PCB Piezotronics 962 Instruction Manual

Software Version 7A+ ©2015 PCB Load & Torque Manual 60809 Revision NR

MODEL 962 RECORDER OPERATION MANUAL 2 TABLE OF CONTENTS GENERAL GUIDELINES ....................................................................................................................................... 5 WARNING SYMBOLS AND TERMS .................................................................................................................... 5 1.0 Product INTRODUCTION ............................................................................................................................... 5 1.1 Equipment ............................................................................................................................................... 5 1.2 Important Features .............................................................................................................................. 6 1.2.1 Display Modes ..................................................................................................................................... 6 1.2.2 Input Channels ..................................................................................................................................... 6 1.2.3 Limit Results Data/XY Graphic Plot Data ........................................................................................... 6 1.2.4 USB Ports ............................................................................................................................................ 6 1.2.5 Instrument Operating Status ................................................................................................................. 6 2.0 SAFETY PRECAUTIONS ................................................................................................................................ 6 3.0 OVERVIEW ...................................................................................................................................................... 6 3.1 Specifications ...................................................................................................................................... 6 3.2 Dimensions ......................................................................................................................................... 7 3.3 Connector Panel ................................................................................................................................. 7 3.4 Connector Pinouts ............................................................................................................................... 7 3.4.1 TTL/IO Pinouts .................................................................................................................................... 7 3.4.2 Channel 1 & Channel 2 Pinouts ........................................................................................................... 8 3.4.3 Connecting a High Level Device ......................................................................................................... 8 3.5 Battery Use & Recharging .................................................................................................................. 8 3.6 Calibration Shunt Resistors ................................................................................................................ 8 3.7 File Types ............................................................................................................................................ 8 3.8 Keypad ................................................................................................................................................ 8 4.0 SCREENS AND MENUS ................................................................................................................................. 9 4.1 Introductory Screen ............................................................................................................................. 9 4.2 Main Screen ........................................................................................................................................ 9 4.3 Setup Menu ......................................................................................................................................... 10 4.3.1 Channels Setup ..................................................................................................................................... 10 4.3.2 Units of Measure .................................................................................................................................. 11 4.3.3 Direction .............................................................................................................................................. 11 4.3.4 Set Torque Limits ................................................................................................................................ 12 4.3.5 Set Recording Time ............................................................................................................................. 12 4.3.6 Set Auto Options .................................................................................................................................. 13 4.3.7 Torque-Force Points ............................................................................................................................. 13 4.3.8 Analysis Setup ..................................................................................................................................... 14 4.3.9 Set Report Format ................................................................................................................................ 16 4.4 Calibration Menu ................................................................................................................................. 16

MODEL 962 RECORDER OPERATION MANUAL 3 4.4.1 ZERO Only .......................................................................................................................................... 16 4.4.2 AUTO Calibration ............................................................................................................................... 16 4.4.3 MANUAL Calibration ......................................................................................................................... 17 4.4.4 Add/Edit Torque/Force Transducer ..................................................................................................... 17 4.5 Print/Disk Menu ................................................................................................................................... 18 4.5.1 Printer ................................................................................................................................................... 18 4.5.2 USB Drive ............................................................................................................................................ 18 4.5.3 USB Host ............................................................................................................................................. 19 4.6 Utility Menu ......................................................................................................................................... 19 4.6.1 Set Date and Time ................................................................................................................................ 19 4.6.2 Clear Results ........................................................................................................................................ 19 4.6.3 Install Defaults ..................................................................................................................................... 20 4.6.4 Check for Smartducers ......................................................................................................................... 20 4.6.5 Set 962 Serial Number ......................................................................................................................... 20 4.6.6 Mode .................................................................................................................................................... 20 4.6.7 Set Analog Outputs .............................................................................................................................. 20 4.6.8 Diagnostics Menu ................................................................................................................................ 21 4.6.9 Change Password ................................................................................................................................. 21 5.0 Using FastPlot2 .............................................................................................................................................. 21 5.1 Start FastPlot2 .................................................................................................................................... 21 5.2 MainView Tab ..................................................................................................................................... 21 5.3 ToolsView Tab .................................................................................................................................... 22 5.4 SetupView Tab .................................................................................................................................... 22 5.5 RundownView Tab .............................................................................................................................. 23 5.6 ReportView Tab .................................................................................................................................. 24 5.7 Exit FastPlot2 ...................................................................................................................................... 24 5.8 Installations of Software Upgrade ....................................................................................................... 25 6.0 M-Alpha Analysis ........................................................................................................................................... 25 6.1 M-Alpha Overview ............................................................................................................................... 25 6.2 M-Alpha Analysis Procedure ............................................................................................................... 25 7.0 MAINTENANCE ............................................................................................................................................... 25 7.1 Battery Use & Re-Charging ................................................................................................................ 25 7.2 Handling & Placement......................................................................................................................... 26 8.0 TROUBLE SHOOTING .................................................................................................................................... 26 9.0 CALIBRATION / REPAIR SERVICES ............................................................................................................ 27 10.0 WARRANTY .................................................................................................................................................. 27 11.0 Sample Test Setups ..................................................................................................................................... 27 11.1 Torque-Tension Testing .................................................................................................................... 27 11.1.1 Scope .................................................................................................................................................. 27

MODEL 962 RECORDER OPERATION MANUAL 4 11.1.2 Torque-Tension Testing Equipment Setup ........................................................................................ 28 11.1.3 Test Procedure ................................................................................................................................... 28 11.2 Power Tool Testing ........................................................................................................................... 29 11.2.1 Scope .................................................................................................................................................. 29 11.2.2 Power Tool Testing Equipment Setup ............................................................................................... 29 11.2.3 Setup Menu for Power Tool Testing .................................................................................................. 29 11.2.4 Power Tool Verification Procedure.................................................................................................... 30 12.0 QUICK REFERENCE .................................................................................................................................... 30 12.1 Add/Edit Transducers........................................................................................................................ 30 12.2 Setup a Test ...................................................................................................................................... 30 12.3 Calibrate Transducers ....................................................................................................................... 30 12.4 Perform a Test .................................................................................................................................. 31 12.5 Save Rundown .................................................................................................................................. 31 12.6 Update Report ................................................................................................................................... 31 12.7 View a Plot ........................................................................................................................................ 31 12.8 Export Data ....................................................................................................................................... 31 12.9 Clear Results ..................................................................................................................................... 31 12.10 View Diagnostics ............................................................................................................................. 31

