Perry NEW Torque Tool OMM TX00100-280

TABLE OF CONTENTS
DESCRIPTION
SECTION
Operation and Maintenance Manual
(TX0100-950-03)
1
Torque Tool Subsea Display User’s O&M Manual
(TL0010-0000-00)(PSS-4200)
2
TX Class 1-4 Torque Tool Assembly Drawing
(TX00100-280-00)
3
Surface Verification Unit User’s Guide
(TX00105-100-00)(PSS-4050)
4
Assembly Drawings
5
Description
Drawing Number
GENERAL ASSEMBLY, TX CLASS 4 TORQUE TOOL
TX00100-300-00
ASSEMBLY, DRIVE MODULE CLASS 1 - 4 TORQUE TOOL
TX00100-220-00
ASSEMBLY, CLASS 1-4 TORQUE TOOL CASE
TX00100-250-00
TX Class 1-4 TORQUE TOOL SPARES KIT
TX00100-270-00
WIRING SCHEDUAL FOR INDUCTIVE SENSORS
A019-959-005
TEST SEPCIFICATION, CLASS 1-4 TORQUE TOOL
A019-959-004
Factory Acceptance Test Documents
6
PSS-4200 Subsea Display
Operations Manual for Standalone
Displays and Subsea FL-4 Units
And accompanying software
August 13, 2009
Manufacured exclusively for Perry Slingsby Systems, Inc. by
ADVANCED WITNESS SERIES, INC.
CONTENTS
1
CONTENTS
CONTENTS.................................................... 1
INTRODUCTION ............................................ 2
Description ..........................................................2
System Specifications..........................................2
Product Overview and Setup .......................... 3
Display Overview ..................................................3
Verification Unit ...................................................5
Torque tool ..........................................................5
OPERATION .................................................. 6
Display Operation ................................................6
Software Operation ..............................................7
Connecting and Waking Up a Unit:....................7
Tester Settings Menu:.......................................9
Charging the Batteries ...................................... 12
Diagrams and Pinouts................................. 12
Wiring Diagrams ............................................... 12
Seacon ROV Cable Pinout ................................. 14
Subsea Verification Parts List ............................ 15
Recommended Spares: ................................. 15
Subsea Verification Parts Diagram .................... 16
PSS-4200 Parts List.......................................... 17
Recommended Spares: ................................. 17
PSS-4200 Parts Diagram ................................. 18
SERVICE AND WARRANTY ............................ 19
PSS-4200 Guide
INTRODUCTION 2
INTRODUCTION
DESCRIPTION
The PSS-4200 Subsea Display is designed to indicate torque values for Subsea
verification units, and indicate torque and turns values for torque tools. It features a
custom made high brightness LED display, integrated rechargeable battery, light
sensor, 4000m depth rating, and a rugged hard anodized aluminum housing. It can
be configured via firmware to operate with a verification unit to indicate torque, or
with a torque tool to indicate torque and turns. The display has inputs to read
‘Intellect” or smart transducers which allows interchanging displays without recalibration of the system.
SYSTEM SPECIFICATIONS
Dimensions
Width: 3.125", Height: 3.75", Depth: 3.23", Weight:2.5
Lbs.
Power Requirements
Internal Battery or 6-36 volt DC input, 3 watt minimum
(reverse polarity protected)
Operating Temperature Range
Data Communications
0˚C to 60˚C
RS-232 (default) or RS-485 (jumper and wiring selectable
on board)
Accuracy
Certified 1% of Indicated Reading for 100-2000 Ft-Lbs for
Verification
Units.
Usable
below
100
Ft-Lbs
with
Approximate accuracy of 2% of indicated reading.
Battery Life
15 hours with display continuously on at 50% brightness
100 hours in sleep mode (display off, maintains serial link,
wakes on command)
Display
4 active digit torque values
3-digit turns display (for tools)
Units
Eight (8) available engineering units: Oz.in., Lb.in., Lb.ft.,
Nm, cNm, KgfCm, gfCm, Kgfm.
Filter
Inputs
Selectable power tool filtering speeds: 125Hz or 250Hz
Quadrature shaft position sensor. +/- 99.9 turns (when
configured for use on torque tools)
Analog - strain gauge inputs. (all configurations)
PSS-4200 Guide
OPERATION 3
PRODUCT OVERVIEW AND SETUP
All units come assembled and wired for immediate service, and only need to
have the appropriate cables plugged in to begin operation. It is also
recommended that the units be fully charged upon receipt, as the batteries
may not be fully charged.
DISPLAY OVERVIEW
Figure 1, Display Detail
The display body includes two connectors for readings, power, and data. The
female connector (A) has two configurations, depending on the unit: Torque
and Turns signals for the Tools version, and Torque and ‘Intellect’ data for
Verification units. The male connector (B) provides power and data
connections for powering, charging, or communicating externally with the
unit. Item (C) is the shorted dummy plug used to enable the internal battery.
The kits also include a non-shorted dummy plug (no red band on the tail)
PSS-4200 Guide
OPERATION 4
which is used to protect the connector on dives where the display will not be
used. DO NOT DIVE below 600 meters without something (a cable or a
dummy plug) plugged into the connectors, as they are only rated for 1000
PSI unmated.
WARNING: The connectors do NOT rotate! They can be adjusted by
disassembling the display but when assembled they can not be turned.
Attempting to turn them may loosen the nut and cause the pressure seal to
fail!
The front of the unit features the
display
matrix
(D)
and
light
sensor (F). The display bezel also
features a label (E) that indicates
if
the
display
was
shipped
configured as a torque tool display
or a verification unit display.
The display also features several
mounting
holes
(figure
2)
for
versatility. Dimensioned drawings
can be found at the end of this
manual.
Figure 2, Mounting Details: 3/8-16 thread
Both units include a special charger and serial breakout box that allows the
display to be charged or communicated with topside with the same cable, and
even at the same time. When the charger cable is plugged in, the internal
battery is shorted to power and the display will be powered on. If external
power is plugged into the charger, it will begin charging the internal battery
and the display will run off of the external power. When the display is
operating with the charger/serial box connected and there is no external
PSS-4200 Guide
OPERATION 5
power, it is slightly less efficient than operating off of the shorting plug
directly, so external power is advised when using the charger/serial box.
The Charger/Serial Breakout Box also features a simple 2.5” x 1.375” by ¼”20 screw mounting pattern for custom installations. Power requirements are
regulated 15v DC, center positive. All units are shipped with a factory
supplied power supply, P.N. DCPA-110.
Figure 3, Charger/ Serial Breakout Box
VERIFICATION UNIT
The verification unit comes with everything bolted up and connected except
for the torque transducer cable and the power jumper or charger cable. To
make the unit ready for operation, simply plug the 12” transducer cable into
the female connectors on the bucket and display, and install the power
jumper or charger/serial breakout cable to the male connector on the display.
TORQUE TOOL
The display is sold pre-configured for use with Perry Slingsby Torque tools.
When sold in this configuration it comes with a special cable that plugs
directly into the Burton connector on the tool. Bolt up the display to the tool
as desired, and then plug in the Burton cable to the tool and to the female
plug on the display. The display can then be powered on using the supplied
shorting plug, the charger/serial breakout box, or the supplied 5 meter pigtail
PSS-4200 Guide
OPERATION 6
breakout cable with appropriate ROV wiring.
The display unit must be
calibrated to the Torque Tool at PSS, Inc. facility.
OPERATION
DISPLAY OPERATION
Basic Function:
Powering on and off
To turn on the display, power first needs to be applied. This can either be
done by applying 6-36 volts to pin 2 (Vin) of the display’s male connector
using the supplied cable, or by shorting the positive battery output of the
male connector (pin 1, Batt) to pin 2 using either the supplied cable or the
supplied shorting plug.
