the ratchet direction. Angle reference is either measured internally by the EZ  
angle or via an attachable spring arm with a magnet (EA-models).  
Attachable spring arms can be fitted with options such as suction cups or  
alligator clips.  
The digital display shows a digital readout of either dynamic torque peak  
torque, or angle. Audible signals and displays indicate the completion of  
tightening for Dynamic Torque Audit, Torque Control, Yield Control (elastic  
limit of bolt), or Angle Control procedures.  
1
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
CHAPTER 2  
Tool Description  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
TOOL DESCRIPTION  
Technical Data  
Length:  
40  
125  
250  
400  
48.5” (1232 mm)  
13.5” (343 mm) 26” (665 mm) 42.5” (1080 mm)  
Square Drive:  
Weight:  
Tool  
Control Unit  
Torque Operational Range:  
3/8” (9.5 mm)  
1/2” (12.5 mm) 3/4” (19mm)  
5 lb (2.3 Kg) 12 lb (5.5 Kg)  
3/4” (19 mm)  
2.4 lb (1.1 Kg)  
2.2 lb (1.0 Kg)  
4.5-45 Nm  
(45-450 dNm)  
3.3-33 lb.ft.  
13.8 lb (6.3 Kg)  
20 - 170 Nm  
108-340Nm  
130-540 Nm  
100-400 lb.ft  
15 - 125 lb.ft. (80-250 lb.ft)  
(40-400 in-lb)  
Minimum Snug Torque  
(default value for  
Torque control mode)  
Torque Resolution:  
Torque Accuracy: Full Scale  
Maximum Angle:  
Angle Resolution:  
Angle Accuracy:  
Angle Reference  
2.3 Nm (23 dNm) 10 Nm  
24 Nm  
(18 lb.ft.)  
24 Nm  
(18 lb.ft.)  
1.7 lb.ft.  
(20 in-lb)  
1 in-lb  
1 %  
1999o  
1o  
(7 lb.ft.)  
0.1 Nm  
0.5 %  
1999o  
1o  
0.1 Nm  
0.5 %  
1999o  
1o  
0.1 Nm  
0.5 %  
1999o  
1o  
1o  
1o  
1o  
1o  
Arm (EA-models)  
EZ Angle* (EVS-models)  
Power Supply Voltage  
Operating time between  
charges  
4 %  
7.5 V  
5.5 hours  
4 %  
7.5 V  
5.5 hours  
4 %  
7.5 V  
5.5 hours  
4 %  
7.5 V  
5.5 hours  
Charging time  
Battery Charger Input Voltage 220/110 V  
Operating Temperature Range  
14 hours  
14 hours  
220/110 V  
0-500 C  
14 hours  
220/110 V  
0-500 C  
14 hours  
220/110 V  
0-500 C  
0-500 C  
* Under recommended conditions  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Sensor I® Expert User Manual  
NOTE  
These specifications apply to the wrench and its control system only  
(without additional apparatus). Accuracies cannot be specified when  
the wrench is used with torque multipliers or if the wrench is operated  
incorrectly.  
NOTE  
The use of universal joints is not recommended. Use of such devices  
may cause inaccuracies in torque and/or angle measurements.  
NOTE  
Exceeding the maximum torque, noted on the wrench, may cause  
damage to wrench or loss of calibration.  
4
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 reference arm potentiometer (EA-models) and ratchet  
head. The wrench head can be indexed 600 either side of the wrench body  
for ease of reading the display.  
NOTE  
Factory Calibration of models 125, 250 and 400 was conducted with the  
wrench head in the normal, non-indexed position. This position is  
recommended where high accuracy of angle values is required. If the  
wrench is to be used in the 60o indexed position and angle accuracies  
equal to or better than 10% are required, then recalibration of angle  
in the indexed position is recommended.  
Torque accuracy remains unaffected by indexing the wrench head.  
5
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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 of the Control Unit.  
Control Unit  
Houses the electronics, power supply and interface connectors for the tool  
cable and battery charger/data communications port. The tool connects  
to the receptacle in the lower portion of the Control Unit. The front panel  
on the upper portion of the Control Unit is the same as all other Expert  
Wrenches.  
6
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
1. Control System Status Lights  
These lights are used to signal operating status:  
RUN  
SNUG  
OK  
The control system is ready to begin a cycle.  
The torque applied to the fastener has reached the snug torque setting.  
The fastener has been tightened correctly in the selected tightening mode.  
One or several of the following fault conditions has occurred:  
a) Operator Error  
FAULT  
b) Low Battery  
c) Torque Overrange  
d) System Failure  
e) Wrench not held steady enough during calibration (Reset)  
f) Wrench is being pulled too slowly.  
g) The mode or parameter adjustment knob has been changed since last reset.  
h) Ratchet head has been indexed since last reset.  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 select  
the Setup mode to adjust communications parameters, setup and  
restore custom modes, and perform diagnostics  
3. Reset Button  
Used to power up the wrench, reset the wrench before every new  
tightening procedure, to set torque and angle values, and to clear  
certain fault conditions. When the Reset button is held in, the top  
functions on the membrane key pad can be selected.  
4. Parameter Adjustment Knob  
When the Reset button is held in, this knob adjusts the value of the  
parameter being displayed.  
8
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 high torque limit  
LA is low angle limit  
HA is high angle limit  
C) These segments will light when serial data during tightening or serial data at  
the end of tightening are selected. They will also flash when data is being sent  
through the serial port.  
RX = receiving, TX = transmitting  
D) This segment will light when CCW ("-LEF") has been selected.  
E) These segments display the values of torque and angle.  
F) These segments light when statistical information is being shown on the  
display.  
9
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
G) This segment will light when the wrench is in calibration mode for torque or  
angle.  
H) This segment indicated that degrees of angle are being displayed on the  
screen.  
I) These segments indicate the cycle number for the tightening or the mode  
number when in setup mode.  
J) These segments indicate the units for torque.  
K) These segments indicate the joint type selection for yield control.  
L) This segment lights when the torque applied to the wrench is over the  
maximum allowable limit.  
M) This segment indicated a low battery condition.  
N) This segment lights when torque and angle offsets are being calculated.  
O) This segment will light when a torque multiplier is programmed for use with a  
particular fastening mode.  
P) This segment will flash when a particular tightening mode has reached its limit  
of 1,000 tightenings. This segment will light continuously when the wrench  
has reached its limit of 2,500 total tightenings for all the tightening modes.  
10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 holding  
in the Reset button and then press the membrane key.  
xCp  
When this key is pressed (with the Reset button held in), the Mean Value is displayed for  
approximately 1.5 seconds, then the Cp Value is displayed until the Reset button is  
released. Repeatedly pressing this key with the Reset button held in, will display Mean  
and Cp values for Torque or Angle.  
Window  
s/Cpk  
Press this key to display and edit the Torque and Angle high and low limits for a  
particular tightening mode. Press this key again to go back to the tightening mode.  
When this key is pressed (with the Reset button held in), the Standard Deviation is  
displayed for approximately 1.5 seconds, then the Cpk Value is displayed until the Reset  
button is released. Repeatedly pressing this key with the Reset button held in, will  
display Standard Deviation and Cpk values for Torque or Angle.  
Display  
Pressing this key changes the value that is being displayed on the screen. Each press  
toggles the display between Peak Torque (Pk), Angle (An), Ld (not used), and Dynamic  
Torque (Tq).  
Units  
Clear  
Pressing this key will change the torque units displayed for the selected mode. All stored  
data will also be converted.  
Pressing this button (while Reset is held in) clears custom tightening modes. This key  
also clears tightening data stored in memory.  
Joint  
Store  
This button changes the joint type for Yield Control tightening.  
Press this button (while Reset is held in) to store Curve Trace Data.  
11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
7. Audible Alarm  
Signals the completion of a tightening procedure by continuous tone  
and signals a fault by an intermittent tone. The audible alarm will only  
sound while torque is being applied to the wrench handle.  
8. Charger/Data Port  
The battery charger inserts into this connector to charge the wrench.  
The serial port cable provided with the wrench also plugs into this  
connector. This port is located in the end of the handle for models  
125, 250 and 400. For model 40, it is located on the rear of the  
Control Unit.  
9. Toggle Lever  
Selects the direction of the ratcheting mechanism; markings "ON" and  
"OFF" apply to right-hand threaded fasteners.  
10. Power Switch  
Located under the cap on the back of the wrench body (models 125,  
250 and 400 not shown) or Control Unit (model 40), this switch turns  
power on and off to the wrench.  
11. Angle Reference Arm Connector (EA-models)  
Provides a fixed reference for angel measurement while operating the  
wrench. It is attached to the work piece by a magnet base and spring  
arm.  
12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
12. [ITEM NO LONGER IN USE]  
13. Control Unit Pivot (model 40 only)  
The pivot separates the upper portion of the Control Unit from the  
lower portion and allows the upper portion to be pivoted back for  
belt-mounted mobile use and pivoted forward for bench top use.  
14. Belt Clip (model 40 only)  
Allows the operator to attach the Control Unit to a belt with the upper  
portion of the Control Unit pivoted back.  