MODEL 962 RECORDER OPERATION MANUAL 5 GENERAL GUIDELINES Operators should read this manual and become thoroughly famil- iar with its contents before attempting to operate the Model 962 recorder. Following the safety considerations and operation in- structions outlined in this manual will minimize the possibility of accidents or injury. Although the procedures covered in this manual have proven safe in use, PCB Load & Torque assumes no responsibility for personal injury or damage to equipment result- ing from their application. After reading this manual, personnel should review all instructions concerning safety procedures pro- vided at the installation location. It is not possible to cover all safety considerations in this manual; therefore, always be alert and work safely. Only qualified system operators should per- form the procedures covered in this manual. WARNING SYMBOLS AND TERMS This symbol on the unit indicates that the user should refer to the operating instructions locat- ed in the manual. This symbol on the unit indicates that high voltage may be present. Use standard safety precautions to avoid personal contact with this voltage. This system indicates safety, earth ground. 1.0 PRODUCT INTRODUCTION The Model 962 Portable Data Recorder manufactured by PCB Load & Torque, is a battery-operated, transient recorder with two transducer inputs that can be used with torque-only, torque-angle, or load transducers. It can serve as a portable threaded fastener laboratory for measuring fastener torque, angle of turn, and clamp load. Ideal for performing fastener analysis, for auditing and certifying power tools, and for testing hand torque wrenches; Model 962 is a cost effective, versatile, and easy-to-use recorder that can collect numeric peak data, XY graphic plots, and store the data to a thumb drive or PC. The data can be easily displayed or printed on the PC running FastPlot2 software. The alphanu- meric setup and calibration menus assure ease of operation. The unit can be used with all RS Technologies' rotary torque-angle and clamp force transducers and other conventional and industry- standard strain gage transducers. The Model 962 can print out a numeric data report that contains basic information about the test along with time and date- stamped data for peak torque, angle of turn, clamp load, and torque at tension data. Statistics including high, low, mean, ±3 Sigma, etc. are calculated and included on this report. The nu- meric test data and the graphic data can be uploaded to a com- puter via the USB port using the FastPlot2 data transfer and plot- ting utility. FastPlot2 can also provide additional graphic analy- sis. 1.1 Equipment Please review the packing list to ensure that all equipment or- dered has been received. Depending on the order, it may include any or all of the following (*indicates option at extra cost): • Model 962 Recorder • USB Cable (type A/B) • FastPlot2 Software • Battery Charger Module • Carrying Case with Strap • Calibration Certificates (for instrument & optional transducers) • Torque/Torque-Angle Sensor(s)* • Fastener Load Washer(s)* • Clamp Load Cell(s)* • Transducer Cable* • Load Cell Cable* • Transducer Junction Box* In the event that some equipment is missing or damaged, please contact the freight carrier, your customs broker and the PCB Load & Torque factory. Indicates a potentially dangerous situation, which can lead to mi- nor or moderate injury or property damage. It may also be used to alert against unsafe practices. CAUTION Indicates a potentially dangerous situation, which can lead to se- vere personal injury or death. Always read the associated infor- mation very carefully before performing the indicated procedure. WARNING Indicates an imminently dangerous situation, which can lead to severe personal injury or death. DANGER

MODEL 962 RECORDER OPERATION MANUAL 6 1.2 Important Features The Model 962 has some important features which may be help- ful to understand prior to use. 1.2.1 Display Modes The Model 962 has two display operating modes: Peak mode will display the Peak values for torque, angle, and load; Track mode will display the torque or load currently being applied to the transducer or load cell. Press the TASK button to toggle between the peak and track modes. 1.2.2 Input Channels Channel 1 is primarily designed to measure torque or torque and angle. Channel 1 is the trigger channel. You will set a threshold or cycle start value for Channel 1 that will initiate the recording cycle. Channel 2 is primarily designed for load measurement using a clamp load cell or fastener load washer. You cannot trigger the recording process using Channel 2. 1.2.3 Limit Results Data/XY Graphic Plot Data The Model 962 generates two kinds of data. The numeric limit results data, which includes time/date stamped peak torque, angle at peak, peak clamp, etc., is stored on-board the Model 962. Af- ter 3 runs are recorded, the Model 962 will calculate statistics for the recorded limits data and display some of which on the Main Screen. It will provide all statistics on the limit results printout and in a file that can be uploaded to a PC via FastPlot2. The other form of data is the XY graphic plot data which in- cludes all of the data samples recorded during the test. This data is used to construct various graphs and plots either displayed on the screen or after being uploaded to a PC. This graphic data is saved either onto a USB drive or uploaded after each run to a PC. 1.2.4 USB Ports There are two USB ports provided on the Model 962. The USB A port is used to store data onto a USB memory stick/thumb drive or to send reports and graphs to a HP Deskjet USB printer. The USB B port is used to exchange information between the Model 962 and a desktop or laptop PC using the FastPlot2 appli- cation provided with the 962. 1.2.5 Instrument Operating Status The lower left corner of the Main Screen will show the operating status of the Model 962. It will read one of the following: “Ready” indicates that the instrument is armed and ready to begin a new test once the threshold/cycle start value for Channel 1 is reached. The Model 962 is put into Ready status either au- tomatically through test setup, or manually by pressing the MAIN key. “Incyc” means the Model 962 is in a recording cycle. “Done” indicates that recording has been completed. 2.0 SAFETY PRECAUTIONS 3.0 OVERVIEW 3.1 Specifications Table 1 - Specifications The Model 962 should not be opened by anyone other than factory personnel. There are no user serviceable parts inside of the Mod- el 962 recorder. Attempting to service the Model 962 will void the warranty and could result in damage to the recorder. CAUTION Cables can damage your equipment. High voltage electrostatic discharge can damage electrical devices. Similar to a capacitor, a cable can hold a charge caused by tribo-electric transfer, such as that which occurs in the following: 1. Laying on and moving across a rug. 2. Any movement through air. 3. The action of rolling out a cable. 4. Contact with a non-grounded person. The solutions for ensuring product safety: 1. Connect the cables only with power switched OFF. 2. Temporarily “short” the end of the cable before attaching it to any signal input or output. CAUTION Torque and Force Input Channels Input Range: ±2.5 mV/V, ±4.5 mV/V, ±2.5 VDC Excitation: 5 VDC, 120 mA Maximum Resolution: 18-bit Non-Linearity: 0.25% Maximum (F.S.) Frequency Re- sponse: 10 kHz Positive Voltage Peak Trap Circuit: 7µs Reset Time Peak Threshold: Software Programmable Peak Reset: Manual or Software Programmable (Automatic Reset) Angle Input Channel Type: Quadrature A/B Track Excitation: 5 VDC Input Frequency: 1000 kHz maximum Display Viewing Area: 4.85 in x 2.68 in (123 mm x 68 mm) Resolution: 240 x 128 Pixels, Backlit LCD Battery Indication: Battery Low Indication Battery Life: 8 Hours Maximum, Continuous Use Charge Time: 3.5 Hours Maximum General Temperature Range: +32°F to +122°F (0°C to +50°C) Non-Condensing Weight: 6.0 Lb (2.7 kg)

MODEL 962 RECORDER OPERATION MANUAL 7 3.2 Dimensions 3.3 Connector Panel The following describes the connector panel features. TTL/IO: RS232 port provides for connection to data recorders or other devices. Channels 1 & 2: Typical setup is Channel 1 is set to torque with a torque-only or torque-angle trans- ducer, and Channel 2 is set to force with a clamp load cell or fastener load cell. ON/OFF Switch: The power switch turns the Model 962 on and off. Battery Charger Indi- cator LED: LED will be lit when the internal battery is charging Battery Charger Jack: Receptacle for the battery charger. USB Port A: Provides for connection to a local USB printer (HP DeskJet compatible), or a flash drive memory stick to store numeric data, graphical data, test setups, and torque transducer/load cell definitions. USB Port B: Provides for connection to a desktop or laptop PC to upload recorded data, test setups, and tool definitions, or to download test setups, tool definitions, or program updates, using included FastPlot2 soft- ware. 3.4 Connector Pinouts This section describes the pinouts for the TTL/IO and channel connectors. 3.4.1 TTL/IO Pinouts Pin Function Pin Function 1 DGnd 14 Din4 2 RX1 15 DOut4 3 TX1 16 N.C. 4 RTS1 17 +5VDC 5 CTS1 18 DIn0 6 DSR1 19 DOut0 7 DGnd 20 DTR1 8 DCD1 21 DGnd 9 Analog_Out 22 RI1 10 DGnd 23 DIn1 11 DOut1 24 DIn2 12 DOut2 25 DIn3 13 DOut3 Figure 1 - Dimensions Table 2 – Mating Connectors 3.07 in (77.9 mm) 8.50 in (215.9 mm) 10.12 in (257.0 mm) TTL/IO CH 2 CH 1 CHARGER USB A USB B TTL/IO Channel 2 Channel 1 ON/OFF Switch Battery Charger Indicator LED Battery Charger Jack USB Port A USB Port B Figure 2 – Connector Panel Mating Connectors Channel 1, Channel 2: DB, 15 Pins TTL/IO: DB, 25 Pins USB Port A: A Type USB Port B: B Type Table 3 – TTL/IO Pinout 14 15 16 17 18 19 20 21 22 23 24 25 1 2 5 4 3 6 7 8 9 10 11 12 13 Figure 3 – DB 25 Pinout