To save battery life, the display is designed to turn on only if enough light is
shining on it. Because of this, it may not turn on after power is applied if the
surroundings are not bright enough.
Once power is applied or pins 1 and 2 are shorted, there are a few ways the
display can be woken up. Under normal operation, the unit just needs to be
exposed to a bright light to wake up. The unit can be set to turn on when
even a dim light is shined on it, but if the thresholds are set too high, even a
bright light may not wake up the display. If the light threshold settings are
not set properly or a bright enough light is not available, the unit may be
forced on using the included software and an RS-232 or RS-485 serial
connection. Once the display software establishes a connection to the display,
the unit can be forced on by setting the Power mode to “ON” using the
dropdown menu on the main software screen, or by lowering the Light
Threshold under “Settings” until the unit wakes up. If the light threshold is
set to 0, the unit will never go to sleep (unless forced to “OFF” using the
Mode dropdown menu mentioned above). For more information on light
thresholds see the software operation section.
If this all sounds complicated, don’t worry – under normal operation the
display just needs to have the shorted dummy plug installed and a light
shined on it to be powered on and awake.
PSS-4200 Guide
OPERATION 7
SOFTWARE OPERATION
Connecting and Waking Up a Unit:
The display comes with software to view
the readings through a serial connection.
At startup, it will try to open a link with
any connected hardware. If it does not
find any connected hardware, it will show
a blank window, as shown in Figure 4.
Figure 4, Nothing Connected.
If the software does not automatically
establish a connection with a connected
unit, click the setup button as shown in
Figure 5 and choose the correct serial
port. Once the right port is chosen, click
the “Connect” button on the main screen.
The software should now connect and a
reading should show up in the main
window, as shown in Figure 5.
Figure 5, COM Port Setup.
PSS-4200 Guide
OPERATION 8
Once connected, a reading should show
up in the main window. Torque tools will
show torque and turns while Verification
Units will only show torque. The window
may need to be resized to show the turns
if it is cut off.
Figure 6, Torque Tool Connected.
If the unit is powered but not awake,
“Sleep” will show in the main screen. To
force the unit awake, click on the “Power”
dropdown menu and select “On”. This
setting is only used for PC communication
and
will
be
returned
to
“Auto”
if
disconnected from the PC. To force the
unit on always, adjust the light settings as
described under “Software Settings”.
Figure 7, Power Modes.
PSS-4200 Guide
OPERATION 9
Once the unit is powered on and awake,
set
the
mode
depending
on
your
operation requirements.
Track
Displays torque as it is being applied to
the transducer, with no peak capturing.
Track
mode
is
used
primarily
for
verifying calibration of the unit.
Peak
Displays
torque
and
retains
exerted
by
the
the
maximum
tool.
Clear
readings by hitting the “Zero” button
onscreen or by setting Autoclear in the
“Tester Settings” Menu.
1st Peak
This mode is use primarily with breakaway and click-type torque wrenches.
Detects the “first peak” of torque exerted by the wrench, capturing the initial
torque as occurs when the torque wrench cams over without capturing the
second peak that is usually exerted by the user. Again, clear readings by
hitting the “Zero” button onscreen or by setting Autoclear in the “Tester
Settings” Menu.
Tester Settings Menu:
After adjusting the peak settings, the
display can be further configured by
clicking the “Tester Settings” Menu.
PSS-4200 Guide
OPERATION 10
There
are
ten
different
settings in the settings menu:
Frequency:
(125 Hz, 250 Hz)
The frequency setting is used
to
filter
frequency
out
any
noise.
high
Generally
Subsea torque tools operate
at a much lower frequency
and this setting can be left at
125 Hz.
Autoclear:
(Off, 0-9 Seconds)
In peak or 1st peak mode, peaks values are displayed until they are cleared
by Autoclear or the user. Choose 0-9 seconds, or “Off” to disable it.
Low Limit:
(0.000-Full Scale)
The low limit specifies the minimum value required to consider a reading
acceptable. Peaks captured below this value will indicate “LOW” next to the
peak indicator in the bottom left of the main window. Set as zero to disable,
or any value up to full scale. This setting is an absolute value – readings
taken in the negative direction will be affected too, so if, for example, the low
limit is set at 500, readings beyond 500 Ft-Lbs in either direction will not be
considered low. The low limit and high limit settings work together to provide
a simple visual indicator to determine if a reading is acceptable. For example,
if a job requires readings of 800 Ft-Lb +/-20 Ft-Lb, set the Low limit at 780
Ft-Lb and the high limit at 820 Ft-Lb. Readings captured out of this range will
be labeled “HIGH” or “LOW” as appropriate.
High Limit:
(0.000-Full Scale)
The high limit specifies the maximum value required to consider a reading
acceptable. Peaks captured below this value will indicate “HIGH” next to the
peak indicator in the bottom left of the main window. Set as zero to disable,
or any value up to full scale. This setting is an absolute value – readings
taken in the negative direction will be affected too, so if, for example, the
high limit is set at 600, readings below 600 Ft-Lbs in either direction will not
be considered high.
Min Peak%:
(2-100)
This specifies the minimum value allowed for a captured peak. Even in peak
mode, torque readings below this value will not be captured as a peak by
PSS-4200 Guide
OPERATION 11
software. Minimum 2% of full scale, or any value up to 100%. This is applied
in both directions.
Sign Lock:
(On, Off)
Sign Lock is used to ignore peaks in a certain direction. It is most commonly
used to measure tightening torques while ignoring loosening torques.
Whichever direction a peak is first captured in becomes the locked peak
direction and no readings in the opposite direction will be captured until the
unit is zeroed or the setting is turned off.
Sleep:
(0-20 Minutes)
Sleep mode determines how long the display will stay on with no activity
before going to sleep, even if light is present. Cycling light or activating the
turns counter will wake it up.
Dark Threshold %:
(0-100)
The dark threshold determines when the display will go to sleep due to
darkness. Lower the number, and less light is needed to keep the display
awake. The higher the number, the more light is needed to keep the display
awake. Setting this to zero prevents the display from going to sleep.
If the unit goes to sleep too easily (even with light shining on it), lower the
Dark Threshold. If the unit won’t turn off, even in darkness, raise this value.
Light Threshold %:
(5-100)
The light threshold determines when the display will wake up from light
shining on its face. The lower the number, the less light is needed to wake up
the display. The higher the number, the more light is needed to wake up the
display. This setting cannot be set to less than 5% above the dark threshold.
That is, if the dark threshold is 10, the light threshold cannot be set below
15.
If the unit turns on too easily (even a little light turns it on), raise the Light
Threshold. If you cannot turn on the display easily enough, even with a light
shining on it, lower the light threshold.
The default dark and light thresholds are 15% and 20%, which allows for the
display to wake up in a well-lit room, and go to sleep when a hand is placed
over the light sensor. Some adjustment of these values may be necessary to
allow the unit to operate as desired.
PSS-4200 Guide
OPERATION 12
CHARGING THE BATTERIES
The batteries in this system should last approximately 15 hours with the
display continuously on at 50% brightness, or 100 hours in sleep mode
(display off, maintains serial link, wakes on command) when fully charged.
The batteries are trickle-charged any time the system is plugged-in, and take
about 8 hours to fully charge. The unit does not indicate when it is charging.
It is recommended the tester be plugged in when not in use. This will not
harm the unit and will increase battery life.
Note that the display will normally go to sleep if it is in the dark, but it will
not go to sleep if it is reading any torque or turns values.
Note: If the tester is to be stored for several months, always ensure the
battery is completely charged prior to storage.
DIAGRAMS AND PINOUTS
WIRING DIAGRAMS
The PSS-4200 Subsea display has two connectors, one female and one male.
