Reliable, Error-Proof Residual Torque Measurement with the LightStar System Key Points

Eliminates false

high and low readings

Angle function

qualifies torque measurement

System solution

reduces training time

Provides instant operator notification

Creates torque angle curve plots

Rugged wrench design ensures long usage life

Narrow wrench head design fits confined spaces

Human reaction time causes overshoot in peak residual torque measurement.

Now there’s a better way to measure residual torque: LightStar Torque and Angle Wrenches from ASI DataMyte. Lightstar wrenches give you the most reliable way to eliminate false readings, increase accuracy and reduce variability of residual torque measurement. The time between fastener motion and operator response is a key driver of variability when measuring peak torque. This is why assessing residual torque by measuring peak torque is subject to operator error that induces false high and false low readings, as well as much higher variability than measured installed torque.

The amount of stiction in a joint can also affect the point at which a fastener begins to turn.

These false high and low readings are a result of the operator’s perception of when the fastener begins to turn. High readings are caused by too much operator follow-through, or overshoot, after fastener motion begins. Low readings are caused by an operator releasing the wrench before fastener thread motion begins due to the operator mistaking a bump or a jar for fastener motion.

A Complete System Solution LightStar wrenches, in conjunction with ASI DataMyte data collectors and software, measure torque at angle using a new technological solution. A solid-state gyro in the torque wrench head is used to capture torque only when the fastener actually turns. The instrumentation and logic built into the data collector differentiates between windup – the flex or twisting of the work piece, drive, socket and extension -- and actual fastener motion.

This system solution consists of:

• LightStar Torque Wrenches with angle measurement option • Model 501 Data Collector with torque board option • TranSend utility software • ASI DataMyte Setup Editor and Reporting and Analysis Software

Eliminates False Readings LightStar technology virtually eliminates operator error and significantly reduces variability. LightStar’s solid-state gyro senses angular displacement, while the advanced firmware of ASI DataMyte data collectors captures residual torque at actual fastener motion. False high readings caused by overshoot and false low readings caused by early release are eliminated, and labor time is no longer wasted chasing nonexistent problems with perfectly good installation tools.

Reduces Costs A multi-colored LED in the wrench head instantly notifies the operator of measurement status when the wrench is connected to an ASI DataMyte Data Collector. This notification happens as soon as fastener motion begins and lets the operator know that the measurement has been taken. This means that you avoid costly recalls, comply with regulatory requirements and safety standards, decrease the possibility of errors, and increase the speed of measurement.

Saves Time You’ll also find that labor time is reduced because less time is needed to take the same number of measurements. Training time is also reduced because accurate readings are no longer highly dependent on the operator. Anyone can take quality measurements with minimal training. Measuring residual torque now requires no more training time than learning to use a digital caliper to measure a diameter.

Detects Problems Sooner Because variability is reduced, residual torque specification limits may be tighter. These tighter limits mean that you will detect actual problems sooner, and prevent costs that result from:

• Quarantined suspect lots • Labor used to check error-free suspect lots • Unnecessary product recalls

Multiple Applications The LightStar wrench is designed for applications where bolted joints must be checked for residual torque following assembly. It can also be used for accurate hand assembly to a target torque, measuring of shear torque on welded fasteners, or for many other applications. LightStar wrenches are available in multiple metric sizes to fit virtually any torque audit application.

How The LightStar Solution Works The LIghtStar system solution includes the LightStar torque wrench, the Model 501 data collector, TranSend Software and ASI DataMyte Setup Editor and Analysis and Reporting Software. When used with LightStar wrenches, the Model 501 with torque option measures torque as qualified by detected angular rotation. The data collector includes three new algorithms that let you customize applications for all types of joint mechanics. These algorithms are: angle restart, angle breakaway and torque at angle. All require a rotationally stable work piece. The Angle Breakaway and Torque at Angle algorithms are not suitable for fasteners torqued to yield. Angle Restart captures torque as the fastener starts moving after overcoming static friction. This form of measurement is particularly useful when the effects of corrosion or locking adhesives need to be removed to more accurately assess clamp load.

The LightStar system uses three new torque algorithms.

Angle Breakaway captures the torque needed to set a fastener in motion. This is often referred to as “torque to turn.” Unlike torque/time breakaway, angle-based breakaway is not subject to variations in operator technique. Torque at Angle captures torque at a user-defined amount of detected rotation, for example, two degrees, past a torque threshold. This measurement strategy is useful in special applications where there is predictable bolt head or work piece rotation before thread rotation.

The algorithms in the Model 501 convert a torque transducer’s analog signal to a digital value that represents the force applied. The LCD panel on the collector displays a torque curve plot for the joint being measured. The algorithm selects the desired point or a unique “Pick-a-Point” feature lets you select any point from the curve as the data value. Existing 501 collectors will need only a firmware update to be compatible with a LightStar wrench with the angle option.