MODEL 962 RECORDER OPERATION MANUAL 8 3.4.2 Channel 1 & Channel 2 Pinouts Pin Function Pin Function 1 -Signal 9 +Excitation 2 +Signal 10 -Excitation 3 GS1 (see below) 11 GS3 4 GS2 (see below) 12 GS4 (see below) 5 Analog Ground 13 Shunt 6 Transducer Type 14 Encoder A * 7 Encoder 5V * 15 Encoder B * 8 Digital Ground * Channel 1 only A jumper MUST be added when wiring a connector for the Model 962 in order to scale the output of the transducer or input device properly unless the device output is ±2.5 VDC. The proper jumper positions are detailed in Table 4a below. Jumper Position Signal Level 3 & 12 Up to 2.5 mV/V 4 & 12 Up to 4.5 mV/V None Up to 2.5 VDC 3.4.3 Connecting a High Level Device When connecting a high level input signal (±2.5 VDC) to the Model 962, connect a jumper between pins 1-5 on the DB 15 connector. Then connect the high level signal to pins 2 (+) and 1 (-) (also see Table 4). 3.5 Battery Use & Recharging The Model 962 can operate for up to 8 hours on a fully charged internal battery. Battery and charger specs are list in Table 5. NOTE: It is recommended that the instrument operate on battery power alone to minimize the interference of electrical noise in the acquired data. 3.6 Calibration Shunt Resistors Calibration shunt resistors are used to scale the output values of the sensors used. The sensor’s calibration value is matched to a calibration shunt resistor and can be found on the sensor’s cali- bration certificate. Attach the resistor(s) as shown in Figure 5. 3.7 File Types There are four types of data that the Model 962 uses to store and upload its setup and recorded data, numeric results data, graphic plot data, test setup data, and tool definition data. The files can be saved on a USB flash drive or downloaded to a PC via the FastPlot2 software. The following describes the file types used in the Model 962. .results: File type that contains the numerical test results and the statistical summary data for the test. (Also can be in the form of M*.* when saved to the USB flashdrive) .test: File type that contains all of the data points used to make up the data plots for the individual test. (Also can be in the form of D*.* when saved to the USB flashdrive) .stp: File type that contains individual test setup data. .xdf: File type that contains individual tool definition data. NOTE: Limit results and XY plot data files saved to a flashdrive are saved in a format based on the date and time. For ex- ample, a limit results file is saved as Mmmddyym.mss, where M = file type (limit results), mm = month, dd=day, yy=year, m.m = minute, ss=second. A XY plot data file is saved as Dmmddyym.mss using the same convention. 3.8 Keypad The Model 962 software utilizes easy to use menu driven naviga- tion. Navigation and input of data is performed using the keypad located on the front of the meter. See Figure 6 below. Table 4 – Channel 1 & Channel 2 Pinouts 1 2 5 4 3 6 7 8 9 10 11 12 13 14 15 Figure 4 – DB 15 Pinout TTL/IO CH 2 CH 1 CHARGER USB A USB B Channel 2 Calibration Shunt Resistor Channel 1 Calibration Shunt Resistor Figure 5 – Calibration Shut Resistors Battery/Charger Battery: 10.8 VDC NiMH 2700 mAh Charger: 18 VDC 1000 mA Table 5 – Battery/Charger SETUP MAIN PRINT UTILS STORE CAL ESC ENTER TASK RECALL 7 A 4 A 1 A - A 8 A 9 A 5 A 2 A 0 A 6 A 3 A . Figure 6 – Model 962 Keypad Table 4a – Connector Jumper Position

MODEL 962 RECORDER OPERATION MANUAL 9 The following describes the operations of the individual buttons on the keypad. MAIN: When Auto Reset is disabled, this button sets the Model 962 to be ready to perform a test. When not in the Ready mode no data can be collected. Must be on the MAIN SCREEN to use this button. See Section 4.2. SETUP: Press this button to enter the SETUP MENU. The SETUP MENU displays options to create and edit recording parameters along with vari- ous data analysis settings. Must be on the MAIN SCREEN to use this button. Refer to Section 4.3. PRINT: Press this button to enter the PRINT /DISK MENU. The PRINT/DISK MENU displays options to print or transfer numeric results, XY data, test setups, and tool definitions. UTILS: Press this button to enter the UTILITY MENU. The UTILITY MENU displays options to change settings, clear memory, and perform diagnostic functions. STORE: Press this button to manually update the numer- ical test results file. Must be on MAIN SCREEN and AutoStore must be disabled. CAL: Press this button to enter the CALIBRATION MENU. The CALIBRATION MENU displays options to calibrate the transducers to the Mod- el 962 as well as add and edit transducers to the tool libraries. ARROWS (��): Use the up and down arrow buttons to navigate through various menus or setup screens. ESC: Press this button to escape from a screen to the previous screen. ENTER: Press this button to save changed settings in various screens. TASK: Press this button to toggle between Peak and Track display modes. Must be on the MAIN SCREEN to use this button. See Section 4.2. RECALL: This button has no currently assigned function. 1-9,.,-: Use these buttons to enter numeric data in vari- ous setup fields. 4.0 SCREENS AND MENUS The Model 962 software utilizes various screens and menus to set up and perform the test, and to analyze the recorded data. The following sections give a brief overview of the various screens and menus. 4.1 Introductory Screen When the Model 962 is powered up (using the “rocker-style” power switch located on the connector panel) the Introductory Screen is displayed. See Figure 7. NOTE: The version number may be needed for some technical support. The Introductory Screen will remain active for a few seconds, after which a calibration screen asking that you “zero” (refer to Figure 30) the enabled channels is displayed or the Model 962 will search to see if any “smart” transducers that include an ID chip are connected (refer to Section 4.6.4). 4.2 Main Screen The MAIN SCREEN is the screen that is shown when a test is performed. It will appear automatically after the powering up sequence and acts as a “home” screen to activate the various menus available in the Model 962. The MAIN SCREEN con- tains the real-time plot data along with channel and statistical values. See Figure 8 below. The top section of the screen displays either the peak or track data readings from the enabled channels. The meter is in the peak mode if “pk” is visible in the top right corner of the MAIN SCREEN as shown in Figure 8. If “pk” is not visible then the meter is in track display mode. MODEL 962 RECORDER Torque-Angle Monitor VERSION 7F-R1 PCB Load & Torque 24350 Indoplex Circle Farmington Hills, MI 48335 Tel: 248-888-8260 Fax: 248-888-8266 Figure 7 – Introductory Screen Figure 8 – MAIN SCREEN