On both units, the male connector connects to the outside world, for
powering and charging the unit, and providing serial communications. The
female connector carries torque signal on both units, and turns signals when
wired for a torque tool, or torque and calibration settings when wired for a
verification unit. For torque tools, it may also be helpful to refer to Perry
Drawing # A019-959-005, which contains information about the tool wiring.
These diagrams indicate how the wires coming from each connector go into
the main processor board of the display on the inside of the housing. The
labels in blue show which wire from which connector goes in each pin - So a
label of “F, P1” indicates the female connector, wire 1 (which connects to pin
1 of that connector). The wires are labeled at their base, but if for any reason
the labels go missing or become unreadable, the face of the connector is also
labeled, and the corresponding wires can be determined with an ohm meter.
PSS-4200 Guide
Diagrams And Pinouts
13
PSS-4200 Guide
Diagrams And Pinouts
14
SEACON ROV CABLE PINOUT
The Standalone Subsea display for Perry Torque Tools comes with a 6 meter long
cable to connect the display directly to the ROV. Connecting the cable allows the user
to communicate via serial with the display using the included software, and to provide
persistent power to the unit. The following key shows the function of each wire in the
cable.
Pin 1) Battery positive terminal. Short this to Pin 2 to run the unit off its
internal battery.
Pin 2) Positive Voltage in. Provide 6-36 Volts DC, 3 Watts minimum to power
the unit off of external power.
Pin 3) Display ground.
Pin 4) RS-232 Serial line transmit. Connect to receive line on PC or ROV serial
port. Note some systems swap Rx and Tx nomenclature, so try reversing
these pins if communication cannot be established. For RS-485
configuration, this is the “A” signal line.
Pin 5) RS-232 Serial line receive. Connect to transmit line on PC or ROV. For
RS-485 configuration, this is the “B” signal line.
Pin 6) RS-232 Serial Ground. RS-485 Serial “Z”.
Pin 7) Not connected when configured for RS-232. For RS-485, this is the “Y”
signal line.
Pin 8) Battery thermistor. Used for feedback when hooked up to the supplied
charger. Not used when supplied with constant power from ROV
PSS-4200 Guide
Diagrams And Pinouts
15
SUBSEA VERIFICATION PARTS LIST
The Subsea Verification kit contains the following items:
1) DCPA-110
AC-DC Power adapter. Plugs into the wall and interfaces
with the charging unit.
2) DCPA-4000-SUB
Subsea Display charging and serial breakout box.
Charges the Subsea display unit and provides access to the
serial port for setup and communication. NOT WATERPROOF.
TOPSIDE OR SEALED USE ONLY.
3) ICBL-232-SUB
Serial Data cable for Charger/Breakout box to PC
4) PSS-4200
Main display Unit.
5) ICBL-4200-TD
Display to Transducer cable. Carries torque signals and
calibration information.
6) PSS-FL-4-SUBSEA
Subsea torque verification unit.
7) CC-PSS-FL-4-SUB
Carrying Case for the kit.
8) CCF-PSS-FL-4-SUB
Carrying Case foam.
9) AWS-FL-4-DK-SUB
Subsea Drive kit.
10) ICBL-4000-CHG-DUM
Female dummy plug for display charging/data port.
Protects display connector when not in use.
11) FL4SSA-FP-2
Female shorting plug for display charging/data port.
Shorts the battery to VIN to power on the unit.
Recommended Spares:
The subsea FL-4 kit contains one of everything needed to get up and running
with the unit. In order to avoid downtime from lost or damage components, however, it
may be desireable to keep some spares on hand of certain components.
DCPA-110
AC-DC Power adapter. Plugs into the wall and interfaces
with the charging unit.
DCPA-4000-SUB
Subsea Display charging and serial breakout box. Charges
the Subsea display unit and provides access to the serial port
for setup and communication. NOT WATERPROOF. TOPSIDE
OR SEALED USE ONLY.
ICBL-232-SUB
Serial Data cable for Charger/Breakout box to PC
ICBL-4200-TD
Display to Transducer cable. Carries torque signals and
calibration information.
AWS-FL-4-DK-SUB
ICBL-4000-CHG-DUM
Subsea Drive kit.
Female
dummy
plug
for
display
charging/data
port.
Protects display connector when not in use.
FL4SSA-FP-2
Female shorting plug for display charging/data port. Shorts
the battery to VIN to power on the unit.
PSS-4200 Guide
Diagrams And Pinouts
16
SUBSEA VERIFICATION PARTS DIAGRAM
PSS-4200 Guide
Diagrams And Pinouts
17
PSS-4200 PARTS LIST
The PSS-4200 kit contains the following items:
1) ICBL-232-SUB
Serial Data cable for Charger/Breakout box to PC
2) DCPA-4000-SUB
Subsea Display charging and serial breakout box. Charges
the Subsea display unit and provides access to the serial port for
setup and communication. NOT WATERPROOF. TOPSIDE OR
SEALED USE ONLY.
3) ICBL-4000-CHG-DUM
Female dummy plug for display charging/data port. Protects
display connector when not in use.
4) FL4SSA-FP-2
Female shorting plug for display charging/data port. Shorts
the battery to VIN to power on the unit.
5) PSS-4200
6) ICBL-4000-SUB-BURT
Main display Unit.
Torque and turns cable. Connects the display to a Perry
Slingsby torque tool.
7) ICBL-4000-DAT
ROV power, charging and data interface Cable. Connects to
the male plug on the display and provides bare pigtail wires for
the ROV to interface with.
8) DCPA-110
AC-DC Power adapter. Plugs into the wall and interfaces
with the charging unit.
9) CC-4200
Carrying Case for the kit.
10) CCF-4200
Carrying Case foam.
Recommended Spares:
The subsea FL-4 kit contains one of everything needed to get up and running
with the unit. In order to avoid downtime from lost or damage components,
however, it may be desireable to keep some spares on hand of certain
components.
ICBL-232-SUB
Serial Data cable for Charger/Breakout box to PC
DCPA-4000-SUB
Subsea Display charging and serial breakout box. Charges
the Subsea display unit and provides access to the serial port for
setup and communication. NOT WATERPROOF. TOPSIDE OR
SEALED USE ONLY.
ICBL-4000-CHG-DUM
Female dummy plug for display charging/data port. Protects
display connector when not in use.
FL4SSA-FP-2
Female shorting plug for display charging/data port. Shorts
the battery to VIN to power on the unit.
ICBL-4000-SUB-BURT
Torque and turns cable. Connects the display to a Perry
Slingsby torque tool.
ICBL-4000-DAT
ROV power, charging and data interface Cable. Connects to
the male plug on the display and provides bare pigtail wires for
the ROV to interface with.
DCPA-110
AC-DC Power adapter. Plugs into the wall and interfaces with
the charging unit.
PSS-4200 Guide
Diagrams And Pinouts
18
PSS-4200 PARTS DIAGRAM
PSS-4200 Guide
Diagrams And Pinouts
19
SERVICE AND WARRANTY
Service
The PSS-4200 is manufactured by AWS for Perry Slingsby Systems. All service,
calibration, or repair of the PSS-4200 must be handled through one of the Perry Slingsby
Systems Service Centers:
Houston
10642 West Little York, Suite 100
Houston, TX 77041
USA
Tel: +1 713 329 8230
Fax: +1 713 329 8299
STATEMENT OF LIMITED WARRANTY
Perry Slingsby products manufactured by Advanced Witness Series, Inc. are warranted
free of defects in material and workmanship for a period of one (1) year from date of
shipment. This warranty does not include failures due to application of torque to
transducers or loaders beyond the stated capacity, operating system with a damaged
transducer cord, nor any other misuse, abuse, or tampering.