15. Battery Access (model 40 only)  
The portion of the Control Unit below the pivot houses the battery. An  
access door secured with four screws allows access to the battery  
when the battery needs replacing. Simply pull the battery from both  
sides to dislodge the battery from the harness.  
16. Tool Cable (model 40 only)  
The tool cable is integral with the Handheld Tool and serves as the  
means of communication between the Control Unit and the Handheld  
Tool. The plug at the end connects to the receptacle on the lower  
portion of the Control Unit.  
13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
CHAPTER 3  
Operation  
Instructions  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
WRENCH OPERATION INSTRUCTIONS  
General Information  
NOTE  
Exceeding maximum torque rating may cause damage to wrench or loss  
of calibration.  
The wrench should only be used for its intended purpose, i.e., for  
tightening, loosening and auditing procedures. It should be operated using  
a smooth steady pull at moderate speed on the wrench handle with feet  
firmly placed on floor.  
The use of extensions to the handle, or application of force to other parts of  
the wrench may cause damage or result in personal injury, or may result in  
inaccurate tightenings.  
If the wrench fails to operate using the recommended procedures described  
in this manual, the cause of malfunction should be corrected by an  
authorized Ingersoll-Rand technician. For a list of authorized  
Ingersoll-Rand service centers, see Appendix D.  
Operation  
Ensure the Power Switch is in the ON position and press the Reset button.  
Primary Operation Modes  
Throughout all the tightening modes there are some common features. At  
any time during or at the end of a tightening the screen can be toggled to  
display the following; Peak Torque (PK), Angle (An), and Dynamic Torque  
(Tq). The present item displayed is indicated in the lower left hand portion  
of the screen. This can be changed by pressing the Display key.  
15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
               
Sensor I® Expert User Manual  
At the top right-hand section of the screen is the cycle count indicator. It  
displays the number of completed tightenings for that mode (up to 999  
tightenings). The counter increments by one at the end of each tightening  
once the Reset button has been pressed.  
For the most accurate results, the wrench should be pulled at a speed  
between 10 and 80 degrees per second. The wrench should be held steady  
while the Reset button is pressed.  
Setting Torque Units  
The units of displayed torque can be toggled between Metric and English  
units by pressing the Units key on the front panel. The current units  
selected are indicated in the center right-hand section of the screen.  
The wrench can also display torque in units of different sizes. The following  
procedure toggles the wrench units between Nm (or lb.ft.) and dNm (or  
in.lb.).  
1. Press the Reset button to power up the wrench.  
2. Move the Mode Selection switch to Setup.  
3. With the Reset button held in, use the Parameter Adjustment Knob to  
select the Custom Setup Mode #107. The main display shows "---", and  
the torque units are displayed in the center right-hand section of the  
screen.  
4. Hold the Reset button and press the Units button to choose units of Nm  
and lb.ft. Press the Joint button to choose units of dNm and in.lb.  
5. Press and hold the Reset button and rotate the Parameter Adjustment  
Knob counterclockwise until the Custom Setup Mode number is below  
20.  
16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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 to power up the wrench. If the  
wrench is left idle for one minute (adjustable) the wrench will turn off  
to save battery power.  
2. Move the Mode Selection switch to Torque Control. See graphic below  
3. Press the Units key to select the desired Torque units. See graphic below.  
17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Sensor I® Expert User Manual  
4. Press and hold in the Reset button. (Initially the snug torque will be  
shown, then after a few seconds the target toque will be shown). See  
graphic below. Note the snug torque in Torque Control mode is not  
adjustable and set to the minimum snug allowable as a default. The  
default snug values for all models are listed in the TOOL DESCRIPTION  
Technical data table in Chapter 2.  
5. With the Reset button held in, use the Parameter Adjustment Knob to  
adjust the target torque to the desired value. See graphic below.  
6. Release the Reset button. If the Fault light is lit then press and hold the  
Reset button again, while holding the wrench steady. Continue to hold  
in the Reset button until the RUN light appears and the FAULT light  
goes off. Release Reset.  
7. Commence tightening with moderate speed steady pulls. Stop as soon as  
the OK light comes on and the alarm sounds.  
18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Dynamic Audit  
1. Press and release the Reset button to power  
up the wrench (if the wrench is left idle for  
one minute the wrench will turn off to save  
battery power).  
2. Move the Mode Selection switch to Dynamic  
Audit.  
3. Press the Units key to select the desired  
Torque units.  
4. Attach the angle reference arm (EA-models  
only) to the wrench, and place the magnet  
on a magnetic surface.  
5. Press and hold in the Reset button. The cap-  
ture angle will be displayed.  
6. With the Reset button held in, use the  
parameter adjustment knob to adjust the  
capture angle to the desired value (see the  
application guide for details). Release the  
Reset button.  
7. Press the Display key until "Pk" is displayed  
on the lower left-hand side of the screen.  
19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Sensor I® Expert User Manual  
8. Press and hold in the Reset button. The  
snug torque will be displayed.  
9. With the Reset button held in, use the  
Parameter Adjustment Knob to adjust the  
snug torque to the desired value (approx.  
50% of expected torque).  
10. Release the Reset button. If the FAULT  
light is lit, then press and hold the Reset  
button again while holding the wrench  
steady. Continue to hold in the Reset but-  
ton until the RUN light appears and the  
FAULT light goes off. Release Reset.  
11. Commence tightening with a steady pull at  
moderate speed. Stop as soon as the OK  
light comes on and the alarm sounds.  
12. When audit is complete, press the Display  
key until "Tq" appears in the lower left-hand  
corner to display the dynamic torque read-  
ing.  
13. Press the Display key until "Pk" appears in  
the lower left-hand corner to display the  
peak (or static) torque reading. This is usu-  
ally the last torque value "seen" by the  
wrench.  
20  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Yield Control  
1. Press and release the Reset button to  
power up the wrench.  
2. Move the Mode Selection switch to Yield  
Control.  
3. Press the Units key to select the desired  
Torque units.  
4. Selects the joint hardness by pressing the  
Joint key on the front panel (the joint  
hardness currently selected is displayed in  
the lower right corner of the screen).  
5. Attach the angle reference arm (EA-models  
only) to the wrench, and place the magnet  
on a magnetic surface.  
6. Press and hold in the Reset button. The  
snug torque will be displayed.  
7. With the Reset button held in, use the  
Parameter Adjustment Knob to adjust the  
snug torque to the desired value. The snug  
torque value should be 30% to 50% of the  
proof load torque expected for that bolt.  
21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Sensor I® Expert User Manual  
8. Release the Reset button. If the FAULT  
light is lit, then press and hold the Reset  
button again while holding the wrench  
steady. Continue to hold in the Reset until  
the RUN light appears and the FAULT light  
goes off. Release Reset.  
9. Commence tightening with moderate speed  
steady pulls. Stop as soon as the OK light  
comes on and the alarm sounds.  
NOTE  
When using EVS-models, avoid ratcheting when the torque is in the  
vicinity of the snug torque and between snug and the yield point.  
22  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 button. "An"  
will be displayed in the lower left corner and  
the angle control point will be shown).  
5. With the Reset button held in, use the  
Parameter Adjustment Knob to adjust the  
angle control point to the desired value.  
Release the Reset button.  
23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Sensor I® Expert User Manual  
6. Press the Display key until "Pk" is displayed  
on the lower left-hand side of the screen.  
7. Press in the Reset button. The snug torque  
will be displayed.  
8. With the Reset button held in, use the  
Parameter Adjustment Knob to adjust the  
snug torque to the desired value.  
9. Release the Reset button. If the FAULT light  
is lit, then press and hold the Reset button  
again while holding the wrench steady. Con-  
tinue to hold in the Reset until the RUN  
light appears and the FAULT light goes off.  
Release Reset.  
10. Press the Display key until "An" appears in  
the lower left-hand corner if angle values  
must be displayed during tightening.  
11. Commence tightening with moderate speed  
steady pulls. Stop as soon as the OK light  
comes on and the alarm sounds.  
12. When tightening is complete, press the  
Display key until "Pk" appears in the lower  
left-hand corner. This will display the peak  
(or static) torque reading.  
24  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
CYCLE COUNTER  
The cycle counter is displayed in the upper right-hand corner of the digital  
display (see Functions of Components). The counter indicates the number of  
completed tightenings stored in memory. The cycle counter will increment  
once the Reset button is pressed after a tightening. A tightening cycle is  
started or initiated once snug torque has been reached. The cycle counter  
will also increment if a tightening has been completed and the wrench has  
powered down. Each tightening mode, including the 20 custom stored  
modes has its own independent cycle counter. The wrench can store a total  
of up to 2500 readings in memory and up to 1000 readings in any one  
tightening mode. When this limit is exceeded, the oldest reading in memory  
is overwritten and "MEM" will flash on the display.  
Resetting the Cycle Counter  
The cycle counter can be reset by either  
1. Changing a control parameter, i.e., Torque, Angle or a window  
limit.  
2. By holding in the Reset button and pressing the Clear key  
simultaneously.  
NOTE  
Both these operations will clear all data and statistics associated with  
the tightening mode for which the cycle counter was cleared.  
25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
     
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 the display along with "LT"  
(low torque limit) flashing in the top left hand corner.  