MODEL 962 RECORDER OPERATION MANUAL 10 The Model 962 can toggle between Peak and Track display modes by pressing the TASK button when the MAIN SCREEN is displayed. The Peak and Track modes are described below. Peak Display Mode: Displays the maximum data the chan- nel read on the previously recorded rundown. Track Display Mode: Displays the real-time data that the channel is currently reading. Track Display Mode data does not get saved to memory. NOTE: Only data for enabled channels will be displayed. The MAIN SCREEN (see Figure 9) includes a real-time plot to graphically display the current test data as it is being recorded. Along the right side of the screen are the statistical values calcu- lated on the test cycles saved for Channel 1. The number of run- downs from which the statistics are calculated is displayed in the bottom right corner Cyc#. NOTE: A minimum of 3 cycles need to be saved in order to view the statistics. Data recording can only be performed when viewing the MAIN SCREEN and when in the Ready mode. The Model 962 is in the Ready mode when “Ready” is displayed in the bottom left corner of the MAIN SCREEN as shown in Figure 9. The screen will display “Done” if not in the Ready mode. NOTE: If Auto Reset is disabled, press the MAIN button when viewing the MAIN SCREEN to set the Model 962 to Ready mode. If Auto Reset is enabled the meter will automatically switch to the Ready mode after a set amount of time (refer to Section 4.3.6). NOTE: The Model 962 does not have to be in the Ready mode to read Track Data to the screen. NOTE: The Model 962 must be displaying the Main Screen before starting up the FastPlot2 software (refer to Sec- tion 6 for more on FastPlot2). 4.3 Setup Menu The SETUP MENU displays options to create and edit recording parameters along with various data analysis settings. This menu can be viewed by pressing the SETUP button when on the MAIN SCREEN. See Figure 10. 4.3.1 Channels Setup Configure the data acquisition channels in the SETUP MENU by pressing the 1 button on the keypad. The CHANNELS SETUP screen is where the channel type is specified and the transducer is selected. See Figure 11. Navigate the CHANNELS SETUP screen using the Arrow (��) buttons on the keypad. Press ESC to exit back to the SETUP MENU. The Channel 1 Configuration is described below. Type: Press the 1 button on the keypad to toggle the Channel 1 type between TORQUE and FORCE. This should match to the sensor type connected to Channel 1. Angle: Press the 2 button on the keypad to ENABLE or DISABLE the ability to measure Angle on Channel 1. Angle Count: Press the 3 button on the keypad to toggle the Angle Count setting between ONEWAY and TWOWAY. Transducer: Press the 4 button on the keypad to select a transducer from a user-defined transducer library (refer to Figure 33). 1) Channels Setup SETUP MENU 2) Units: Nm, N, mm 3) Direction: CW 4) Set Torque Limits 5) Set Recording Time 6) Set Auto Options 7) Torque-Force Pts 8) Analysis Setup 9) Set Report Format Make Selection or : Exit. Ready Figure 9 – MAIN SCREEN – Ready Mode Figure 10 – SETUP MENU Channel 1 CHANNELS SETUP 1) Type: TORQUE 2) Angle: ENABLED 3) Angle Count: TWOWAY 4) Transducer: 03923 Channel 2 5) Inputs: ENABLED 6) Type: FORCE 7) Transducer: 59810 Make Selection or : Exit. Figure 11 – CHANNELS SETUP Screen

MODEL 962 RECORDER OPERATION MANUAL 11 Set the Angle Count to ONEWAY to allow for angle measure- ments to be positive for both clockwise (CW) and counter- clockwise (CCW) movements. Set the Angle Count to TWO- WAY to allow for positive and negative angle measurements. Figure 12 illustrates the difference between ONEWAY and TWOWAY Angle Counts. NOTE: Most test setups will require the Angle Count to be set to TWOWAY. NOTE: Angle measurements can only be performed with torque transducers with angle measuring capabilities. Angle values will read zero if the torque transducer cannot read angle or if the channel type is set to force even if Angle is set to ENABLE. After a transducer has been selected, the channel precision needs to be set. Channel precision refers to how many digits to the right of the decimal place will be visible. The SET CHANNEL PRECISION screen is shown in Figure 13 Navigate the SET CHANNEL PRECISION screen using the Arrow (��) buttons on the keypad. Use the numeric buttons on the keypad to input the values. Press the ENTER button to save the values and press ESC to exit back to the CHANNELS SET- UP screen. NOTE: A transducer definition will need to be set up prior to being able to select one from the library. The Channel 2 Configuration is described below. Inputs: Press the 5 button on the keypad to ENABLE or DISABLE Channel 2 data acquisition. If there is no sensor attached to Channel 2 then it should be set to DISABLED. Type: Press the 6 button on the keypad to toggle the Channel 2 type between TORQUE and FORCE. This should match to the sensor type attached to Channel 2. Transducer: Press the 7 button on the keypad to select a transducer from a user-defined transducer library (refer to Figure 33). Set CHANNEL PRECISION after selecting a transducer (see Figure 13). NOTE: A typical setup is Channel 1 set to torque and Channel 2 is set to force. Depending on application, channels can be set to either both torque or both force. Never set Channel 1 to force while having Channel 2 set to torque. NOTE: A transducer definition will need to be set up prior to being able to select one from the library. Refer to Sec- tion 4.4.4. 4.3.2 Units of Measure The displayed and recorded units of measure are established in the SETUP MENU by pressing the 2 button on the keypad. Re- peatedly pressing the 2 button will toggle through the available unit choices. The units displayed are the units that the meter is currently set for. Table 6 shows the order of the available units as they are toggled. 4.3.3 Direction The angle direction that is considered positive is set in the SET- UP MENU by pressing the 3 button on the keypad. Repeatedly pressing the 3 button will toggle between CW and CCW. If CW is selected, then clockwise will be considered the positive angle direction. If CCW is selected, then counter-clockwise will be considered the positive angle direction. NOTE: Use CCW when recording loosening of right-handed threads or when tightening left-handed threads. Torque Load Dimension lbft lb In lbin lb In ozin Oz In Nm N mm kNmm N mm kgcm kg mm kgm kg mm Table 6 – Units Figure 12 – Angle Count SET CHANNEL PRECISION CAL Tq (Nm): 15.0 Input Torque: 1 Angle: 0 Set No. of Places Aft Decimal. : Select Item. : Save : Exit. Figure 13 – SET CHANNEL PRECISION Screen

MODEL 962 RECORDER OPERATION MANUAL 12 4.3.4 Set Torque Limits Set the Torque Limits by pressing the 4 button on the keypad when viewing the SETUP MENU. The Torque Limits set the recording parameters and visual target values for the real-time plot on the MAIN SCREEN. See Figure 14 below. Navigate the Set Torque Limits screen using the Arrow (��) buttons on the keypad. Use the numeric buttons on the keypad to input the values. Press the ENTER button to save the values and press ESC to exit back to the SETUP MENU. NOTE: Setup values entered into the Model 962 will not be saved unless the ENTER button is pressed. The recording window is set using the Cycle Start, Cycle End, and the Cycle End Time parameters. The recording cycle starts once the Channel 1 data point designated by Cycle Start is meas- ured. The recording cycle ends once the Channel 1 data set falls below the Cycle End value for the time set by Cycle End Time. This sequence is illustrated in Figure 15. The Cycle Start and Cycle End parameters are described below. Cycle Start: The Channel 1 data point that triggers the start of the data recording. This data point also designates the starting point for measuring angle. Cycle End: The Channel 1 data point that triggers that begins the sequence for ending the data re- cording. This value should be less than the Cycle Start value. Cycle End Time: The time value that the Channel 1 data pint must be below the Cycle End value to end the data recording. NOTE: Data recording will end when either the Channel 1 input drops below Cycle End for the length of the time in Cy- cle End Time, or when the Full Scale data recording time (see Section 4.3.5) is completed, whichever comes first. The Low, Target, and High Torque parameters are described below. Low Torque: The Channel 1 data point that signifies the minimum acceptable peak value. This value is used to calculate The Cpk statistic. Must be greater than Cycle Start. Target Torque: The Channel 1 data point that signifies the target peak value. This value is displayed on the real-time plot on the MAIN SCREEN. Must be greater than Low Torque and less than High Torque. High Torque: The Channel 1 data point that signifies the maximum acceptable peak value. This value is used to calculate the Cpk statistic and is used to scale the real-time plot on the MAIN SCREEN. Must se greater than Target Torque. Some additional features of the MAIN SCREEN are shown in Figure 16 below. 4.3.5 Set Recording Time Set the Recording Time by pressing the 5 button on the keypad when viewing the SETUP MENU. The Recording Time parame- ters establish a length for the recording window. See Figure 17. Set Torque Limits Cycle Start (Nm): 5.0 Cycle End (Nm): 4.0 Cycle End Time (sec): 2.0 Low Torque (Nm): 20.0 Target Torque (Nm): 25.0 High Torque (Nm): 30.0 : Select Item. : Save : Exit. RECORDING TIME Full Scale (sec): 10.0 Advance Time (sec): 2.0 : Select Item. : Save : Exit. Figure 14 – Set Torque Limits Screen Figure 15 – Recording Window Parameters Figure 16 – MAIN SCREEN High Torque Target Torque Cycle Start Cpk Stat. Figure 17 – RECORDING TIME Screen