When used with impact
type wrenches, the warranty is limited to the electronic digital display units only. This
warranty does not cover calibrations.
All freight charges are the responsibility of the company or individual returning the
item(s) for repair. Freight collect shipments will not be accepted.
Any modification to any of this equipment, without the express written approval of AWS
will void this warranty. AWS disclaims any and all liability, obligation or responsibility for
the modified product; and any claims, demands or causes of action for damage or for
personal injuries resulting from the modification and/or use of such a modified AWS
product.
ADVANCED WITNESS SERIES, INC.'S OBLIGATION WITH RESPECT TO ITS PRODUCTS
SHALL BE LIMITED TO REPAIR OR REPLACEMENT, AND IN NO EVENT, SHALL ADVANCED
WITNESS SERIES, INC. BE LIABLE FOR ANY LOSS OR DAMAGE, CONSEQUENTIAL OR
SPECIAL, OF WHATEVER KIND OR NATURE OR ANY OTHER EXPENSE WHICH MAY ARISE
IN CONNECTION WITH OR AS A RESULT OF SUCH PRODUCTS OR THE USE OR
INFORMATION THEREOF IN A JOB.
THIS WARRANTY IS EXPRESSLY MADE IN LIEU OF
ALL OTHER WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE.
NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES WHETHER OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE OTHER
THAN THOSE EXPRESSLY SET FORTH ABOVE SHALL APPLY TO ADVANCED WITNESS
SERIES.
PSS-4200 Guide
PSS-4050 Torque Display
User’s Guide
USER'S GUIDE
October, 2007
Manufacured exclusively for Perry Slingsby Systems, Inc. by
ADVANCED WITNESS SERIES, INC.
CONTENTS 1
CONTENTS
CONTENTS ................................................... 1
INTRODUCTION ............................................ 2
Description .......................................................... 2
System Specifications ......................................... 2
OPERATION.................................................. 3
Display Operation ................................................ 3
Back Panel Inputs ............................................... 4
Transducer Input (12-pin connector)................. 4
DC In ............................................................... 4
RS-232 ........................................................... 4
Charging the Batteries ......................................... 4
RS-232 ............................................................... 4
RS232 Transfer Protocol .................................. 5
RS232 Datastream Format .............................. 5
RS232 Cable Pinouts ....................................... 5
PROGRAMMING & NAVIGATION ..................... 6
Menu Tree ........................................................ 7
Button Operation: ............................................ 7
MENU TREE: ........................................................ 8
1 PEAK OPTIONS MENU................................... 8
DESCRIPTION OF FUNCTIONS ...................... 11
Operating Mode................................................. 11
Peak .............................................................. 11
1st Peak ........................................................ 11
Track ............................................................. 11
Auto .............................................................. 11
Selecting a Transducer....................................... 11
Engineering Units .............................................. 11
Full Scale .......................................................... 12
Low Limit ........................................................... 12
High Limit .......................................................... 12
SERVICE AND WARRANTY ............................ 13
1
AWSAWS-4050 Guide
Introduction 2
INTRODUCTION
DESCRIPTION
The PSS-4050 Torque Display is designed to provide for a wide range of torque
testing applications in the smallest foot print at a very reasonable price.
Features include an LCD graphics display, built-in battery pack for remote
testing and an Intellect External port for easy expansion with our entire line of
torque and load transducers. A menu based user interface allows for a wide
range of software configurations while keeping the tester easy to use.
SYSTEM SPECIFICATIONS
Dimensions
Power Requirements
Operating Temperature Range
Data Communications
Accuracy
Width: 3.7", Height: 5.7", Depth: 0.75", Weight:1.5 Lbs.
9V DC, 150 mA (120V mains adapter standard, 240v
mains adapter avaliable) or internal NiMH batteries.
0˚C to 50˚C
RS-232-C
0.5% of Indicated Reading with AWS series transducers.
Optional 0.25% of Indicated.
Range
10% to 100%
Optional 5% to 100%
Lockout Combinations
Display
Mode, Auto Clear, Mode & Auto Clear, Engineering Units,
Mode & Engineering Units, Auto Clear & Engineering Units,
Mode & Auto Clear & Engineering Units, None (Off)
4 active digits
Optional 5 active digits
Units
8 Selectable engineering units.
Special units available, please inquire.
Filter
Selectable Hz filter: 125, 250, 500, 1000, 1500, & 2000
2 Guide
AWSAWS-4050
Operation 3
OPERATION
DISPLAY OPERATION
Button Function:
(note: PSS-4050 Tester differs slightly in appearance from the unit shown)
1: Turns the display On
Zero the Transducer
Clears the reading in Peak and 1st Peak Mode
2: Turns the display Off
3: Programmable 'Soft Buttons'. The function of these buttons vary with the
current menu set and is shown on the bottom two lines of the display.
4: Accepts the reading into memory
Scrolls back one level in the menu system
5: Zero or clear button.
2
1
3
5
4
3 Guide
AWSAWS-4050
Operation 4
BACK PANEL INPUTS
The back of the PSS-4050 contains various interface connections:
Transducer Input (12-pin connector).
To install or remove the cable simply push in or pull out. Do this by gripping
the outer metal case of the cable and NEVER from the cord itself. THIS IS NOT
A TWIST LOCK CABLE!
DC In
The interface for the AC Adapter supplied with the unit. Use this if you plan on
working under Mains power. Use only the AC adapter provided with the unit.
Use of another power source will void the warranty and may cause severe
damage to the display.
RS-232
If you are downloading to a printer, data collector, computer, etc., this is the
mini-plug interface for the RS-232 cable. Values are sent via RS-232 every
time the unit auto-clears or the ENT/clr button is pressed
CHARGING THE BATTERIES
1. The batteries in this system should last approximately 12 hours when fully
charged. The Low-Battery indicator on the display will illuminate when the
battery voltage is low.
Typically, the user will have between 15-30
minutes before the batteries become too weak to power the unit.
2. The batteries are charged any time the system is plugged-in.
In Fast
Charge mode, i.e. the unit is plugged in and the power is OFF, charge time
is between 2 and 4 hours depending on battery charge level. The green
LED on the front panel will flash when the battery is charging and turned
off. It is recommended the tester be plugged in when not in use. This will
not harm the unit and will increase battery life.
Note: If the tester is to be stored for several months, always ensure the
battery is completely charged prior to storage.
RSRS-232
The PSS-4050 display can be connected to a printer, computer or data
collector via its RS232 interface. Every time a reading is accepted into
memory, a peak is cleared, or data is transmitted via the print data menu(s),
it is transmitted via the RS-232 port. To download single readings, go to the
DATA MENU. When in the Auto Mode,
Mode, readings are output at 10 S/Second.
4 Guide
AWSAWS-4050
Operation 5
RS232 Transfer Protocol
Protocol
Value
Cable
9 pin to miniplug.
Baud
9600
Parity
None
Bits
8
S Bit
1
Flow
None
RS232 Datastream Format
Normal Mode:mmmbsdddddbuuuuucl
Mode:
Auto Mode:sddddddcl
Mode:
where:
m
s
Memory Location
Sign (space or – for
c
Carriage Return
l
Line Feed
Normal mode, + or – in
Auto mode)
d
Data with Decimal Point
u
Units
b
Blank
RS232 Cable Pinouts
Pin #
Description
Pin #
Description
1
Unused
6
Unused
2
Transmit
7
Unused
3
Receive
8
Unused
4
Unused
9
Unused
5
Ground
5 Guide
AWSAWS-4050
Programming and Navigation 6
PROGRAMMING & NAVIGATION
NAVIGATION
ENTERS THE MENU
SELECTS MODE
SYSTEM
OF OPERATION
The four buttons on the bottom row are programmable or "Soft Buttons". The
functionality of the buttons will vary with the current selection. There are two
ways to change settings, or otherwise gain access to the operation of the
tester:
1. Live programming: Where the "soft" buttons have text above them,
pressing the button will scroll through the options. In the picture above,
pressing the down arrow will scroll through the Modes of Operation. These
include Peak, 1st Peak and Track.