4. Press and hold in the Reset button. The present low torque limit will be  
shown.  
5. While holding in the Reset button, use the Parameter Adjustment Knob  
to adjust the low torque limit to the desired value. Release the Reset  
button and press the Window key.  
6. To adjust the high torque limit (HT), low angle and high angle limits,  
(LA, HA), press the Window key until the desired limit is flashing. Then  
hold in the Reset button and adjust as in step 5 above.  
7. When all adjustments have been made, press the Window key until all  
indicators (LT, HT, LA, HA) have stopped flashing on the display.  
8. Press the Reset button until the RUN light appears and commence tight-  
ening.  
NOTE  
In Yield Control, LA and HA must be greater than or equal to 12° for  
hard joints, 16° for normal joints, or 24° for soft joints. LT and HT  
limits must be greater than the snug torque for all modes.  
26  
Download from Www.Somanuals.com. All Manuals Search And Download.  
     
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 top left hand corner.  
4. Press and hold in the Reset button. The present low torque limit will be  
shown.  
5. While holding in the Reset button, use the Parameter Adjustment Knob  
to adjust the low torque limit to the torque value (target torque value  
for Torque Control). Release the Reset and press the Window key.  
6. To delete the torque high limit (HT), press the Window key until "HT" is  
flashing. Then hold in the Reset button and adjust this to the snug  
torque value (target torque value for torque control). Release the Reset  
button and press the Window key.  
7. To delete the angle low limit (LA), press the Window key until "LA" is  
flashing. Then hold in the Reset button and adjust this value to zero.  
Release the Reset button and press the Window key.  
8. To delete the angle high limit (HA), press the Window key until the "HA"  
is flashing. Then hold in the Reset button and adjust this value to zero.  
Release the Reset button and press the Window key.  
9. When all adjustments have been made, press the Window key until all  
indicators (LT, HT, LA, HA) have stopped flashing on the display.  
10. Press and hold the Reset button until the RUN light appears and com-  
mence tightening.  
27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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 Control Limits  
1. After the Reset button is pressed any limits that have been set will be  
indicated on the display with the corresponding segments lit (LT, HT, LA,  
HA).  
2. Once snug torque is reached, the torque/angle lower limit indicators (LT,  
LA) will flash on the screen until their respective values are reached.  
3. Once the lower limit values are reached, the indicators LT, LA will  
become solid.  
4. If a high limit is exceeded HT or HA will begin flashing.  
5. All limits that have been set will be indicated on the display with the  
corresponding segments lit (LT, HT, LA, HA).  
28  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Sensor I® Expert User Manual  
Statistics  
The following statistical information is available for each custom and  
primary tightening mode:  
Mean  
x
Standard Deviation  
Process Capability Index  
Process Capability Index  
σ
Cp  
CpK  
NOTE  
Cp and CpK are not available for angle in Dynamic Torque Audit mode as  
the control limits for low angle (LA) and high angle (HA) are not used.  
The statistical calculations are based on all stored final tightening data  
points for that tightening mode. Lower and upper control limits used for the  
calculation of the Process Capability Indices, Cp and CpK, use the values of  
low torque (LT), high torque (HT), low angle (LA) and high angle (HA)  
entered for each custom and primary tightening mode.  
The statistics can be viewed as follows:  
1. Select desired custom or primary tightening mode and confirm that the  
cycle count is a number above zero.  
2. While holding in the Reset button, press the x key. The display will show  
the x symbol on the top of the display and the Pk symbol on the bottom  
of the display. The main display will show the mean value of the torque  
which is shown for approximately 1.5 seconds, after which the process  
capability, Cp, is shown until the Reset button is released.  
3. Repeat the above process to display the mean, x, and process capability,  
Cp, for angle (An).  
29  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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® Expert wrench has the capacity to store up to 20 custom  
configurations of the primary tightening modes. These modes are numbered  
1 through 20 and are stored and accessed through the Setup Mode.  
Setup and Storage of Custom Tightening Modes  
1. Use the Mode Selection switch to select the primary tightening mode  
from which the Custom Mode is to be setup, i.e., Torque Control,  
Dynamic Audit, Yield Control or Angle Control.  
2. Program all required control points and window limits.  
3. Turn the Mode Selection switch to Setup. Hold in the Reset button, and  
use the Parameter Adjustment Knob to select an empty custom mode.  
Empty modes will be indicated by a flashing mode number between 1  
and 20.  
4. With the Reset button still held in, move the Mode Selection switch to  
the primary tightening mode required and press the Store key.  
5. Release the Reset button.  
30  
Download from Www.Somanuals.com. All Manuals Search And Download.  
     
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  
to select the Custom Mode number desired. Note: Empty modes will be  
flashing.  
4. Release the Reset button.  
5. Press in the Reset button again if the FAULT light appears. Hold until  
the green RUN light appears and the FAULT light goes off.  
6. Commence tightening.  
NOTE  
Once Custom Modes are stored, these control values cannot be changed.  
To change values in a Custom Mode first delete the mode and then store  
the new configuration.  
Identifying Custom Tightening Modes  
Once in a particular custom tightening mode, the primary mode from which  
it came can be identified by pressing the Reset button and looking at the  
values being displayed on the screen.  
If two numbers are displayed on the screen with the "Pk" segment lit, the  
Custom Mode is a Torque Control strategy. The first number indicates the  
snug torque, the last indicates the target torque.  
If the segment "Tq" lights on the screen with the first number, and An lights  
with the second number, then the Custom Mode is a Dynamic Audit strategy.  
31  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Sensor I® Expert User Manual  
The first number indicated the snug torque value (50% of the expected  
torque), 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 displayed is the  
snug torque value (50% of the expected torque at yield).  
If the segment "Pk" lights on the screen with the first number, and "An"  
lights with the second number, then the custom mode is Angle Control. The  
first number is the snug torque and the second number is the target angle.  
Clearing Custom Tightening Modes  
Custom tightening mode can be cleared by following the procedure below:  
1. Press the Reset button to power the wrench.  
2. Move the Mode Selection switch to the Setup position.  
3. Hold in the Reset button and use the Parameter Adjustment Knob to  
select the Custom Mode to be cleared.  
4. With the Reset button held in, move the Mode Selection switch to the  
primary mode from which the Custom Mode was based (i.e., Torque Con-  
trol, Dynamic Audit, Yield Control or Angle Control. If you no longer  
know which mode your strategy came from, refer to the previous section.  
5. With the Reset button still held in, press the Clear key.  
6. Release the Reset button.  
32  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Sensor I® Expert User Manual  
DATA STORAGE AND RETRIEVAL  
The charger/data port (item 8 in Chapter 2: Tool Description) has an  
integral RS232 serial port. This an be connected to a PC, and with the  
InterLink software or a terminal program, the data can be uploaded to the  
computer. Examples of all outputs can be found in Appendix A. The  
communication parameters on the PC must be set as follows in order to  
transmit any data from the wrench.  
Data Bits:  
Stop Bit:  
Parity:  
8
1
None  
None  
Handshake:  
The baud rate must match the current baud rate of the wrench. Valid baud  
rates can be 19200, 9600, 4800, 2400, 1200 & 600.  
For use with the InterLink software, the wrench must be set to 2400.  
Instructions for use of this program are located in the CD jacket and the  
Help file of the software.  
Setup of Wrench for Data Upload  
1. Connect the serial cable from the charger/data port to the serial port of  
the computer.  
2. Setup parameters in a computer terminal program.  
3. Press the Reset button to turn on the wrench.  
4. Move the Mode Selection switch to Setup.  
5. With the Reset button held in, use the Parameter Adjustment Knob to  
select Custom Setup Mode #110 (the present baud rate will be shown,  
divided by 100 to fit on the display).  
6. Move the Mode Selection switch to Torque Control.  
33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
     
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 Reset button and adjust the Custom Setup Mode number  
below 20.  
10. Release the Reset button and move the Mode Selection switch to the  
desired tightening mode.  
Data Out During Tightening  
Once this function is activated, a torque data point will be transmitted via  
the serial port for every degree increment of the tightening angle beyond  
snug.  
1. Connect the serial cable from the charger/data port to the serial port of  
the computer.  
2. Press the Reset button to turn on the wrench.  
3. Move the Mode Selection switch to Setup.  
4. With the Reset button held in, use the Parameter Adjustment Knob to  
select Custom Setup Mode #101. Note: A symbol "RX" appears on the  
left-hand side of the digital display and the main display shows "--.-".  
5. Rotate the mode select switch to the tightening mode for which the  
option is to be enabled. The display will show "OFF".  
34  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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 "---" with TX on.  
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.  
Data Out at End of Tightening  
Once this function is activated, the final tightening data will be transmitted  
to the PC via the serial port when Reset button is pressed at the completion  
of tightening.  
1. Connect the serial cable from the charger/data port to the serial port of  
the computer.  
2. Press the Reset button to power up the wrench.  
3. Move the Mode Selection switch to Setup.  
4. With the Reset button held in, use the Parameter Adjustment Knob to  
select Custom Setup Mode #100. Note: A symbol "TX" appears on the  
left hand side of the digital display and the main display shows "---".  