MODEL 962 RECORDER OPERATION MANUAL 13 Navigate the Recording Time screen using the Arrow (��) but- tons on the keypad. Use the numeric buttons on the keypad to input the values. Press the ENTER button to save the values and press ESC to exit back to the SETUP MENU. NOTE: Input values will not be saved unless the ENTER button is pressed. The Recording Time parameters are described below and illus- trated in Figure 18. Full Scale: This value sets the duration of the test in sec- onds. Be sure this value is set to a time period long enough to record the entire test including the Advance Time. Advance Time: This value designates a portion of the Full Scale time to record data prior to the Cycle Start value. Any time set aside for recording prior to Cycle Start must be accounted for when setting the Full Scale time. NOTE: The Recording Window is made up of parameters from the Set Torque Limits (refer to Section 4.3.4) and the Recording Time. If the Recording Time is not long enough to capture the entire parameters set by the Torque Limits the Recording Window will end when the Recording Time runs out. 4.3.6 Set Auto Options The Auto Options are set in SETUP MENU by pressing the 6 button on the keypad. This menu is illustrated in Figure 19. Navigate the AUTO OPTIONS screen using the Arrow (��) buttons on the keypad. Press ESC to exit back to the SETUP MENU. The Auto Options parameters are described as follows. Auto Reset: When ENABLED, automatically resets the Model 962 to the Ready mode after the test is performed and the amount of time set in the Re- set Time field elapses. When DISABLED, press the MAIN button on the keypad to reset the Model 962 to the Ready mode. Reset Time: Amount of time designated in seconds that the Model 962 will wait after a test to set the re- corder back into the Ready mode. This parame- ter is available only if the Auto Reset is ENA- BLED. AutoStore Results: When ENABLED, the numerical results of the last recorded test are automatically stored into the results memory. When DISABLED, the STORE button on the keypad must be pressed to store the numerical results of the last test into the results memory (refer to Figure 6). AutoStore XYData: When ENABLED, the XY (plot) data from the last recorded test are automatically stored to a USB drive placed in the USB A port (refer to Figure 2). When DISABLED, the PRINT but- ton on the keypad must be pressed to open the PRINT/DISK MENU and store the graphic data to the USB drive, or to the connected PC. AutoSend at EOT: When ENABLED, a data packet is automatical- ly sent via the RS232 port of the IO connector at the end of each recorded test. The data packet contains the numeric peak value results of the test. Data is sent using 38400 baud, no parity, 8 bits, and 1 stop bit. When DISABLED, no End Of Test data will be sent to the PC. 4.3.7 Torque-Force Points The Torque-Force Points are set in SETUP MENU by pressing the 7 button on the keypad. The Torque-Force Points are used to pull a torque value at a specified load or a load value at a speci- fied torque from the current test and place it in the results file. NOTE: This feature is available only if Channel 2 is ENABLED (refer to Section 4.3.1). To view data on the results re- port, make sure that Torque-Force is ENABLED in the REPORT FORMAT screen (refer to Section 4.3.9). Enable desired options: AUTO OPTIONS 1) Auto Reset: ENABLED 2) Reset Time (sec): 10 3) AutoStore Results: DISABLED 4) AutoStore XYData: DISABLED 5) AutoSend at EOT: DISABLED Make Selection or : Exit. Select Point Type: FORCE Set Torque-Force Points FORCE-PT0 (N): 26689 FORCE-PT1 (N): 0 FORCE-PT2 (N): 0 FORCE-PT3 (N): 0 FORCE-PT4 (N): 0 PT=0 to Disable : Select Item. : Save : Exit. Figure 18 – RECORDING TIME Parameters Figure 19 – AUTO OPTIONS Screen Figure 20 – Set Torque-Force Points Screen

MODEL 962 RECORDER OPERATION MANUAL 14 Navigate the Set Torque-Force Points screen using the Arrow (��) buttons on the keypad. Use the numeric buttons on the keypad to input the values. Press the ENTER button to save the values and press ESC to exit back to the SETUP MENU. NOTE: Input values will not be saved unless the ENTER button is pressed. The Torque Force parameters are described below. Select Point Type: With the box around the Select Point Type field, press the ENTER button on the key- pad to toggle between TORQUE and FORCE. If TORQUE is selected then load values will be pulled out of the data file at the designated torque value. If FORCE is selected then torque values will be pulled out of the data file at the designated load value. See Figure 21. FORCE / TORQUE PTS 0-4: Using the numeric buttons on the keypad, input the designated torque or force points. Set the point to 0 (zero) to disable the point. 4.3.8 Analysis Setup Access the ANALYSIS MENU from the SETUP MENU by pressing the 8 button on the keypad. Specialized data analysis can be performed on the test data when the parameters from the ANALYSIS MENU are set (see Figure 22). The results of the analysis are placed in the results file. 4.3.8.1 Measurement Window Feature This feature is used when testing may produce an initial spike that should not be captured as the peak value, such as when using an impulse-type tool. A window can be programmed at the end of the data recording that will be used to determine the peak val- ue. For example, if 5 seconds of data are recorded and the Measurement Window is set to 4 seconds, only the last 4 seconds of data will be used to determine the peak value; any peak torque that occurs during the first 1 second of data is ignored. Set this window by pressing the 1 button on the keypad from the ANALYSIS MENU to display the screen shown in Figure 23. The Measurement Window parameters are described below. Window Type: Press the 1 button on the keypad to toggle be- tween TIME, ANGLE, and OFF. Set the Win- dow Type to TIME or ANGLE to set a window at the end of the recording time. Set the Window Type to OFF to disable this feature. Window Size: Press the 2 button on the keypad to set the Win- dow Size in units of either seconds or degrees. Once a value has been input press the ENTER button on the keypad to save the entry. 4.3.8.2 M-Alpha Feature Enable the M-Alpha torque-angle signature analysis method by pressing the 2 button while in the ANALYSIS MENU. The M- Alpha method is used to estimate the amount of clamp load (force) in a bolted joint by studying the torque-angle relationship. See Figure 24. NOTE: To view data on the results report, make sure that M- alpha Data is ENABLED in the REPORT FORMAT screen (refer to Section 4.3.9). 1) Measurement Window ANALYSIS MENU 2) M-Alpha 3) Friction Coefficient Make Selection or : Exit. 1) Window Type: TIME Measurement Window Parameters 2) Window Size (sec): 1.0 Make Selection or : Exit. Figure 21 – Torque-Force Points Figure 22 – ANALYSIS MENU Figure 23 – Measurement Window Parameters Screen Figure 24 – M-Alpha Parameters Screen 1) Lower Tangent Tq: ENABLED M-Alpha Parameters 2) Percent of Peak: 80 Make Selection or : Exit.