The Up Arrow will scroll through the
engineering units.
2. Menu Driven: There are two sets of menus in the display.
a.
Bottom right Oval button will scroll through the Tester Operating
Functions. For basic testers, this includes the RUN MODE and MEMORY
(MEM) MODE.
Toggling this button will change the functions of the
other soft buttons appropriately.
b.
MENU (bottom left oval) will take you to the main menu system.
Shown below is a sample of one menu screen
6 Guide
AWSAWS-4050
Programming and Navigation 7
MENU
LOCATION
MENU ACTION
BUTTONS
MENU SCROLL
BUTTONS
RETURNS TO
PREVIOUS MENU
MENU TREE
Operation Overview: There are 8 buttons on the display face: Off, On, four
(4) programmable or ‘soft’ buttons Zero and Enter. The exact function of the
soft buttons is defined by the bottom two rows of text and will vary depending
on the current mode of operation. Pressing the ENT button will take you back
to the previous screen, until you return to the run mode.
Button Operation:
Run Mode (Current mode displayed):
ON: Clears the peak reading if saved, Zero’s the display and erases the
memory location otherwise.
ENT: Save current reading in memory if memory is on and clears the peak
reading.
Memory Mode (MEM displayed instead of Run):
ON: Goes to run mode without erasing memory location.
ENT: Scrolls to next empty location.
7 Guide
AWSAWS-4050
Programming and Navigation 8
Either Mode:
RUN -> MEM: (soft button) changes the mode of the arrow buttons.
Up and Down: (soft buttons) Units and mode respectively for RUN; Memory
location for MEM. Depends on the right programmable button.
MENU: Enter menus.
MENU Operation:
ENT: Previous menu.
Up and Down: Scroll through the current menu.
Programmable keys: Menu actions.
The text varies depending of the active
menu selection.
MENU TREE:
1 PEAK OPTIONS MENU
SEL: Enters menu.
1-1 Auto clear
+, - Set time in seconds.
Auto-clear works in Peak and 1st Peak modes, freeing the operator
from manually clearing the display after taking a reading. Auto-clear can be
set from one to nine seconds, or completely off.
With AutoClr disabled, this reading will continue to display until the
operator stores it by pressing the ENT button, or clears it by pressing the On
button.
Pressing the + key will change "Off" to a value of "1", referring to the
number of seconds the system will hold a reading on the screen before
clearing. Repeatedly press
arrow key to scroll from "Off to "9". When the
desired value is shown, press the enter button.
Once the unit is returned to operational mode, AC will show on the
bottom of the display. Because AutoClr is now active, this reading will show for
the user specified number of seconds and then clear the display. From now on,
every reading will clear and be stored automatically into memory.
* Remember AutoClr has no effect in Track Mode.
1-2 Filter
+, - Set filter value in Hz.
125, 250, 500, 1000, 1500 & 2000.
8 Guide
AWSAWS-4050
Programming and Navigation 9
1-3 Peak Blanking
+, - Set blanking in percent of full scale.
Peak Blanking sets the minimum threshold at which torque is captured
as a peak. Pressing the + and - buttons will toggle this from 2% through 50%
of Full Scale. Pressing the ENT button will accept this value and return to Run
Mode.
1-4 Sign Lock
+, - Toggle On or Off.
The Sign Lock feature allows the user to select the torque direction of
the peak to be captured. With Sign Lock ON, the initial direction or sign is the
default direction. Any peak measured in the non-selected direction will be
measured, but not captured as a peak. To reset the sign, either cycle the
power or zero the unit.
With Sign Lock OFF, the tester will capture both CW and CCW torque.
1-5 Edit Limits
High or Low edits that limit.
Limit editing:
Up and Down: Change the digit specified (5 is decimal point, OFF turns
the limit off)
DIG: Changes which digit to edit.
ENT: Accepts changes.
2 SYSTEM MENU
SEL: Enters menu.
2-1 Sleep
+, -: Set time in minutes.
To conserve battery life, the display is equipped with a "sleep" mode,
which sets the limit to standby after a user-settable amount of time has
passed without activity. Press the + key to increase the number of minutes the
unit will wait for input, or the - key to decrease the number. The highest
possible sleep setting is 20 minutes. Press ENT to accept the value and
continue to the next function.
2-2 Lockout Menu
SEL: Enter menu.
2-2-1 Mode Lockout
+, -: Toggle on or off.
9 Guide
AWSAWS-4050
Programming and Navigation 10
2-2-2 Units Lockout
+, -: Toggle on or off.
2-2-3 Scroll Lockout
+, -: Toggle on or off.
2-3 Contrast
+, -: Change the contrast of the display.
2-4 Information
SYS: Gives detailed info about the system.
TD: Gives detailed info about the transducer.
3 DATA MENU
SEL: Enters menu.
3-1 Print Memory
Send: Prints the currently saved readings.
3-2 Clear Memory
CLR: Followed by ENT clears the readings saved in memory.
3-3 Reset All
CLR: Followed by ENT clears all readings and all sets. Should be used
approximately every 5000 readings.
10 Guide
AWSAWS-4050
Description of Functions 11
DESCRIPTION OF FUNCTIONS
FUNCTIONS
The following is a description of the standard features of the AWS product line.
OPERATING MODE
Current operating mode (Peak, 1st Peak or Track) will show on the display.
Press the key to toggle between them.
Peak
Displays and retains the maximum torque experienced by the wrench, as
occurs when operating the wrench in the tightening direction. The Peak Mode
is used for all power tools and some dial wrenches.
1st Peak
Detects the “first peak” of torque experienced by the wrench, capturing the
initial torque as occurs when the torque wrench cams over. First Peak is used
primarily for Click torque wrenches and cam over screwdrivers.
Track
Displays torque as it is being applied to the transducer. Track mode is used
primarily for verifying calibration of the unit.
Auto
Displays torque on the display as it is being applied to the transducer.
Readings are also out-put via RS-232 at 10 samples/second.
This mode is
used when calibrating a tool the the host controller.
SELECTING A TRANSDUCER
IMPORTANT NOTE: On power-up, the transducer that is selected will be active
and ready to use. When changing the shaft, you MUST Zero the unit. Do this
by pressing the On/Zero. The shaft capacity can be verified by going to the
Information screen in the Systems Menu (2-4). Full Scale capacity screen is
shown. Press the ENT button twice to return to the run mode.
ENGINEERING UNITS
Shows the current engineering units.
Press the key to cycle through the
eight possible choices: Kgf m, KgfCm, gfCm, cNm, Nm, FT LB, IN LB, IN OZ.
11 Guide
AWSAWS-4050
Description of Functions 12
FULL SCALE
This screen shows the Full-Scale value of the Torque Shaft. This is not a field
adjustable value.
LOW LIMIT
Use the low limit setting as a means of visually flagging the operator when a
reading fails to reach a desired minimum value. A small down arrow will
appear on the screen if a peak is captured below the limit setting.
The limit is adjusted by using the navigation buttons to set the first four digits
to the desired value.
position.
The fifth digit is used to select the decimal point
The up and down buttons under the “Soft” button Change will
change the value from 0-9. Pressing the “soft” DIG will scroll through the digit
positions.
When the correct value is entered, pressing the ENT button will
return you to the menu system.
Once all the digits have been set, press the MEM key to accept the value and
return to Program Function mode. The next time a reading is taken, "LO" will
appear on the display if the captured value is less than the low limit
HIGH LIMIT
Use the high limit setting as a means of visually flagging the operator when a
reading falls over a desired maximum value. High limits are set in the identical
way as low limits. Please refer to the Low Limit section for details.