5. Rotate the mode Select switch to the tightening mode for which the  
option is to be enabled. The display should show "OFF".  
6. While holding the Reset button, press the Units key to select the  
option. The display will show "ON". Pressing the Joint key deselects it.  
7. Rotate the Mode Select switch back to the Setup position. The display  
should now show "---" with TX on.  
35  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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 a  
particular tightening mode. A parameter dump can be performed on any  
primary or custom tightening mode. It is recommended that once custom  
modes have been setup that a parameter dump be initiated so there is a  
permanent record of the wrench's settings. This is not necessary if the  
wrench was programmed via the InterLink software.  
NOTE  
Tightening parameters of torque that are downloaded and uploaded in  
units of Nm or lb.ft. are rounded to the nearest Nm or lb.ft. If higher  
resolution or greater precision is required in the parameters that are  
transmitted, use units of dNm or in.lb. Actual data points transmit with  
a resolution of 1/10th of the units.  
1. Connect the serial cable from the charger/data port to the serial port of  
the computer.  
2. Press the Reset button to power up the wrench.  
3. Move the Mode Selection switch to Setup.  
4. With the Reset button held in, use the Parameter Adjustment Knob to  
select Custom Setup Mode #109. Note that an "A" appears on the main  
display.  
5. Move the Mode Selection switch to Torque Control.  
36  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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:  
A-  
Angle Control  
J-  
b-  
Yield (joint) Control  
Dynamic Audit  
t-  
Torque Control  
1 through 20-  
Custom tightening modes 1-20  
7. Release the Reset button once the tightening mode has been selected.  
8. Press the Display button and the tightening parameters will be transmit-  
ted.  
9. Move the Mode Selection switch to Setup.  
10. Press the Reset button and adjust the Custom Setup Mode number  
below 20.  
End of Tightening Data Dump  
The Sensor I® Expert wrench stores end of tightening data for up to 1000  
tightenings for each tightening mode. This final tightening data (Torque,  
Angle and optional External Channel) can be uploaded to a PC by  
completing the following:  
1. Connect serial cable from the charger/data port to the serial port of the  
computer.  
2. Press the Reset button to power up the wrench.  
3. Move the Mode Selection switch to Setup.  
4. With the Reset button held in, use the Parameter Adjustment Knob to  
select Custom Setup Mode #109. Note that an "A" appears on the main  
display.  
37  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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:  
A-  
Angle Control  
J-  
b-  
Yield (joint) Control  
Dynamic Audit  
t-  
Torque Control  
1 through 20-  
Custom tightening modes 1-20  
7. Release the Reset button once the tightening mode has been selected.  
8. Press the Joint button and the tightening parameters, end of tightening  
data and statistics will be transmitted.  
9. Move the Mode Selection switch to Setup.  
10. Press in the Reset button and adjust the Custom Setup Mode # below  
20.  
Tightening Curve Storage  
Up to 10 tightening curves can be stored in the Sensor I® Expert Wrench for  
later retrieval via the serial port. Tightening curves can be stored provided  
the following conditions have not occurred: wrench has powered down, has  
been switched to another tightening mode or another tightening has  
commenced.  
The following procedure shows how to store a tightening curve.  
38  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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 Dump  
The following procedure shows how to initiate a curve data dump.  
1. Connect serial cable from the charger/data port to the serial port of the  
computer.  
2. Press the Reset to power up the wrench.  
3. Move the Mode Selection switch to Setup.  
4. With the Reset button held in, use the Parameter Adjustment Knob to  
select Custom setup Mode #111. NOTE: The main display shows an inte-  
ger from 0 to 9.  
5. Release the Reset button.  
6. Move the Mode Selection switch to Torque Control.  
7. Hold in the Reset button and rotate Parameter Adjustment Knob to  
select the curve buffer number to be transmitted.  
8. Press the Display key. The main display will show the number of sample  
points in the selected curve buffer to be transmitted. The "Tx" will flash  
while the serial data is being sent. When all the data, parameter and  
39  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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® Expert wrench may be used with a torque multiplier to  
increase its effective torque output up to a maximum multiplication factor  
of ten times (x 10) the capacity of the wrench.  
Enabling this custom mode, the wrench can be enabled to select four levels  
of multiplication for each primary tightening mode. These are as follows:  
x 1 (default value)  
x 5  
x 4  
1. Multiplication Factor =  
2. Multiplication Factor =  
3. Multiplication Factor =  
4. Multiplication Factor =  
x .01 (selectable upto x 10.00 maximum  
Setup of a Torque Multiplier  
A multiplier should be used when tightening in that mode if the "MUL"  
symbol is indicated. All torque parameters, (i.e., snug, target torque, and  
torque QC limits) are now scaled by the multiplier value. Similarly, any angle  
parameter, (i.e., target angle or angle QC limit) is divided by the multiplier  
value. It is a good idea to check that your parameters for the tightening  
mode are as desired by reviewing the QC limits with the Window key. The  
snug and target torque can also be checked by selecting the display of peak  
torque (Pk) and holding in the Reset button.  
40  
Download from Www.Somanuals.com. All Manuals Search And Download.  
     
Sensor I® Expert User Manual  
If while in a primary or custom tightening mode, the MUL symbol is on but  
the user is unsure of the multiplier value, it can be checked by following the  
procedure described in steps 2 and 3.  
To disable a multiplier in a primary mode, follow the step by step procedure  
to set the multiplier, but select 1.00 as the multiplier value.  
1. Turn Mode Select switch to Setup mode.  
2. Press and hold in the Reset button and rotate Parameter Adjustment  
Knob until Custom Setup Mode #104 is indicated in the top right hand  
corner of the display. Note the symbol "MUL" is indicated in the top cen-  
ter of the display and the main display shows "---".  
3. Rotate the Mode Select switch to the tightening mode for which the mul-  
tiplier is to be enabled. This display should show 1.00.  
4. While holding in the Reset button, press the Units key to step through  
the multiplier values above. Pressing the Joint key will reset the multi-  
plier value to 1.00.  
5. To adjust the programmable value, begin with the display at "10.00" and  
ensure that the Reset button is released. Rotate the Parameter Adjust-  
ment Knob until the display shows the desired value. Increments are in  
0.01 steps.  
6. Rotate the Mode Select switch back to the setup position. The display  
now should show "---" with "MUL" indicated.  
7. Holding in the Reset button, adjust the Custom Mode number below 20.  
41  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 in  
operation at any time.  
NOTE  
Entering the multiplier set mode for a particular tightening mode  
resets the cycle count and flushes the data buffer for that mode.  
Use of a Torque Multiplier  
The torque multiplier can be used when the capacity of the Expert wrench is  
below that required for the tightening application.  
Once setup as described in Setup of a Torque Multiplier, the wrench is then  
used in any of the primary modes as previously described. The joint  
selection setting should be set at “soft” joints for Yield Control Tightening.  
This is done by using the Joint key.  
NOTE  
Users should be aware of any torque reaction requirements or capacity  
restrictions on the torque multiplier being used.  
LEFT HAND FASTENERS  
Custom Setup Mode #103 allow the user to select tightening direction (CW  
or CCW).  
1. The wrench display shows "---".  
42  
Download from Www.Somanuals.com. All Manuals Search And Download.  
     
Sensor I® Expert User Manual  
2. Press the Reset to power up the wrench.  
3. Move the Mode Selection switch to Setup.  
4. With the Reset button held in, use the Parameter Adjustment Knob to  
select Custom setup Mode #103. NOTE: The main display shows an inte-  
ger from 0 to 9.  
5. Rotate the mode select switch to select the mode for which the tighten-  
ing direction is to be changed. The display will indicate "-rit" for CW  
tightenings or "-LEF" for CCW tightenings.  
6. Press and hold the Reset button. Depress the Units key to select CW  
tightenings ("rit") or the Joint key to select CCW tightenings ("-LEF").  
7. Rotate the mode select switch back to the Setup position. With the  
Reset button held in, use the Parameter Adjustment Knob to set the  
Custom Setup Mode number below 20.  
8. Release the Reset button. The tightening direction is set for the mode  
selected in step 5 above.  
NOTE  
After the first time a tightening is performed, changing the tightening  
direction will increase the amount of time required to find the optimum  
offset point. While the offset is being determined, the display will  
show a flashing "OFFSET". The wrench is ready for use when the  
flashing ceases.  
RESET ADJUSTMENT (EVS-models only)  
Some tightening applications do not require accurate angle measurement.  
Custom Setup Mode #214 allows the user to decrease the sensitivity of reset  
of the wrench at the expense of angle measurement accuracy. Angle  
accuracy will depend on the elapsed time during which the wrench is moved  
43  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Sensor I® Expert User Manual  
and stillness of the wrench when it is reset. The shorter the tightening  
period, the smaller the error will be. The more stable the wrench is at reset,  
the smaller the error. See the Application Guidelines at the front of this  
manual for additional guidelines.  
1. Press the Reset button to power up the wrench.  
2. Move the Mode Selection switch to Setup.  
3. With the Reset button held in, use the Parameter Adjustment Knob to  
select the Custom Setup Mode #214. The main display shows a number  
between 4 and 10.  