MODEL 962 RECORDER OPERATION MANUAL 15 The M-Alpha parameters are described below. Lower Tangent Tq: Press the 1 button on the keypad to ENABLE or DISABLE this function. When ENABLED, the clamp angle (see Figure 25) from the M-Alpha process will be included on the results file. Percent of Peak: When the Lower Tangent Tq is set to ENABLE press the 2 button on the keypad to set the Per- cent of Peak to establish a point to project a tan- gent line through using the peak torque value as the second point (see Figure 25). It is important that both the Peak and the Percent of Peak val- ues lie within the elastic tightening zone. Once a value has been input press the ENTER button on the keypad to save the entry. NOTE: For more information on the M-Alpha Torque-Angle Signature Analysis Methods refer to Section 7. 4.3.8.3 Friction Coefficient Enable friction coefficient analysis by pressing the 3 button while in the ANALYSIS MENU. See Figure 26. The Reference Friction Parameters are used to calculate the Reference friction coefficient per the DIN 946 specification. NOTE: This feature is only available when Channel 2 is enabled and set to FORCE. To view data on the results report, make sure that Friction Data is ENABLED in the RE- PORT FORMAT screen (refer to Section 4.3.9). NOTE: The Reference friction coefficient of the DIN 946 speci- fication is calculated with the same equations used for the Total friction coefficient of the ISO 16047 specifica- tion. Navigate the Reference Friction Parameters screen using the Ar- row (��) buttons on the keypad. Use the numeric buttons on the keypad to input the values. Press the ENTER button to save the values and press ESC to exit back to the SETUP MENU. NOTE: Input values will not be saved unless the ENTER button is pressed. The Friction parameters are described below. Calc Friction At: With the box around the Calc Friction At field, press the ENTER button on the keypad to toggle between FORCE and TORQUE. If FORCE is selected, then a clamp load value will be specified at which the Reference friction coefficient is cal- culated. If TORQUE is selected, then a torque value will be specified at which the Reference friction coefficient is calculated. Clamp / Torque: Use the numeric buttons to enter a value at which the Reference friction coefficient will be calculat- ed. Once a value has been input press the ENTER button on the keypad to save the entry. Nominal Dia: The nominal diameter of the fastener being tested (see Figure 27). Pitch: Thread pitch of the fastener being tested (see Fig- ure 27). Bearing Dia: The bearing diameter of either the bolt head or nut (whichever one is being turned (see Figure 27). Thru Dia: The through hole diameter of the washer (see Fig- ure 27). NOTE: Thread Pitch is determined as the length or width of the thread. For example, a metric fastener may be specified as a M10 x 1.5. M10 indicates nominal diameter of 10 mm and the thread pitch of 1.5 mm. For English fasten- ers, an additional calculation is needed to determine thread pitch. For example, an English fastener may be specified as a 3/8-20 with 3/8 being the nominal diame- ter (3/8-inch = 0.375 in) and 20 indicating 20 threads per inch. To determine the thread pitch, divide 1 by the threads per inch to get the width of the threads in inches (1 / 20 = 0.05 in). Figure 25 – M-Alpha Analysis Figure 26 – Reference Friction Parameters Screen Figure 27 – Fastener Dimensions for Friction Calculations Reference Friction Parms Calc Friction at: FORCE Clamp (N): 26689 Nominal Dia (mm): 10.00 Pitch (mm): 1.50 Bearing Dia (mm): 15.00 Thru Dia (mm): 10.50 : Select Item. : Save : Exit.

MODEL 962 RECORDER OPERATION MANUAL 16 4.3.9 Set Report Format The results file can be customized to show as much or as little data as needed. Set the REPORT FORMAT in the SETUP MENU by pressing the 9 button on the keypad. See Figure 28. Press the keypad number that corresponds with the report data to ENABLE/DISABLE the data. ENABLE the data to include it in the results file. DISABLE the data to omit it from the results file. 4.4 Calibration Menu The CALIBRATION MENU displays options to calibrate the attached transducers to the meter, “zero” the channels, add trans- ducers to the library, or edit existing transducers in the library. This menu can be viewed by pressing the CAL button when on the MAIN SCREEN. See Figure 29. Calibration operations scale the output of the transducer to the meter to insure that the voltage readings by the meter translate to the proper torque or load measurements. 4.4.1 ZERO Only ZERO the data acquisition channels in the CALIBRATION MENU by pressing the 1 button on the keypad. See Figure 30. The CHANNELS SETUP ZERO screen is where the enabled channels zeroing operation is performed. This includes sending zero volts through the attached unloaded transducers and record- ing the output. The Model 962 uses this output as the reference for unloaded conditions and makes sure that no artificial offsets are present in the collected data. Unload the enabled channels and press the ENTER button on the keypad to perform the operation. NOTE: It is recommended that a ZERO operation be performed after the channels are calibrated. 4.4.2 AUTO Calibration AUTO Calibration refers to the operation of automatically cali- brating the transducer to the Model 962 using the shunt calibra- tion method. The operation consists of the meter using a preci- sion resistor (mounted on the binding posts of the meter) to simu- late an output signal and scaling the simulated output to the de- fined calibration value. The AUTO CALIBRATION MENU is accessed through the CALIBRATION MENU by pressing the 2 button on the keypad. See Figure 31. From the AUTO CALIBRATION MENU press the 1 button on the keypad to AUTO calibrate Channel 1 and press the 2 button on the keypad to AUTO calibrate Channel 2. When prompted make sure the appropriate channel is unloaded and then press the ENTER button on the keypad. The Model 962 will perform a zero balance check and display “Zero Taken”, it will then per- form an automatic shunt calibration and should display “Shunt Calibration Successful”. This procedure should be performed for both channels if enabled. NOTE: An error will occur if an acceptable voltage change be- tween the zero and shunted reading is not measured. In the case of an error, the AUTO calibration will be aborted. If an error occurs check to make sure the transducers connections are tight and also check to see that the shunt calibration resistors are installed correctly. Torque (Nm): CALIBRATION MENU Model: 03923 PPR: 1440 F.S.: 67.0 CAL: 68.0 CH2-Force (N): Model: 59810 F.S.: 25000 CAL: 23830 UNLOAD TRANSDUCERS! Press : for ZERO. Enable desired report data: REPORT FORMAT 1) Enabled Channels: ENABLED 2) Test Setup: ENABLED 3) Standard Results: ENABLED 4) Torque-Force: DISABLED 5) Friction Data: DISABLED 6) M-alpha Data: DISABLED Make Selection or : Exit. Figure 28 – REPORT FORMAT Screen 1) ZERO Only CALIBRATION MENU 2) AUTO Calibration 3) MANUAL Calibration 4) Add/Edit Torque Transducer 5) Add/Edit Force Transducer Make Selection or : Exit. Figure 29 – CALIBRATION MENU Figure 30 – CALIBRATION MENU ZERO Screen 1) Torque Channel CALIBRATION MENU 2) CH2-Force Channel Make Selection or : Exit. Figure 31 – AUTO CALIBRATION MENU