NOTE ON LIMITS: The green LED on the front of the display will flash when a
peak is captured that falls within the limit setting.
12 Guide
AWSAWS-4050
Service and Warranty 13
SERVICE AND WARRANTY
Service
The PSS-4050 is manufactured by AWS for Perry Slingsby Systems. All service,
calibration, or repair of the PSS-4050 must be handled through one of the Perry
Slingsby Systems Service Centers:
Houston
10642 West Little York, Suite 100
Houston, TX 77041
USA
Tel: +1 713 329 8230
Fax: +1 713 329 8299
STATEMENT OF LIMITED WARRANTY
Perry Slingsby products manufactured by Advanced Witness Series, Inc. are warranted
free of defects in material and workmanship for a period of one (1) year from date of
shipment. This warranty does not include failures due to application of torque to
transducers or loaders beyond the stated capacity, operating system with a damaged
transducer cord, nor any other misuse, abuse, or tampering. When used with impact
type wrenches, the warranty is limited to the electronic digital display units only. This
warranty does not cover calibrations.
All freight charges are the responsibility of the company or individual returning the
item(s) for repair. Freight collect shipments will not be accepted.
Any modification to any of this equipment, without the express written approval of AWS
will void this warranty. AWS disclaims any and all liability, obligation or responsibility for
the modified product; and any claims, demands or causes of action for damage or for
personal injuries resulting from the modification and/or use of such a modified AWS
product.
ADVANCED WITNESS SERIES, INC.'S OBLIGATION WITH RESPECT TO ITS PRODUCTS
SHALL BE LIMITED TO REPAIR OR REPLACEMENT, AND IN NO EVENT, SHALL ADVANCED
WITNES SERIES, INC. BE LIABLE FOR ANY LOSS OR DAMAGE, CONSEQUENTIAL OR
SPECIAL, OF WHATEVER KIND OR NATURE OR ANY OTHER EXPENSE WHICH MAY ARISE
IN CONNECTION WITH OR AS A RESULT OF SUCH PRODUCTS OR THE USE OR
INFORMATION THEREOF IN A JOB. THIS WARRANTY IS EXPRESSLY MADE IN LIEU OF
ALL OTHER WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES WHETHER OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE OTHER
THAN THOSE EXPRESSLY SET FORTH ABOVE SHALL APPLY TO ADVANCED WITNESS
SERIES.
13 Guide
AWSAWS-4050
FROM
PIN NO.
NAME
SIGNAL / CABLE NAME
TERM. TYPE
BURTON CONNECTOR
1
2
3
4
5
5
6
6
7
8
DRAWN
SAW
SUPERSEDED BY
16.1.04
ISSUE
1
2
3
DATE
DO CHECKED
SWA
SWA
SWA
TO CHECKED
DFA
DFA
DFA
TO APPROVAL
DFA
DFA
DFA
DATE
ALTERATION
This Sheet A001-000-297 Issue 2, Wiring Schedule
4
5
6
7
PROD PROD PROD PROD
21.1.04 1.11.06 7.2.07
REFER TO DRAWING ALTERATION SHEET
WIRE
TYPE
AWG
NAME
TO
PIN NO.
TERM. TYPE
WIRES FROM SENSORS
RED
BLUE
BLACK
WHITE
BROWN
BROWN
BLUE
BLUE
BLACK
BLACK
STRAIN GAUGE EXCITATION + V
STRAIN GAUGE EXCITATION - V
STRAIN GAUGE SIGNAL + V
STRAIN GAUGE SIGNAL - V
INDUCTIVE SENSOR #1 EXCITATION + V
INDUCTIVE SENSOR#2 EXCITATION + V
INDUCTIVE SENSOR#1 EXCITATION – V
INDUCTIVE SENSOR#2 EXCITATION – V
INDUCTIVE SENSOR #1 SIGNAL + V
INDUCTIVE SENSOR #2 SIGNAL + V
STATUS
SUPERSEDES
COLOUR
8
ALL RIGHTS RESERVED BY PSSL
USED ON
WIRING SCHEDULE TITLE © Copyright PSSL
WIRING SCHEDULE
FOR INDUCTIVE SENSOR
DRAWING NUMBER
A019-959-005
SHEET 1 OF 1
A4
Test Specification
EQUIPMENT TO BE TESTED
Class 2-4 Torque tool A019-959-002 (and variants)
RELATED DOCUMENTS
Health and Safety Executive Guidance GS4
(FOR HYDRAULIC PRESSURE TESTING ONLY)
AIM OF TEST
1. Setup the Torque tool correctly
2. Performance test to get pressure/torque characteristics
TEST EQUIPMENT REQUIRED
2-off calibrated pressure gauges 0-200 bar.
1-off hydraulic power pack 8 lpm @ 210 bar.
1-off haydraulic hand pump 210 bar.
1-off Class 4 torque verification unit A019-958-101 or similar
1-off Electronic Voltmeter with built in continuity tester.
1-off Bench power supply capable of supplying 10v DC
2-off SUN RPEC-LAN pressure relief valves with mounting bodies
1-off 082-01-403 (Burton 5501-1508-0015) Straight Moulded 8 Pin Connector C/W 4 MTR Tails.
1-off Continuity Tester (Audible alarm type)
1-off load cell, 1 tonne or better
1-off Smart VP A286-001-050 (or variant)
Test Report Number :
………………………………..
Date of test:
………………………………..
Tester Name :
………………………………..
NOTE: Engrave test report number on stainless steel motor mounting plate
Issue
1
Status
Prod
Tech. App. DFA
Date
29.8.04
TO Check
DF
Date
28.8.03
DO Check S Walton
Date
28.8.03
Drawn
S Walton
Date
28-8-03
2
3
PROD
PROD
DFA
PCL
11.3.04
29.9.04
Supersedes
Superseded by
4
PROD
DFA
13.7.05
© Copyright PSSL
Title
Class 2-4 Mk II
Latching Torque Tool
Test Specification
This Sheet A001-000-300 Issue 1, Word for Windows Blank A4 Sheet
5
PROD
SWA
1.7.08
6
PROD
All Rights Reserved by PSSL
Used on
A019-959-002
Drawing No.
A019-959-004
Page No. 1 of 14
1.
SPECIFICATION
Interface: ISO 13628-8 Figure 18 Rotary Torque Receptacle Class 2 to 4
The tool operates within two ranges achieved by changing the internal gearbox set from
1:5 ratio to 1:1 ratio with an adaptor:
•
120Nm-540Nm (90 Ftlbs-400 FtLbs)
•
540Nm-2700Nm (400Ftlbs-2000 FtLbs)
This covers torque ranges ISO class 2 to 4.
(Note that class 1 has same dimensions as class 2 but at lower torque than tool can
supply)
1.1 CONFORMANCE TO STANDARD INTERFACE
Refer to the table attached to the end of this document summarising most of the ISO
13628 dimensions.
Compare the tool interface to the dimensions shown. In all cases there must be a
clearance between the tool and the standard receptacle detail.
Comments ……………………………………………………………………………….….…..
………………………………………………………………………………………………..…..
…………………………………………………………………………………………..………..
Client ………………………… PSSL ……………..….……. Date ……………………..…..
Drawing No.
Issue
Level
1
4
2
4
3
4
4
4
5
4
6
4
A019-959-004
Page No. 2 of 14
2.
PERFORMANCE AND FUNCTION TESTING
2.1 TORQUE TESTS. OPTION 1: NO SMART VP AVAILABLE
The performance test is to be performed using the torque verification unit. Control
pressure with the SUN pressure relief valves mounted in the hoses to the tool. Fit
pressure gauges in both hoses.