4. Release the Reset button and turn the Parameter Adjustment Knob to  
increase shown if the reset is to be made less sensitive. Turn the Param-  
eter Adjustment Knob to decrease the number shown if increased mea-  
surement accuracy is required making wrench reset more sensitive.  
5. Press and hold the Reset Button and rotate the Parameter Adjustment  
Knob counterclockwise until the Custom Setup Mode number is below  
20.  
6. Release the Reset button. The reset adjustment is now saved.  
7. Move the Mode Selection switch to one of the tightening modes and test  
the reset.  
44  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
8. Repeat until the angle accuracy and reset of the wrench are suitable to  
the application.  
NOTE  
The default reset adjustment value for models 125, 250 and 400 is 4.  
The default reset adjustment value for model 40 is 6. This has been set  
on the basis of a balance between wrench reset sensitivity and angle  
accuracy. Increasing the Reset Adjustment value will increase the  
probability of angle error as well as the maximum allowable angle error.  
The maximum allowable error will occur if the wrench is moving and  
allowed to reset and the minimum speed is used during the tightening.  
The table below shows the effect of increasing the Reset Adjustment  
value on maximum angle error.  
Models 125, 250, 400  
Model 40  
Reset Adjustment Value  
Additional Maximum Angle Error (% +/-) Additional Maximum Angle Error (% +/-)  
4
5
---  
-4%  
-2%  
---  
4%  
6
10%  
13%  
17%  
22%  
26%  
7
2%  
5%  
7%  
9%  
8
9
10  
For highest angle accuracy results, adjust the Reset  
Adjustment to the lowest setting possible, reset the wrench  
while the wrench is resting on a table or other stable surface  
and maintain a turning speed of between 20 and 80 degrees  
per second. This will achieve consistent errors within +/-2%.  
For applications where higher angle accuracy is required,  
models EA40, EA125, EA250 and EA400 are recommended.  
45  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
CHAPTER 4  
Battery Charging  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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: Tool  
Description).  
1. Remove the protective cap from the wrench handle (models 125, 250  
and 400 only).  
2. Insert the battery charger connector into charger/data port and plug the  
charger into the main AC electric supply. (All models).  
3. After the battery is charged, remove the charger connector. (All models.)  
4. Reinstall the protective end cap (models 125, 250 and 400 only).  
NOTE  
It takes approximately 14 hours to completely charge a fully discharged battery,  
resulting in approximately 5.5 hours of continuous use. Shorter charging times may  
result in reduced hours of continuous use.  
The battery should be charged as soon as possible after "LO BAT" appears on the  
display. The wrench can be operated in the "LO BAT" condition. When it reaches a  
level where it cannot operate with accuracy, "---" will show on the display and the  
wrench will not operate.  
It is recommended that batteries be fully charged for each work shift.  
51  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
CHAPTER 5  
Diagnostics  
& Troubleshooting  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
DIAGNOSTICS AND TROUBLESHOOTING  
Introduction  
This chapter provides troubleshooting information using the built-in  
diagnostic test modes. Tests can be performed by selecting Custom Setup  
Mode numbers between 200 and 212. When diagnostics are complete, rotate  
the Mode Selection switch to Setup and turn the parameter adjustment knob  
to select a Custom Setup Mode number below 20. Then turn the Mode  
Selection switch to a Primary Mode to reactivate the wrench Timeout  
feature. If any of the following tests are beyond values listed, go back to  
the primary mode and reset the wrench. Also make sure the wrench has not  
had any torque applied. If tests continue to be out of value limits, please  
contact an authorized Ingersoll-Rand service center shown in Appendix D.  
Torque Channel A/D Display (Custom Mode #200)  
1. The value displayed should be in the range 25-29 when no torque is  
applied to the wrench. Applying torque in the clockwise (CW) direction  
will cause this value to increase. Applying torque in the opposite (CCW)  
direction will cause the displayed value to decrease.  
2. If Custom Mode #103 has been set for CCW tightening ("-LEF"), the dis-  
play will indicate a value between 846 and 853. CW torque then  
decreases the number, and CCW increases it.  
Angle Reference Arm Test Mode (EA - Models, Custom Mode  
#201)  
If the wrench has been calibrated, the display value will be 15 5 at the low  
end (CW). Rotate the angle reference arm between full CW and full CCW. The  
change in value as the arm is moved should have no discontinuities. At the  
high end (CCW), the value will be in the range of 560 5. For Models 125,  
250 and 400, if the values are not correct, loosen the setscrew on the angle  
reference arm lever and rotate the lever relative to the shaft until the value  
49  
Download from Www.Somanuals.com. All Manuals Search And Download.  
         
Sensor I® Expert User Manual  
at the low end is correct-the high end should follow. Model 40 should be  
returned 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 Angle Test Mode (Custom Mode #207)  
1. If Custom Setup Mode #103 has been set for CW ("rit") tightenings, the  
display should indicate a number between 95 and 105. Moving the  
wrench in the CW direction should cause the number to increase. Moving  
the wrench in the CCW direction should cause the number to decrease.  
2. If custom Setup Mode #103 has been set for CCW tightenings ("-LEF"),  
the display should indicate a value between 795 and 805. Moving the  
wrench in the CW direction should cause the number to decrease.  
Membrane Keypad Test Mode (Custom Mode #208)  
Pressing any of the membrane keys should toggle an adjacent display  
legend on and off.  
Head Position Test (Models EVS125-, EVS250- and EVS400-, Cus-  
tom Mode #208)  
Index the head. Buzzer should sound when head is in either position off of  
the center.  
Buzzer and LED Test Mode (Custom Mode #209)  
The LED's should flash on and off. Pressing any of the membrane keys should  
cause the buzzer to sound.  
Display/Serial Link Test Mode (Custom Mode #210)  
1. All display segments should be lit except the "CYCLE" legend.  
50  
Download from Www.Somanuals.com. All Manuals Search And Download.  
           
Sensor I® Expert User Manual  
2. Connect the serial cable to the charger/data port. Insert the test con-  
nector into the end of the serial cable. The buzzer should sound to indi-  
cate the Serial Data feature is operating.  
Software Version Number Test (Custom Mode #211)  
The "SOFT" segment should light, and the main display should display the  
software version number.  
Time-out Adjustment (Custom Mode #212)  
This mode allows for adjustment of the wrench time-out feature. The default  
is 1 minute of non-use time, but this can be adjusted minute by minute.  
51  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
CHAPTER 6  
Calibration  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 and  
referencing external measuring equipment to compare the results. The  
Parameter Adjustment Knob on the wrench's front panel is used to match  
the wrench display readings to that of the reference equipment. Calibration  
values are stored in nonvolatile memory. Any previously entered setup  
parameters already stored in tightening modes are scaled to reflect the  
altered calibration. Performing calibration causes all final tightening data  
and stored curves to be flushed from memory. Calibration requires torque  
instrumentation certified to national standards at 0.1% of torque. Currently  
angle measurements are not traceable to a national standard.  
When calibration is complete, rotate the Mode Select switch back to the  
setup position. Press the Reset button and rotate the Parameter Adjustment  
Knob CCW until the Custom Setup Mode number is below 100. This is  
necessary to activate the Timeout feature. Update records or label with new  
calibration information and data.  
NOTE  
If calibration equipment is not available, it is recommended that the  
wrench be returned to an authorized Ingersoll-Rand service center for  
an annual recalibration.  
NOTE  
If the wrench has an angle reference arm (models EA-), calibrate angle  
before calibrating torque. If the wrench has an EZ angle non-contact  
angle sensor (models EVS-), calibrate torque before calibrating angle.  
53  
Download from Www.Somanuals.com. All Manuals Search And Download.  
       
Sensor I® Expert User Manual  
Torque Calibration  
Torque calibration procedure described is for the 125 lb.ft. model wrench.  
For other wrench models, use the following information for calibration:  
Model 40: 45-450 dNm Range, 170 dNm +/-1 dNm Calibration point  
Model 250: 115-330 Nm Range, 220 Nm +/-0.5 Nm Calibration point  
Model 400: 140-530 Nm Range, 330Nm +/-0.5 Nm Calibration point  
1. Make sure the wrench has been set to operate in the clockwise (“rit”)  
direction (see Chapter 3, Left Hand Fasteners, for additional instruc-  
tions).  
2. With no force on the wrench, press the Reset button while in Torque  
Control mode and hold until the yellow RUN light illuminates. Release  
Reset. Select Setup position with the Mode Select switch.  
3. Hold in the Reset button, select Custom Setup Mode #114, and turn the  
mode switch to the Torque Control position.  
4. Press the Window key while holding in the Reset button. "CAL" will dis-  
play on the screen.  
5. Release the Reset button and apply torque to the wrench equal to  
approximately 100Nm. Make sure the external torque meter is showing  
the dynamic torque rather than peak hold torque.  
6. Wait until the meter stabilizes.  
7. Turn the Parameter Adjustment Knob until the reading on the wrench  
matches within 0.1Nm of the reading on the meter.  
8. Apply torque to the wrench equal to approximately 165Nm and check  
that the torque readings match within the specified tolerance.  
54  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Sensor I® Expert User Manual  
9. Apply torque to the wrench equal to approximately 25Nm and check that  
the torque readings match within specified tolerance.  