MODEL 962 RECORDER OPERATION MANUAL 17 The CALIBRATION MENU will display automatically after this operation. NOTE: It is recommended that a ZERO operation be performed after a calibration operation (refer to Section 4.4.1). 4.4.3 MANUAL Calibration MANUAL Calibration refers to the operation of manually cali- brating the transducer to the Model 962. The operation consists of the meter sending a zero voltage through the attached trans- ducer to get a baseline. A calibration load is then applied to the transducer. The resulting output signal is read by the Model 962 and used to scale the meter’s gain. The MANUAL CALIBRA- TION MENU is accessed through the CALIBRATION MENU by pressing the 3 button on the keypad. See Figure 32. From the MANUAL CALIBRATION MENU press the 1 button on the keypad to MANUALLY calibrate Channel 1 or press the 2 button on the keypad to MANUALLY calibrate Channel 2. When prompted make sure the appropriate channel is unloaded and then press the ENTER button on the keypad. The Model 962 will perform a zero balance check and display “Zero Taken”. Manually apply the calibration load load to the transducer and press the ENTER button on the keypad. The voltage difference will be measured and the outputs will be scaled accordingly. This procedure should be performed for both channels if enabled. NOTE: The MANUAL Calibration can be performed if an au- tomatic shunt calibration is not possible, or if you have access to a certified load or torque application device. It requires accurate calibration loading to ensure accurate results. NOTE: It is recommended that a ZERO operation be performed after a calibration operation (refer to Section 4.4.1). 4.4.4 Add/Edit Torque/Force Transducer The Model 962 allows for storage of transducer definitions for ease of transducer selection when setting up a test. Adding and editing stored transducers can be accessed through the CALI- BRATION MENU by pressing the 4 key for torque transducers or 5 key for load cells on the keypad. See Figure 33. Navigate the Add/Edit Transducer screen using the Arrow (��) buttons on the keypad. Place the box around a currently defined transducer and press the ENTER button to edit the definition. See Figure 34. Place the box around a blank space (at end of list) and press the ENTER button to add a new definition. Press the ESC button to exit back to the CALIBRATION MENU. NOTE: The load cell definition screens are identical to the torque screens except they do not have a field for Pulses Per Rev (PPR). Navigate the DEFINE TOOL MENU screen using the Arrow (��) buttons on the keypad. Place the box around a field and use the numeric buttons to input the definitions. The transducer definition parameters are described below. Model No: Define the transducer with a model number (up to 5 digits). Serial No: Define the transducer with a serial number (up to 8 digits). FS Tq/Force: Input the full scale torque or load value of the transducer. This value can be found on the unit’s calibration certificate. Make sure the proper units are current (refer to Section 4.3.2) Cal Tq/Force: Input the calibration torque or load value of the transducer. This value can be found on the unit’s calibration certificate. Make sure the proper units are current (refer to Section 4.3.2) Model# (Nm) (Nm) PPR F.S. Cal 02727 813.5 813.8 2898 03922 15.0 15.0 1440 03923 67.8 68.0 1440 12548 67.8 68.1 1440 39050 136.0 136.0 0 39225 0.0 0.0 0 : Select Tool. : Select : Exit. DEFINE TOOL MENU Model No: 03922 Serial No: 51069 FS Tq (Nm): 15.0 Cal Tq (Nm): 15.0 Pulses Per Rev: 1440 PPR=0 FOR TOOLS W/NO ANGLE : Select Item. : Save : Exit. Figure 33 – Add/Edit Torque Transducer Screen Figure 34 – DEFINE TOOL MENU Torque Screen Figure 32 – MANUAL CALIBRATION MENU 1) Torque Channel CALIBRATION MENU 2) CH2-Force Channel Make Selection or : Exit.

MODEL 962 RECORDER OPERATION MANUAL 18 Pulses Per Rev: Input the pulses per revolution to define the angle encoder of the torque transducer. This value can be found on the unit’s calibration certificate. This value is not applicable for load cells. NOTE: Input values will not be saved unless the ENTER button is pressed. 4.5 Print/Disk Menu The PRINT/DISK MENU displays options to print, save, and download the test data. View this menu by pressing the PRINT button on the keypad when on the MAIN SCREEN. See Figure 35. 4.5.1 Printer To print directly from the Model 962, press the 1 button while in the PRINT/DISK MENU to open the PRINTER MENU. See Figure 36. The numerical results file or various test plots can be directly printed to a USB HP Desk Jet-compatible printer con- nected to the USB A port. 4.5.1.1 Print Results Press the 1 button on the keypad when in the PRINTER MENU to print the Limit Results file directly to a HP Desk Jet- compatible printer connected to the USB A port. 4.5.1.2 Print XY Plot Press the 2 button on the keypad when in the PRINTER MENU to open the SELECT XY PLOT MENU. See Figure 37. Press the numeric number button on the keypad corresponding to the desired test plot to view the plot on screen. Once the plot is displayed on the screen, press the PRINT button on the keypad to send the plot directly to a printer or press the ESC button on the keypad to escape back to the SELECT XY PLOT MENU. NOTE: XY Plot choices depend on meter setup. If angle is not enabled, the angle choices are not displayed. If a load cell is not being used, the load/force choices are not dis- played. 4.5.2 USB Drive To save data to a USB flash drive from the Model 962, press the 2 button while in the PRINT/DISK MENU to open the USB DISK DRIVE MENU. See Figure 38. The results files, run- down files, setup files, and tool definitions can be saved to a USB flash drive via the USB A port. Using this menu, test set- ups and tool definitions can be uploaded from a flash drive to the Model 962. The USB drive options are described below. Results File � � � � Disk: Press the 1 button on the keypad to save the currently stored numeric data results to a USB flash drive in port USB A (refer to Figure 2). 1) Printer PRINT/DISK MENU 2) USB Drive 3) USB Host Make Selection or : Exit. Figure 35 – PRINT/DISK MENU 1) Print Results PRINTER MENU 2) Print XY Plot Make Selection or : Exit. 1) InpTq vs. Time SELECT XY PLOT 2) InpTq vs. Angle 3) RPM vs. Time 4) RPM vs. Angle 5) InpTq, Angle vs. Time 6) InpTq, CH2-Force vs. Time 7) InpTq, CH2-Force vs. Angle 8) CH2-Force vs. InpTq Make Selection or : Exit. Figure 36 – PRINTER MENU Figure 37 – SELECT XY PLOT MENU 1) Results File � Disk USB DISK DRIVE MENU 2) Current Rundown � Disk 3) Current Setup � Disk 4) Tool Definitions � Disk 5) Disk � Current Setup 6) Disk � Tool Definitions Make Selection or : Exit. Figure 38 – USB DISK DRIVE MENU