The system is to be run on AWS 22 or 32 oil. Record results in terms of pressure (bar)
and torque (Nm).
(1) Assemble the tool for 120Nm to 540Nm operation.
(2) Operate the tool in either direction for 5 minutes to ensure the tool is operating
correctly and the motor is filled with oil.
(3) Assemble tool into the verification unit.
•
Operate CW to stall then adjust the pressure relief to get approximately 20 bar.
Operate CCW to back off and then CW to stall again. Take the torque reading
from the verification unit and the pressure in A and B lines.
•
Increase pressure relief by approximately 20 bar. Operate CCW to back off and
then CW to stall again. Take the torque reading from the verification unit and the
pressure in A and B lines.
•
Repeat the above in steps of 20 bar up to 200bar (or maximum rated torque
reading). At each step, take the torque and pressure results. (It is important,
after adjusting the pressure relief valve, to back the tool off then drive back on to
stall before taking the torque and pressure reading - as this is how the tool is
used in service and will develop slightly more peak torque when driven to stall).
•
Both CW and CCW torque is to be measured by this method.
(4) Remove verification unit, rotate the tool so that the socket and motor are in a
different stall position and reinsert. Repeat testing (3).
(5) Plot the test results separately for CW and CCW and add trend lines. Plot pressure
difference against torque. Plot in Nm against bar and also convert to lbsft against
psi. The torque to differential pressure relationship should have a clear trend,
investigate if not.
(6) Set the tool up for 540Nm to 2700Nm operation, and repeat steps 2-5.
(7) Set the tool at approximately 2700Nm and repeatedly test, CW and CCW. Remove
verification unit, operate to rotate the socket by at least 90 degrees and reinsert.
Repeat testing. Determine the typical scatter as a percentage +/- of the average.
(8) Inspect the socket, interface etc for any signs of damage. Some surface scuffing is
normal.
•
Attach Test Result charts.
•
Enter typical repeatability at 2700Nm +/- of full-scale torque ………… %
Drawing No.
Issue
Level
1
4
2
4
3
4
4
4
5
4
6
4
A019-959-004
Page No. 3 of 14
2.2 TORQUE TESTS. OPTION 2: SMART VP AVAILABLE
The performance test is to be performed using the torque verification unit, and a PSSL
Torque Tool Control Unit. Fit calibrated pressure gauges to both hoses.
The system is to be run on AWS 22 or 32 oil. Record results in terms of pressure (bar)
and torque (Nm).
(1) Assemble the tool for 540Nm to 2700Nm operation.
(2) Connect the verification unit to the Surface Computer.
(3) Operate the tool in either direction for 5 minutes to ensure the tool is operating
correctly and the motor is filled with oil.
(4) Assemble tool into the verification unit. Stall in one direction and increase pressure
until either maximum pressure or 2700Nm is achieved, note the pressure. This step
is to ensure during auto calibration the maximum torque of the tool is not exceeded.
(5) Set up for auto calibration as below, the maximum set pressure should be as per
step 4.
(6) Start the test, when complete repeat for CW. During testing verify the pressure
transducer is operating by checking the read pressures against the readout from the
pressure gauges.
(7) Remove verification unit, rotate the tool so that the socket and motor are in a
different stall position and reinsert. Repeat testing (6).
(8) Plot the test results separately for CW and CCW and add trend lines. Plot pressure
difference against torque. Plot in Nm against bar and also convert to lbsft against
psi. The torque to differential pressure relationship should have a clear trend,
investigate if not. A screen dump of the Torque Characteristics page will be
acceptable.
Drawing No.
Issue
Level
1
4
2
4
3
4
4
4
5
4
6
4
A019-959-004
Page No. 4 of 14
(9) Set the tool at approximately 2700Nm and repeatedly test, CW and CCW. Remove
verification unit, operate to rotate the socket by at least 90 degrees and reinsert.
Repeat testing. Determine the typical scatter as a percentage +/- of the average.
(10) Inspect the socket, interface etc for any signs of damage. Some surface scuffing is
normal.
•
Attach Test Result charts.
•
Enter typical repeatability at 2700Nm +/- of full-scale torque ………… %
Drawing No.
Issue
Level
1
4
2
4
3
4
4
4
5
4
6
4
A019-959-004
Page No. 5 of 14
2.3 INTERNAL TURNS COUNTER. OPTION 1: NO SMART MANIFOLD AVAILABLE.
Tools fitted with inductive type counters
Turns are counted by means of two internal inductive type switches, the sensor triggers
are located on the output side of the gearbox. The sensor trigger is a ring of ferrous
metal with five slots cut out. For one complete revolution of the tool, five pulses will be
generated. The second turns counter has the same output but is slightly offset so that it
can be used for direction indicating when used with the tool mounted electronic turns
counter or any non-Perry Slingsby control systems.
To test operation of the counter, connect pin 5 to a +10v supply and pin 6 to 0v (REF
High Torque tool 1500Nm with Feedback Wiring Schedule). Connect a voltmeter
between pins 6 and 7. When a pulse is generated the reading should be the same as the
input voltage. Repeat for the second switch on pins 6 and 8.
1. Operate tool at low speed and check operation of turns counter. Check five pulses
are generated per revolution of the output socket
2. Operate for four socket revolutions and confirm 20 counts. Reverse tool direction
and confirm 20 counts for four socket revolutions
3. Repeat for the other switch.
Comments ……………………………………………………………………………….….…..
………………………………………………………………………………………………..…..
…………………………………………………………………………………………..………..
Client ………………………… PSSL ……………..….……. Date ……………………..…..
Tools fitted with reed switch type counters
Turns are counted by means of an internal reed type switch, the counter is located on
the output side of the gearbox. Four magnets are employed at 90° relative position to
each other, measuring the drive motor speed. One motor turn will close the reed switch
four times. Output from the reed switch 1 is on pins 5 and 6 of the Burton connector and
is self powered. Connect output from tool to an audible continuity tester. Output from
reed switch 2 is on pins 7 and 8 of the Burton connector
1. Operate tool at low speed and check operation of turns counter. An audible beep is
emitted when a magnet passes the switch.
2. Check counter reflects actual movement of socket. There are 4 counts per socket
revolution.
A second reed switch is connected between pins 7 and 8, repeat test.
Comments ……………………………………………………………………………….….…..
………………………………………………………………………………………………..…..
…………………………………………………………………………………………..………..
Client ………………………… PSSL ……………..….……. Date ……………………..…..
Drawing No.
Issue
Level
1
4
2
4
3
4
4
4
5
4
6
4
A019-959-004
Page No. 6 of 14
2.4 INTERNAL TURNS COUNTER. OPTION 2: SMART MANIFOLD AVAILABLE.
If a Smart manifold is available it can be used to verify turns.
(1) Set the turns limit on the software to five turns.
(2) Switch the turns limit on.
(3) Operate the tool in the CW direction.
(4) Make a mark on the socket of the tool at TDC.
(5) Reset the turns count.
(6) Operate the tool CW. Count the turns and confirm that the socket stops
with the mark at TDC. Very little offset should be observed.
(7) Repeat for CCW.
Comments ……………………………………………………………………………….….…..
………………………………………………………………………………………………..…..
…………………………………………………………………………………………..………..
Client ………………………… PSSL ……………..….……. Date ……………………..……
2.5 LATCH FINGER OPERATION.
The tool is equipped with two latching wings that deploy from the front of the tool and
locate in the API 17D class 4 receptacle. The wings deploy simultaneously and are
operated one direction by hydraulic fluid, via a port on the back of the tool. The wings
return by spring force alone, this is in case of loss of hydraulic power the tool will
automatically disengage from the bucket.