10. After checking the low end and high end torque, use the Parameter  
Adjustment Knob to balance throughout the specified torque range (20  
Nm-170 Nm).  
11. Press the Display key to complete calibration in the CW direction. A  
scale factor and offset will display for approximately 3 seconds.  
12. Release the torque on the wrench. Set the Mode Select switch to the  
Setup position.  
13. Press the Reset button and adjust the Mode number below 20. This  
saves the CW calibration value.  
14. Be sure you are in Setup. With the Reset pressed, adjust the mode  
number to #103 and turn the Mode Selector switch to Torque Control.  
Select CCW ("-LEF") by pressing Reset and the Joint key simulta-  
neously.  
15. Set Mode Select switch to Setup, press the Reset button, and adjust  
the mode number below 20. Release Reset.  
16. Move the mode switch to Torque Control and wait for the wrench to  
adjust the offset.  
17. After the flashing OFFSET disappears (this may take several seconds),  
press and release the Reset button.  
18. Repeat steps 2 through 12 to calibrate the wrench in the CCW direction.  
19. Press in the Reset button and adjust the Mode number below 20. This  
will save the CCW calibration value.  
20. At this point, it is recommended that the scale factor and offset are  
checked and recorded with the calibration records. To check these, set  
55  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 return the  
wrench CW ("rit") direction. Select Setup, hold in Reset and adjust the  
Mode below 20.  
Angle Reference Arm Calibration (EA - models)  
1. Hold in the Reset button and select Custom setup Mode #119. The  
wrench should display "0.0o".  
2. Rotate the Mode Select switch to the Angle Control position.  
3. Press the Reset button and Window key simultaneously. "CAL" should  
appear on the wrench display. Calibration is now enabled.  
4. Release the Reset button and rotate the angle reference arm to the full  
CW position. Apply torque until SNUG light illuminates. Maintain torque,  
and rotate the angle reference arm from the full CW to the full CCW  
position. The displayed value will be 219 1. If not, use the wrench's  
parameter knob to bring the displayed value within specification.  
Release torque from the wrench.  
NOTE  
For model 40, use 234+/-1° for the full sweep angle calibration. For  
models 250 and 400, use 217 +/-1°.  
5. Press the Display key to exit calibration mode.  
6. Select Setup, hold in Reset and adjust the Mode below 20.  
EZ Angle Calibration (EVS - models)  
1. Before entering the calibration mode it is necessary to zero the wrench's  
angle sensor offset voltage. This is accomplished by setting the wrench  
56  
Download from Www.Somanuals.com. All Manuals Search And Download.  
       
Sensor I® Expert User Manual  
on a flat surface, selecting Angle Control and pressing the Reset button  
until the front panel's FAULT light is extinguished and the green RUN  
light appears. Then proceed as follows:  
NOTE  
If this calibration procedure takes longer than 10 minutes or the  
wrench ambient temperature changes more than 5° Celsius, step 1  
should be repeated.  
2. Hold in the Reset button and select Custom Setup Mode #120. The  
wrench display will read "0.0°".  
3. Rotate the Mode Select switch to the Dynamic Audit position.  
4. Press the Reset button and Window key simultaneously. A CAL legend  
should appear on the wrench display. Calibration is now enabled.  
Release Reset.  
5. Set the external monitoring equipment's snug torque to match the  
Torque Control Mode default snug torque of the wrench. The default  
snug values for all models are listed in the TOOL DESCRIPTION Technical  
Data table in Chapter 2.  
6. Apply more than the snug torque to the wrench and rotate it through a  
known angle at a rate of between 20 and 45 degrees/second (do NOT  
ratchet the wrench). The wrench's displayed angle value will be the  
same as that shown on the external monitoring equipment6 ( 2°). If  
not, turn the wrench's Parameter Adjustment Knob until they match.  
7. Press the Reset button, and repeat step 6 to verify calibration.  
8. Press the Display key to exit calibration.  
9. Select Setup, hold in Reset and adjust the Mode below 20 to save.  
57  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Appendix A  
Sample of  
Data Reports  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Appendix A  
These reports are accessed by the methods noted in "Data Storage and  
Retrieval". The information provided by the optional InterLink software will  
have a different format.  
Sample Reports  
Parameter Dump  
Tightening Configuration No  
Torque Units  
: Torque Control Mode  
: Nm  
Load Units  
: kN  
External channel  
Angle Transducer  
Multiplier  
: Load Cell  
: Non Contact Angle Measurement  
: 1.00  
: Off  
Serial data during tightening  
Serial data at end of tightening : Off  
Tightening Direction  
: Clockwise  
Control Strategy  
Target Value  
: Torque Control  
: 0020  
Snug Torque  
: 0010  
Low Torque Limit  
High Torque Limit  
Low Angle Limit  
High Angle Limit  
: 0020  
: 0020  
: 0000  
: 0000  
62  
Download from Www.Somanuals.com. All Manuals Search And Download.  
           
Sensor I® Expert User Manual  
End of Tightening Data Dump  
Tightening Configuration No  
Torque Units  
: Torque Control Mode  
: Nm  
Load Units  
: kN  
External channel  
: Load Cell  
Angle Transducer  
: Non Contact Angle Measurement  
Multiplier  
: 1.00  
: Off  
: Off  
Serial data during tightening  
Serial data at end of tightening  
Tightening Direction  
: Clockwise  
Control Strategy  
Target Value  
: Torque Control  
: 0020  
Snug Torque  
: 0010  
Low Torque Limit  
High Torque Limit  
Low Angle Limit  
High Angle Limit  
: 0015  
: 0025  
: 0020  
: 0040  
End of Tightening data :  
T,0020.4 A,0029 E,0000  
T,0020.7 A,0032 E.0000  
T,0020.9 A,0032 E,0000  
T,0020.1 A,0032 E,0000  
T,0020.9 A,0035 E,0000  
63  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Sensor I® Expert User Manual  
End of Tightening Data Dump (cont.)  
TORQUE  
Mean  
Sigma  
Cp  
: 0020.6  
: 000.34  
: 004.60  
: 004.02  
Cpk  
ANGLE  
Mean  
Sigma  
Cp  
: 0031.9  
: 001.87  
: 001.84  
: 001.50  
Cpk  
EXTERNAL  
Mean  
Sigma  
Cp  
: 0000.1  
: 000000  
: N/A  
Cpk  
: N/A  
64  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Tightening Curve Data Dump  
Torque Units: Nm  
Load Units: kN  
Multiplier: 1.00  
Tightening Direction: Clockwise  
Control Strategy: Angle Control  
Target Value: 0030  
Snug Torque: 0020  
Low Torque Limit: 0020  
High Torque Limit: 0020  
Low Angle Limit: 0030  
High Angle Limit: 0030  
T,0021 A,0001 E,0000  
T,0022 A,0002 E,0000  
T,0023 A,0003 E,0000  
T,0024 A,0004 E,0000  
T,0025 A,0005 E,0000  
T,0026 A,0007 E,0000  
T,0027 A,0008 E,0000  
T,0028 A,0009 E,0000  
T,0029 A,0010 E,0000  
T,0030 A,0011 E,0000  
T,0031 A,0012 E,0000  
T,0032 A,0014 E,0000  
T,0034 A,0015 E,0000  
T,0035 A,0016 E,0000  
T,0035 A,0017 E,0000  
T,0036 A,0018 E,0000  
T,0038 A,0019 E,0000  
T,0039 A,0021 E,0000  
65  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Sensor I® Expert User Manual  
Data Out at End of 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,0030.5,T,A,0017,-,E,0000,-  
T,0020.2,-,A,0000,A,E,0000,-  
T,0013.8,t,A,0001,a,E,0000,-  
T,0020.5,-,A,0000,a,E,0000,-  
T,0017.8,t,A,0000,a,E,0000,-  
T,0013.8,t,A,0001,a,E,0000,-  
Data Out During Tightening  
T,0020.1,A,0001,E,0000  
T,0023.4,A,0002,E,0000  
T,0027.4,A,0003,E,0000  
T,0029.1,A,0004,E,0000  
T,0033.2,A,0005,E,0000  
T,0037.1,A,0007,E,0000  
T,0039.8,A,0008,E,0000  
T,0041.4,A,0009,E,0000  
T,0044.0,A,0010,E,0000  
T,0047.5,A,0011,E,0000  
66  
Download from Www.Somanuals.com. All Manuals Search And Download.  
       
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Appendix B  
List of  
Setup Modes  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Appendix B  
Custom Modes  
Custom Modes 1 through 20 are the Custom Tightening modes. They are  
memory locations used to store tightening strategies for later recall.  
Custom Modes 100 through 120 are the Custom Setup Modes and are used  
for both advanced option selection performing calibration. The Custom  
Setup Modes are:  
Custom Mode  
100  
Function  
Serial data out at end of tightening.  
Serial data out during tightening.  
Not used.  
101  
102  
103  
Tightening direction.  
104  
105  
Torque multiplier enable/disable.  
Not used.  
106  
Not used.  
107  
Torque Units selection.  
108  
Not used.  
109  
110  
111  
112  
Tightening mode parameter upload via serial port.  