Model 501 Data Collector The rugged yet lightweight ASI DataMyte 501 is the ideal solution for torque audits, especially when a portable device is required. The 501 is designed to collect data from a wide variety of torque wrenches, torque transducers and rundown tools, as well as serial and analog gages and metrology tools. The 501 may be ordered with or without an SPC option for on-board SPC analysis. Easy-to-use with intuitive, menu-driven commands, the 501 features a large LCD panel to display collected information, with a backlight option for use in low-light conditions. The ergonomic design has keys oriented for both right- and left-hand operation, and the contoured grip reduces operator fatigue and possible motion injuries.

Torque Applications In addition to residual torque applications, the Model 501 can also be used for these torque operations:

• Real-time installation torque from DC/electric, air stall or impulse tools can be captured with Peak or Pulse strategies. Angle of rotation or pulse count between Snug and Peak may be captured concurrently with appropriate transducer.

• Torque tool cutoff and angle encoder accuracy can be verified off-line. • Hand assembly and rework operations can be performed where a fastener is to be driven to a given torque or is to a

given angle past a given torque. Rugged Design The 501 data collector is designed to survive a four-foot drop to a concrete surface without loss of function. It resists damage from puddled oil, water-based cutting fluid, abrasives, dust, metal chips and filings. Standard power is delivered by two rechargeable commercial AA batteries or by an AC adaptor. A standard red/green/yellow LED display provides visual indication of in/out of spec conditions and caution alerts for operators. A standard internal warning buzzer, or an optional lapel buzzer, also serves as a warning indicator. The LEDs are position and color coded for easy recognition, even by operators who are unable to distinguish colors.

TranSend Software

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1 269 537 8051073

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ASI DataMyte TranSend utility software simplifies data transfer between ASI DataMyte data collectors, Applied Stats software, third party analysis systems and Microsoft® Excel® spreadsheets. TranSend lets you upload torque curve data from the 501 Data Collector. This data is uploaded to either a tab-delimited file or directly to an Excel spreadsheet to automatically produce a chart using an Excel macro. All relevant characteristic and gage configuration values are available along with the torque curve data. This has two distinct benefits:

• All torque, time and angle sampling values are available for further analysis by a fastener engineer for troubleshooting or blueprinting a fastening system.

• Immediate technical support is available by e-mailing the Excel file directly to ASI DataMyte.

With TranSend you can:

• Create and manage setups for ASI DataMyte data collectors. • Upload and download gage configurations for ASI DataMyte data

collectors. A single click uploads torque/time and torque/angle curves from 501 data collectors to Excel spreadsheets. • Upload data from data collectors to Excel, and/or text files.

• Upload torque curve plots from a 501 data collector to Excel spreadsheets for display.

• Update 501 data collector firmware. • Export setups to ASI DataMyte software.

ASI DataMyte Setup Editor and Analysis and Reporting Software In addition to TranSend, Setup Editor software can be used to configure and manage torque data collection setups and to upload collected data. The Setup Editor program is designed to work with the 501 data collector and offers an easy-to-use spreadsheet environment to create and edit setups. An automated setup wizard simplifies design of new setups and existing setups can also be "cloned" or copied for reuse. Setups also can be password protected to ensure data security. The Setup Editor with RCSL can be used to transfer collected data directly into the database for further analysis and reporting using Analysis and Reporting software. The Analysis and Reporting program offers a full range of charts and reports, and report creation is simplified using built-in tools. It is designed to be HTML compliant for use on both intranets and extranets for quick and easy reporting.

LightStar Series B Torque Wrench Construction and Specifications LightStar torque wrenches are constructed of reinforced aluminum alloy for optimum performance, light weight and a service life of up to 1 million cycles. The wrench’s torque sensor with strain-gauge bridge is mounted directly on the turning axis. This provides increased accuracy and makes the wrench insensitive to point of load. The ergonomic handle is made of soft durable foam, and is easily replaced when it becomes worn. The cable connector is designed to withstand 5000 insertions. LightStar wrenches are designed with industry-standard output compatible with third-party instrumentation and are also compatible with all existing torque measurement algorithms. They are available in multiple metric sizes, ranging from 5 Nm to 750 Nm.