To test operation of the wings, couple the hydraulic hand pump to the lock line on the
rear of the tool, apply a pressure of 210 bar, check for leakage and that the piston is fully
forward and the wings do not foul. Release the pressure and operate through the full
range of travel, checking that the wings do not foul. Place tool in torque verification unit
and repeat procedure, ensure tool is held in bucket. Upon releasing pressure, the wings
should retract.
Load test of latch fingers (when specifically requested on WO)
The test is to confirm that the axial load capacity of the torque tool is 1000 kg. If specific
load test fixtures are not available, use a torque verification unit housing as a bucket and
make up load brackets attaching to at least 4-off M8 bolts on the motor mounting plate.
Use a calibrated load cell in the rigging.
The tool should be inserted in the bucket interface, the latches set with 200 bar pressure
(and held on) and the main body of the torque tool pulled on its main axis to a load
reading of 1000 kg. Hold for 5 minutes then release load.
The tool latches should show no movement under load.
Comments ……………………………………………………………………………….….…..
………………………………………………………………………………………………..…..
…………………………………………………………………………………………..………..
Client ………………………… PSSL ……………..….……. Date ……………………..…..
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2.6 TORQUE SENSOR SECTION HOUSING.
The tool has a built in torque sensor section that is used to measure torque between the
socket and the front reaction housing. The section is supplied from the manufacturer with
a calibration certificate; this will provide details of the relationship between applied torque
and voltage produced. The purpose of this test is to confirm the operation of the sensor,
not re-perform its calibration.
Supply 10V DC from a bench power supply on pins 1 and 2 of the Burton connector, 1 is
positive and 2 is negative. Measure the output signal on pins 3 and 4 on a voltmeter, 3
is positive and 4 is negative.
1. Obtain a copy of the calibration certificate accompanying the sensor section and
include it with the test certificate.
2. Operate the tool whilst in the verification unit, at a torque of 2700Nm the reading on
the voltmeter should be according to the sensor manufacturer’s certificate (typically
of the order of 4-6mV).
3. Reduce the pressure to the tool. As the torque drops, the reading on the voltmeter
should drop. Check that at half torque the reading is halved.
4. Repeat in reverse direction.
Comments ……………………………………………………………………………….….…..
………………………………………………………………………………………………..…..
…………………………………………………………………………………………..………..
Client ………………………… PSSL ……………..….……. Date ……………………..…..
2.7 WEIGHT TESTS
Testing only required for first build. It does not have to be repeated on subsequent
builds if the weight is already known.
ITEM
Description
(1)
Fully assembled weight in air
……………… kg
(2)
Fully assembled weight in water
……………… kg
Comments ……… (note if oil filled or drained) ………………………….………….….…..
………………………………………………………………………………………………..…..
…………………………………………………………………………………………..………..
Client ………………………… PSSL ……………..….……. Date ……………………..…..
2.8 ADDITIONAL EQUIPMENT
Note testing of any additional or optional equipment below
………………………………………………………………………………………………..…..
………………………………………………………………………………………………..…..
…………………………………………………………………………………………..………..
Client ………………………… PSSL ……………..….……. Date ……………………..…..
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Page No. 8 of 14
3.
RESULTS SHEET
Title …………………………………………
Pressure Pressure
Torque
Measured
in
in
Voltage
measured
direction direction
(Mv)
(Nm)
CW
CCW
Pressure Pressure
Torque
Measured
in
in
Voltage
measured
direction direction
(Mv)
(Nm)
CW
CCW
(bar)
(bar)
(bar)
(bar)
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Page No. 9 of 14
Pressure Pressure
Torque
Measured
in
in
Voltage
measured
direction direction
(Mv)
(Nm)
CW
CCW
Pressure Pressure
Torque
Measured
in
in
Voltage
measured
direction direction
(Mv)
(Nm)
CW
CCW
(bar)
(bar)
(bar)
(bar)
Torque Verification unit Serial No and calibration date ………………………………….
Pressure gauge Serial No and calibration date …….. ………………………………….
Pressure gauge Serial No and calibration date …………….………………………….
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Page No. 10 of 14
4.
APPENDIX – ISO 13628-8 FIGURE 18 INTERFACE
N
H
K
G
C (M IN )
A(SQ UA RE)
F
A
M
0 .2 5 A
35 °
4 HO LES 1 2 . 5 D IA TH
C 'BO RED 2 0 D IA x 1 3
L
E
øB
øK
A
SEE N O TE 1
E
45°
0 .2 5 A
D
D RILL & C 'SIN K 4 HO LES O N PC D
TO SUIT SHAFT A N D BEA RIN G
J
SHAFT BEARIN G
A
SEE N O TE 2
SEC TIO N A-A
N o te s.
I) Ho le D ia to su it sh a ft & b e a rin g
Ii) Pro file o f fla n g e p la te to su it in sta lla tio n (re c e p ta c le c a n b e b o ttle d o r w e ld e d in p la c e ).
Figure 18 — Rotary torque receptacle
Rotary actuator intervention fixture classification
Class
Max design torque
Nm
(lbf.ft)
1
67
(50)
2
271
(200)
3
1 355
(1 000)
4
2 711
(2 000)
5
6 779
(5 000)
6
13 558
(10 000)
7
33 895
(25 000)
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Table 1 — Dimensions for receptacle classes 1-7 (see Figure 18)
Dimension
Class
1
2
3
4
5
6
7
17,50
(0,687)
17,50
(0,687)
28,60
(1,125)
38,10 (1,5)
50,80
(2,000)
66,67
(2,625)
88,90 (3,5)
B
154,0 (6,06)
154,0 (6,06)
154,0 (6,06)
154,0
(6,06)
190,5 (7,50)
243,0 (9,56)
243,0 (9,56)
C
41,0 (1,62)
41,0 (1,62)
41,0 (1,62)
41,0 (1,62)
63,5 (2,50)
89,0 (3,50)
89,0 (3,50)
D
38,0 (1,50)
38,0 (1,50)
38,0 (1,50)
38,0 (1,50)
57,0 (2,25)
82,25 (3,25)
82,25 (3,25)
E
32,0 (1,25)
32,0 (1,25)
32,0 (1,25)
32,0 (1,25)
38,0 (1,50)
44,5 (1,75)
44,5 (1,75)
F
82,5 (3,25)
82,5 (3,25)
82,5 (3,25)
82,5 (3,25)
127,0 (5,00)
178,0 (7,00)
178,0 (7,00)
G
140,0 (5,51)
140,0 (5,51)
140,0 (5,51)
140,0
(5,51)
140,5 (5,53)
-
-
H
181,0 (7,12)
181,0 (7,12)
181,0 (7,12)
181,0
(7,12)
206,0 (8,12)
-
-
J
12,0 (0,47)
12,0 (0,47)
12,0 (0,47)
12,0 (0,47)
-
-
-
K
168,5 (6,63)
168,5 (6,63)
168,5 (6,63)
168,5
(6,63)
-
-
-
L
89,0 (3,50)
89,0 (3,50)
89,0 (3,50)
89,0 (3,50)
-
-
-
M
25,4 (1,00)
25,4 (1,00)
25,4 (1,00)
25,4 (1,00)
-
-
-
N
194,0 (7,63)
194,0 (7,63)
194,0 (7,63)
194,0
(7,93)
-
-
-
A (square
AF)
NOTE 1 Dimensions shown are in mm (in)
NOTE 2 All dimensions are toleranced as follows:
.X
± 0,5 mm (0,020 in)
.XX ± 0,25 mm (0,010 in)
C + 1,27 mm (0,05 in) − 0 mm (0 in)
NOTE 3 Alternate to dimension A may be end effector shapes as found in annex D for the appropriate torque
range.
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Page No. 12 of 14
Intentionally Blank Page.
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Page No. 13 of 14