Serial baud rate selection.  
Stored tightening curve upload via serial port.  
Not used.  
113  
114  
Temperature display/calibration.  
Torque calibration.  
115  
Not used.  
116  
117  
118  
External channel setup/calibration for load cell.  
External channel setup/calibration for torque cell  
Not used.  
119  
120  
Angle Reference Arm setup/calibration.  
EZ Angle sensor setup/calibration.  
67  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Sensor I® Expert User Manual  
Custom Modes 200 through 220 are the Custom Diagnostic modes and are  
used for wrench testing. The Custom Diagnostic modes are:  
Custom Mode  
200  
Function  
Display Torque channel A/D converter value/4  
Display angle reference arm A/D converter value/4  
Display external channel A/D converter value/4  
Display Torque Offset D/A channel A/D converter value/4  
Display Battery channel A/D converter vale/4  
Display Temperature channel A/D converter value/4  
Display EZ-Angle Offset D/A channel A/D converter value/4  
Display EZ-Angle channel A/D converter value/4  
Membrane keypad test/Ratchet head position test  
Buzzer test/LED test  
201  
202  
203  
204  
205  
206  
207  
208  
209  
210  
LCD test/Serial communication test  
211  
Software version number  
212  
Time-out adjustment  
213  
No function implemented  
214  
Reset Adjustment  
215-220  
No function implemented.  
68  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Appendix C  
Spare Parts List  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Appendix C  
Spare Parts Listing - MODEL 40  
Description  
Part #  
CPN  
*Wrench Assembly, EZ angle  
*Wrench Assembly, Auditor  
Ratchet Head Replacement Kit  
Ratchet Head Assembly (EA-)  
Ratchet Head Assembly (EVS-)  
Plastic Overmold Sleeve Grip  
Reset Switch Assembly  
Reset Switch Button Cover  
Tool Cable Assembly (EA- MODELS)  
Tool Cable Assembly (EVS- MODELS)  
Angle Sensor PCB (EVS- MODELS)  
Potentiometer cap (EZ- MODELS)  
Handle Front cap  
EZS40A-HHT  
EA40A-HHT  
E40HDKIT  
EA40A-HD  
EVS40A-HD  
TRH-40-135  
E40A-RST-SW  
E40-BTTN-CVR  
EA40A-CBL  
EVS40A-CBL  
E40A-VS  
EA40-CAP  
E40FRCP  
E40RRCP  
40HWLBL  
40HWLBL-F  
40HWLBL-S  
40HWLBL-G  
40HWLBL-I  
40HLGLBL  
40HLGLBL-F  
40HLGLBL-S  
40HLGLBL-G  
89934541  
89930952  
89935159  
89930978  
89934442  
04683264  
89931000  
04706370  
89930960  
89934533  
89931216  
89931018  
89933618  
89931208  
89931471  
89935522  
89935530  
89935548  
89935555  
89931455  
89935563  
89935571  
89935589  
Handle Back cap  
Handle decal - warning - English  
Handle decal - warning - French  
Handle decal - warning - Spanish  
Handle decal - warning - German  
Handle decal - warning - Italian  
Handle decal - logo - English  
Handle decal - logo - French  
Handle decal - logo - Spanish  
Handle decal - logo - German  
*NOTE: This component must be recalibrated with its mating unit.  
69  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Sensor I® Expert User Manual  
Spare Parts Listing - MODEL 40 (cont.)  
Description  
Part #  
CPN  
Handle decal - logo - Italian  
PCB Expert 40 Display  
PCB Expert 40 Control  
Angle Ref. Arm (EA- models only)  
*Control Unit (Both versions)  
Carrying Case  
Shoulder Strap  
Mode Selector Knob  
Parameter Adjustment Knob  
Tool Receptacle/Wire Assembly  
Recharge Connector and Ribbon Cable Assembly E40A-RIBBON  
40HLGLBL-I  
T03710-69  
E40-PCB-MAIN 04705760  
T14471-89  
EXP40A-CU  
EXP40-CASE  
E40-STRP  
T14350-01  
T14337-01  
E40A-RCPT  
89935597  
04539516  
04315396  
04706933  
10327054  
89931760  
04313482  
04313474  
04705653  
04705661  
04313078  
04313185  
12 Pin Recharge Connector  
2 Pin connector  
T25197-01  
T25295-01  
Battery Harness  
E40A-BAT-TERM 04705604  
Battery Access Panel  
Pivot Indexer Hardware Kit  
Belt clip assembly  
EXP40-BCAC  
E40PVKIT  
E40A-BELT-CLIP 04705620  
10324598  
89935167  
Power switch cap plug (Black)  
NiMH Battery -- 7.2 V 300 mA  
Charger 110V  
Charger 220V  
British 3-Conductor 2.5M Right Angle Plug  
Euro plug 2.5M  
T28088-01  
T95313-01  
04313557  
04537700  
04538955  
04538963  
89934269  
89934277  
04544078  
T95301-110T  
T95301-220T  
95301-CORDB  
95301-CORDE  
T66104-01  
Serial Cable Assembly  
*NOTE: This component must be recalibrated with its mating unit.  
70  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Spare Parts Listing - MODEL 40 (cont.)  
Description  
Part #  
CPN  
Rear Control Unit Decal - English  
Rear Control Unit Decal - French  
Rear Control Unit Decal - German  
Rear Control Unit Decal - Spanish  
Rear Control Unit Decal - Italian  
Front Control Unit Decal - English  
Front Control Unit Decal - French  
Front Control Unit Decal - German  
Front Control Unit Decal - Spanish  
Front Control Unit Decal - Italian  
Front Panel - English (EVS- models)  
Front Panel - German (EVS- models)  
Front Panel - French (EVS- models)  
Front Panel - Spanish (EVS- models)  
Front Panel - Italian (EVS- models)  
Front Panel - English (EA- models)  
Front Panel - German (EA- models)  
Front Panel - French (EA- models)  
Front Panel - Spanish (EA- models)  
Front Panel - Italian (EA- models)  
E40-PR-LABEL  
E40-PRLBL-F  
E40-PRLBL-G  
E40-PRLBL-S  
E40-PRLBL-I  
04705786  
89935449  
89935456  
89935464  
89935472  
E40-OPER-LABEL 04705752  
E40-OPLBL-F  
E40-OPLBL-G  
E40-OPLBL-S  
E40-OPLBL-I  
T21475-69AEE  
T21475-69AEG  
T21475-69AEF  
T21475-69AES  
T21475-69AEI  
T21475-AEE  
T21475-AEG  
T21475-AEF  
89935480  
89935498  
89935506  
89935514  
04539763  
04544110  
04540415  
04625992  
04540423  
04623200  
04629234  
04629218  
04629242  
04629259  
T21475-AES  
T21475-AEI  
71  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Spare Parts Listing - MODEL 125  
Description  
Part #  
CPN  
PCB Expert Display  
PCB Expert Control  
T03710-69  
T03711-69  
T14154-89  
T53125-89  
T66104-01  
T14372-79  
T14327-88  
T14327-87  
T19979-125E  
T19979-125F  
T19979-125G  
T19979-125S  
T19979-125I  
T14338-01  
T14350-01  
T14335-01  
T51122-02  
T14330-EX  
T28088-01  
T28653-01  
T95313-01  
T95313-99  
T95301-110T  
T95301-220T  
95301-CORDB  
04539516  
04539524  
04312732  
04313672  
04544078  
04313391  
04539029  
04539367  
04539748  
04540431  
04544094  
04625984  
04540449  
04313540  
04313482  
04313037  
04313052  
04539912  
04313557  
04313128  
04537700  
04537718  
04538955  
04538963  
89934269  
Angle Ref Arm (EA- models only)  
Carrying Case with Inserts  
Serial Cable Assembly  
Ratchet Head Replacement Kit  
Ratchet Head Assembly (EA-)  
Ratchet Head Assembly (EVS-)  
Rear Panel - English  
Rear Panel - French  
Rear Panel - German  
Rear Panel - Spanish  
Rear Panel - Italian  
Spring Rotation Mech  
Mode Selector Knob  
Plastic Molded Hand Grip  
Reset/Power Switch  
Rear Panel Gasket  
Cap Plugs (Back)  
Circlip  
NiMH Battery -- 7.2V 300 mA  
Battery Replacement Kit  
Charger 110V  
Charger 220V  
British 3-Conductor 2.5M Right Angle Plug  
72  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Spare Parts Listing - MODEL 125 (cont.)  