Connector Pinouts 1

3

10

9

2 7

6

4 511

128

1 No connection

2 +5 VDC 3 Ground 4 Red LED 5 Green LED 6 B Phase 7 A Phase 8 No connection 9 - Signal 10 + Signal 11 Bridge Voltage - 12 Bridge Voltage +

Model No. Range Color Code Length H H1 Width Weight Drive

LSU-N005AC .5-5 Nm Violet 238mm 36mm 29mm 28mm 358 gm ¼” square LSU-N010AC 1-10 Nm Silver 238mm 36mm 29mm 28mm 358 gm ¼” square LSU-N025AC 2.5-25 Nm Red 298mm 40mm 29mm 28mm 425 gm ⅜” square

LSU-N075AC 7.5-75 Nm Blue 362mm 40mm 29mm 28mm 470 gm ⅜” square

LSU-N150AC 15-150 Nm Gold 598mm 52mm 38mm 40mm 1142 gm ½” square

LSU-N300AC 30-300 Nm Black 598mm 52mm 38mm 40mm 1142 gm ½” square

LSU-N750AC 75-750 Nm Green 1268mm 81mm 57mm 60mm 4188 gm ¾” square Full Scale Output: 2.00 mV/V1

Shunt Calibration: 2.00 mV/V ±0.25% with 43.575 kOhm resistor1

Over Scale: ±150% Full Scale Continuous Load2

Accuracy: ±0.25% Full Scale, maximum Nonlinearity: ±0.25% Full Scale, maximum Bridge Resistance: 350 Ohms nominal Excitation voltage, torque: 10 VDC maximum, 2.5 VDC typical Power Supply voltage: 5 VDC +/- 5% Zero Balance: ±1% Full Scale, maximum Angle Resolution: 0.037 degrees 1Output and shunt calibration are matched to less than ±0.25% to assure interchangeability. 2No permanent degradation of performance.

Quadrature output: 9828 pulses per revolution Quadrature output voltage: 0 to 5 V Connector: LEMO EGG 2B 312 CLL Mating Connector: LEMO FGG 2B 312 CLAD 72 Z Connecting Cable: ASI DataMyte P/N 95232 Socket Retainer Type: Ball and Spring Operating Temp. Range: -20°C to 50°C Drop Test: Four feet to concrete

Other dimensions or sizes available on request. Each wrench is shipped with a calibration certificate that certifies that it meets or exceeds technical specifications. Wrenches are calibrated in the clockwise direction so the output of the 350 Ohm strain gauge bridge is 2.00 mV/V at full-scale reading. Specifications subject to change without notice.

Office: 763.553.1040 Toll free: 800.455.4359

Fax: 763.553.1041

2800 Campus Drive ٠ Suite 60 Plymouth, Minnesota 55441

www.asidatamyte.com ©2007 ASI DataMyte Inc.

70217-003A 010308

Model 501 Data Collector Specifications Hardware

Weight: 15.4 oz. (431.2 gm) Dimensions: 4.08 x 10.5 x 1.77 in. (10.3 x 26.6 x 4.5 cm) Construction: Case: ABS plastic. Keypad: Silicone rubber Power Supply: 2 AA 1.5V rechargeable batteries with

external AC charger/adaptor; 8-hour battery life Display: 128x128 dot matrix LCD panel; backlit panel option Audible output: buzzer with volume and tone control Standard connectors: 1 serial, 1 remote buzzer output, 1 DC

power in, 1 digital gage, 1 thumb/footswitch; torque module or analog module are optional

Numerical precision: 8 digits Torque module accuracy: Voltage signal: 2.0mV/V,

Dynamic: +/-0.20%, Static: +/-0.10%* Filter: 5-pole low pass, user programmable between 100Hz

and 10kHz Sample rate: Up to 20kHz Data acquisition rate: Up to seven peak readings for

separate characteristics per second (for testing “cam over” torque screwdrivers; see rate plot at right)

Operating temperature range: 32-115°F, (0-45°C) 10-90% non-condensing humidity

Keypad: Simple or alphanumeric Wrist strap and belt clip

Other Features Red/green/yellow dual LED alert Flash memory for upgrades Six languages: English, French, German, Italian,

Portuguese, Spanish plus user-defined terminology Password protection Optional VIN check digit validation

Compatibility

ASI DataMyte Data Setup Editor software, all versions ASI DataMyte TranSend software (Vers. 4.0 or greater

required for residual torque measurement ) RCSL (Remote Client Serial Link), all versions

TranSend System Requirements Microsoft Windows® 98SE, Windows 2000 Sp4, Windows XP Sp2, or Windows NT 4.0 (service pack 6a or greater) operating system Microsoft Excel (Not mandatory): Office 2000 / XP / 2003 / 2007 The personal computer must meet the following requirements: • Minimum 50 Mbytes of free hard disk space • Minimum of Pentium 100 MHz (Intel Pentium® processor recommended) • Minimum of 32 Mbytes of memory • Mouse (required) • CD-ROM access (via network) or direct CD-ROM support • Serial port connection (i.e., COM port) • Printer (optional)

DSE Hardware Requirements DAR Hardware Requirements Processor Pentium compatible Processor Pentium compatible CPU 250 MHz CPU 300 MHz RAM 64 MB RAM 128 MB Disk space available 100 MB Disk space available 50 MB Monitor 15” VGA (min. resolution 800x600) Monitor 15” VGA (min. resolution 800x600) Pointing device Required Pointing device Required CD-Rom drive Recommended for installation CD-ROM drive Required Internet Explorer Ver. 5.0 or later