Description  
Part #  
CPN  
Euro plug 2.5M  
Head Indexing Set Screw  
Insulating Spacer  
Ribbon Cable, 26 AWG  
Ribbon Cable Converter, 10 pin (2x5)  
Connector Mounting Plate  
Connector 12 pin  
95301-CORDE  
SETSCR-10-24-395  
T14334-01  
T66103-01  
T25728-01  
T14333-01  
T25197-01  
T25295-01  
T21475-69AEE  
T21475-69AEG  
T21475-69AEF  
T21475-69AES  
T21475-69AEI  
T21475-AEE  
T21475-AEG  
T21475-AEF  
T21475-AES  
T21475-AEI  
89934277  
04630059  
04313086  
04540050  
04539656  
04313110  
04313078  
04313185  
04539763  
04544110  
04540415  
04625992  
04540423  
04629200  
04629234  
04629218  
04629242  
04629259  
Connector 2 pin  
Front Panel - English (EVS- models)  
Front Panel - German (EVS- models)  
Front Panel - French (EVS- models)  
Front Panel - Spanish (EVS- models)  
Front Panel - Italian (EVS- models)  
Front Panel - English (EA- models)  
Front Panel - German (EA - models)  
Front Panel - French (EA - models)  
Front Panel - Spanish (EA- models)  
Front Panel - Italian (EA- models)  
73  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Spare Parts Listing - MODEL 250  
Description  
Part #  
CPN  
PCB Expert Display  
PCB Expert Control  
Angle Ref Arm (EA-models only)  
Carrying Case  
Serial Cable Assembly  
Foam Inserts  
Ratchet Head Replacement  
Ratchet Head Assembly (EA-)  
Ratchet Head Assembly (EVS-)  
Rear Panel - English  
Rear Panel - French  
Rear Panel - German  
Rear Panel - Spanish  
Rear Panel - Italian  
Spring Rotation Mech  
Mode Selector Knob  
Plastic Molded Hand Grip  
Reset/Power Switch  
Rear Panel Gasket  
T03710-69  
T03711-69  
T14154-88  
T14418-01  
T66104-01  
T14415-01  
T14381-01  
T14393-89E  
T14393-89EV  
T19979-250E  
T19979-250F  
T19979-250G  
T19979-250S  
T19979-250I  
T14395-01  
T14350-01  
T14335-01  
T51122-02  
T14330-EX  
T28088-01  
T28653-01  
T95313-01  
T95313-99  
T95301-110T  
T95301-220T  
04539516  
04539524  
04314555  
04314522  
04544078  
04314688  
04314365  
04628145  
04628350  
04628988  
04628996  
04629002  
04629010  
04629028  
04314498  
04313482  
04313037  
04313052  
04539912  
04313557  
04313128  
04537700  
04537718  
04538955  
04538963  
Cap Plugs (Back)  
Circlip  
NiMH Battery -- 7.2V 300mA  
Battery Replacement Kit  
Charger 110V  
Charger 220V  
74  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Spare Parts Listing - MODEL 250 (cont.)  
Description  
Part #  
CPN  
British 3-Conductor 2.5M Right Angle Plug  
Euro plug 2.5M  
95301-CORDB  
95301-CORDE  
89934269  
89934277  
Head Indexing Set Screw  
SETSCR-10-24-395 04630059  
Insulating Spacer  
Ribbon Cable, 26 AWG  
Ribbon Cable Convertor, 10 pin (2x5)  
Connector Mounting Plate  
Connector 12 pin  
T14334-01  
T66103-01  
T25728-01  
T14333-01  
T25197-01  
T25295-01  
T21475-69AEE  
T21475-69AEG  
T21475-69AEF  
T21475-69AES  
T21475-69AEI  
T21475-AEE  
T21475-AEG  
T21475-AEF  
T21475-AES  
T21475-AEI  
04313086  
04540050  
04539656  
04313110  
04313078  
04313185  
04539763  
04544110  
04540415  
04625992  
04540423  
04629200  
04629234  
04629218  
04629242  
04629259  
Connector 2 pin  
Front Panel - English (EVS- models)  
Front Panel - German (EVS- models)  
Front Panel - French (EVS- models)  
Front Panel - Spanish (EVS- models)  
Front Panel - Italian (EVS- models)  
Front Panel - English (EA- models)  
Front Panel - German (EA- models)  
Front Panel - French (EA- models)  
Front Panel - Spanish (EA- models)  
Front Panel - Italian (EA- models)  
75  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Spare Parts Listing - MODEL 400  
Description  
Part #  
CPN  
PCB Expert Display  
PCB Expert Control  
Angle Ref Arm (EA- models only)  
Carrying Case  
Serial Cable Assembly  
Foam Inserts  
Rachet Head Replacement  
Rachet Head Assembly (EA-)  
Rachet Head Assembly (EVS-)  
Rear Panel - English  
Rear Panel - French  
Rear Panel - German  
Rear Panel - Spanish  
Rear Panel - Italian  
Spring Rotation Mech  
Mode Selector Knob  
Plastic Molded Hand Grip  
Reset/Power Switch  
Rear Panel Gasket  
T03710-69  
T03711-69  
T14154-88  
T14418-01  
T66104-01  
T14415-01  
T14381-01  
T14394-89E  
T14394-89EV  
T19979-400E  
T19979-400F  
T19979-400G  
T19979-400S  
T19979-400I  
T14395-01  
T14350-01  
T14335-01  
T51122-02  
T14330-EX  
T28088-01  
T28653-01  
T95313-01  
T95313-99  
T95301-110T  
T95301-220T  
04539516  
04539524  
04314555  
04314522  
04544078  
04314688  
04314365  
04628228  
04628368  
04629036  
04629044  
04629986  
04629051  
04629069  
04314498  
04313482  
04313037  
04313052  
04539912  
04313557  
04313128  
04537700  
04537718  
04538955  
04538963  
Cap Plugs (Back)  
Circlip  
NiMH Battery -- 7.2V 300mA  
Battery Replacement Kit  
Charger 110V  
Charger 220V  
76  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Spare Parts Listing - MODEL 400 (cont.)  
Description  
Part #  
CPN  
British 3-Conductor 2.5M Right Angle Plug  
Euro plug 2.5M  
95301-CORDB  
95301-CORDE  
89934269  
89934277  
Head Indexing Set Screw  
SETSCR-10-24-395 04630059  
Insulating Spacer  
Ribbon Cable, 26 AWG  
Ribbon Cable Converter, 10 pin (2x5)  
Connector Mounting Plate  
Connector 12 pin  
T14334-01  
T66103-01  
T25728-01  
T14333-01  
T25197-01  
T25295-01  
T21475-69AEE  
T21475-69AEG  
T21475-69AEF  
T21475-69AES  
T21475-69AEI  
T21475-AEE  
T21475-AEG  
T21475-AEF  
T21475-AES  
T21475-AEI  
04313086  
04540050  
04539656  
04313110  
04313078  
04313185  
04539763  
04544110  
04540415  
04625992  
04540423  
04629200  
04629234  
04629218  
04629242  
04629259  
Connector 2 pin  
Front Panel - English (EVS- models)  
Front Panel - German (EVS- models)  
Front Panel - French (EVS- models)  
Front Panel - Spanish (EVS- models)  
Front Panel - Italian (EVS- models)  
Front Panel - English (EA- models)  
Front Panel - German (EA- models)  
Front Panel - French (EA- models)  
Front Panel - Spanish (EA- models)  
Front Panel - Italian (EA- models)  
77  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Appendix D  
Service Centers  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
Appendix D  
Service Centers  
USA  
Ingersoll-Rand Company  
Automation and Integration Center  
1872 Enterprise Dr.  
Rochester Hills, MI 48309  
Tel: +1 (248) 293-5700  
Fax: +1 (248) 293-5800  
EUROPE  
Ingersoll-Rand Company  
Fastener Tightening System Division  
Swan Lane, Hindley Green, Nr.Wigan  
Lancashire WN2 4EZ  
United Kingdom  
Tel: (44) 01942 502 661  
Fax: (44) 01942 502 660  
77  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Sensor I® Expert User Manual  
DECLARATION OF CONFORMITY  
Ingersoll - Rand, Co.  
We  
(supplier's name)  
Swan Lane, Hindley Green, Wigan WN2 4EZ, U.K.  
(address)  
declare under our sole responsibility that the product,  
Sensor I® Expert Electronic Wrenches  
to which this declaration relates, is in compliance with the provisions of  
98/37/EC, 73/23/EEC, 93/68/EEC, 89/336/EEC and 92/31/EEC  
Directives.  
EN792-1, EN26789, EN60204,  
EN60950, EN50081, EN50082  
By using the following Principle Standards:  
EX-0000-EX-4999  
Serial No. Range  
B. Seager  
James Wardlaw  
Name and signature of authorised persons  
Name and signature of authorised persons  
November, 2000  
November, 2000  
Date  
Date  
78  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sensor I® Expert User Manual  
NOTICE  
SAVE THESE INSTRUCTIONS. DO NOT DESTORY  
When the life of the tool has expired, it is recommended that the tool be disassembled,  
degreased and parts be separated by material so that they can be recycled.  
79  
Download from Www.Somanuals.com. All Manuals Search And Download.  
www.irtools.com  
© 2004 Ingersoll-Rand Company  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Infinity Speaker 505CS User Manual
Jenn Air Cooktop CVGX2423 User Manual
Jensen Car Stereo System CDH4110 User Manual
JVC DVR LPT0923 001B User Manual
Kenmore Dishwasher 6651378 User Manual
Kenwood Car Stereo System DDX8029 User Manual
Kettler Bicycle 08847 400 User Manual
Keys Fitness Fitness Equipment ST DB4 User Manual
KitchenAid Clothes Dryer KEYS677E User Manual
Klipsch Speaker ksw 08 new User Manual