MODEL 962 RECORDER OPERATION MANUAL 19 Current Rundown � � � � Disk: Press the 2 button on the keypad to save the XY data of the current test to a USB flash drive in port USB A. Current Setup � � � � Disk: Press the 3 button on the keypad to save the current test setup to a USB flash drive in port USB A. Tool Definitions � � � � Disk: Press the 4 button on the keypad to save the transducer libraries to a USB flash drive in port USB A. Disk � � � � Current Setup: Press the 5 button on the keypad to upload the test setup from the USB flash drive in USB A port into the Model 962. Disk � � � � Tool Definitions: Press the 6 button on the keypad to upload the transducer definitions from the USB flash drive in the USB A port into the Model 962. 4.5.3 USB Host To send the data to a PC from the Model 962, press the 3 button while in the PRINT/DISK MENU to open the USB HOST MENU. See Figure 39. The results files, rundown files, setup files, and tool definitions can be uploaded to a connected PC via the USB B port. NOTE: FastPlot2 software must be installed on the PC to trans- fer data with the Model 962. The USB Host menu options are described below. Results File � � � � Host: Press the 1 button on the keypad to send the numeric data results to a PC via the USB B port. Current Rundown � � � � Host: Press the 2 button on the keypad to send the current XY data to a PC via the USB B port. Current Setup � � � � Host: Press the 3 button on the keypad to send the current test setup to a PC via the USB B port. Tool Definitions � � � � Host: Press the 4 button on the keypad to send the transducer libraries to a PC via the USB B port. NOTE: For more information on the FastPlot2 software refer to Section 6. 4.6 Utility Menu The UILITY MENU displays options to manage miscellaneous Model 962 settings. This menu can be viewed by pressing the SETUP button when on the MAIN SCREEN. See Figure 40. 4.6.1 Set Date and Time To set the date and time on the Model 962, press the 1 button on the keypad while in the UTILITY MENU to open the SET DATE AND TIME screen. See Figure 41. Navigate the SET DATE AND TIME screen using the Arrow (��) buttons on the keypad. Use the numeric buttons on the keypad to input the values. Press the ENTER button to save the values and press ESC to exit back to the UTILITY MENU. NOTE: Input values will not be saved unless the ENTER button is pressed. 4.6.2 Clear Results To clear the numeric results file on the Model 962, press the 2 button on the keypad while in the UTILITY MENU to open the CLEAR RESULTS screen. Refer to Figure 42. 1) Set Date and Time UTILITY MENU 2) Clear Results 3) Install Defaults 4) Check for Smartducers-OFF 5) Set 962 Serial Number 6) Mode: STANDARD 7) Set Analog Outputs 8) Diagnostics Menu 9) Change Password Make Selection or : Exit. 1) Results File � Host USB HOST MENU 2) Current Rundown � Host 3) Current Setup � Host 4) Tool Definitions � Host Make Selection or : Exit. Figure 39 – USB HOST MENU Figure 40 – UTILITY MENU SET DATE AND TIME Month (1-12): 3 Day (1-31): 14 Year (xx): 14 Hour (0-23): 12 Min (0-59): 3 : Select Item. : Save : Exit. Figure 41 – SET DATE AND TIME Screen

MODEL 962 RECORDER OPERATION MANUAL 20 Press the ENTER button on the keypad to clear the numeric re- sults file. Press the ESC button to exit back to the UTILITY MENU. NOTE: Be sure to print or save the numeric results file prior to clearing the results. 4.6.3 Install Defaults To set the Model 962 back to factory preset condition, press the 3 button on the keypad while in the UTILITY MENU to open the INSTALL DEFAULTS screen. See Figure 43. NOTE: This operation will erase all of the settings and trans- ducer definitions. Make sure this information is saved or documented prior to installing defaults. NOTE: The password is set in the Change Password screen (re- fer to Section 4.6.9). The default password is 268. Use the numeric buttons on the keypad to input the password. If any of the information is incorrect an error will appear and the Model 962 will return to the UTILITY MENU. 4.6.4 Check for Smartducers To set the Model 962 to check for transducers with Auto-ID chips, press the 4 button on the keypad while in the UTILITY MENU to toggle this mode between ON and OFF. NOTE: This feature is typically enabled only if the Model 962 will be used with multiple transducers that have Auto- ID chips to simplify the setup and calibration. 4.6.5 Set 962 Serial Number To set the serial number on the Model 962, press the 5 button on the keypad while in the UTILITY MENU to open the SET 962 SERIAL NO screen. See Figure 44. Use the numeric buttons on the keypad to input the serial num- ber. Press the ENTER button to save the values and press ESC to exit back to the UTILITY MENU. NOTE: Input values will not be saved unless the ENTER button is pressed. 4.6.6 Mode To change the mode of the Model 962 to GMPT, press the 6 but- ton on the keypad while in the UTILITY MENU to toggle this mode between STANDARD and GMPT. NOTE: GMPT mode is for a very specific application and will not record data unless commended by a tool station con- troller. This mode should typically be set to STAND- ARD. 4.6.7 Set Analog Outputs To enable and set up the analog output on the IO connector on the Model 962, press the 7 button on the keypad while in the UTILITY MENU to open the SET OUTPUTS screen. See Fig- ure 45. The Model 962 can thus be set up to transmit real-time the output signal from Channel 1, or the Angle on Channel 1, or the output signal of Channel 2. CLEAR RESULTS Clear all results? : Clear : Exit. INSTALL DEFAULTS Password: CAUTION: Installing Defaults WILL Erase Current Settings SET 962 SERIAL NO Serial No: : Save : Exit. SET OUTPUTS 1) Output Channel: CHAN 1 2) Full Scale (Nm): 0.0 Full Scale is 10vdc Output Make Selection or : Exit. Figure 42 – CLEAR RESULTS Screen Figure 43 – INSTALL DEFAULTS Screen Figure 44 – SET 962 SERIAL NO Screen Figure 45 – SET OUTPUTS Screen

MODEL 962 RECORDER OPERATION MANUAL 21 Press the 1 button on the keypad to toggle the Output Channel between: OFF, CHAN 1, CHAN 2, and ANGLE. Press the 2 button on the keypad to enter the full scale output. Press the ESC button on the keypad to exit back to the UTILITY MENU. NOTE: Enabling the analog outputs is used for very specific applications where these output signals will be read by remote data acquisition or control equipment. This mode should typically be set to OFF. 4.6.8 Diagnostics Menu To check the channel inputs on the Model 962, press the 8 button on the keypad while in the UTILITY MENU to open the TRANSDUCER INPUTS screen. See Figure 46. Press the ENTER button to toggle the Channel Shunt between ON and OFF and press ESC to exit back to the UTILITY MENU. 4.6.9 Change Password To set the password on the Model 962, press the 9 button on the keypad while in the UTILITY MENU to open the CHANGE PASSWORD screen. See Figure 47. Use the numeric buttons on the keypad to input the values. Once the numbers are entered the next field will appear. If any of the information is incorrect an error will appear and the Model 962 will return to the UTILITY MENU. NOTE: This password is only used to protect the re-initialize process (Install Defaults). 5.0 USING FASTPLOT2 Use the following procedure to start and use FastPlot2. This procedure assumes you have installed the software on the com- puter by running the setup.exe file located on the installation disc. 5.1 Start FastPlot2 Before starting FastPlot2, the USB cable must be connecting the Model 962 to the PC, and the Model 962 must be powered up and displaying the Main Screen. Click on the FastPlot2 icon on your desktop or select FastPlot2 from the Program Group in which you have installed the program. The initial FastPlot2 screen looks like that shown in Figure 48 below. Figure 48 – FastPlot2 MainView Screen Note the following parts of the screen: • The Title Bar at the top of the screen that identifies the application on the left and provides the Minimize, Full Screen/Window, and Exit buttons on the right. • The Tab Bar below the Title Bar that gives you access to the Main View, ToolsView, SetupView, Run- downView, and Reports View screens. The functions of the FastPlot2 software are divided up into the different view screens. Most of the screens have a context menu that is displayed by right-clicking on the screen. This will pro- vide you with additional functions such as Load, Save, Print, etc. 5.2 MainView Tab In the MainView Tab you can accomplish the following tasks. Access Rights: Choose which way to access the data generated by the Model 962. Torque (AD Cnts): 10 TRANSDUCER INPUTS Angle (Enc Cnts): 0 Force (AD Cnts): 14 Ang2 (Enc Cnts): 0 Battery: 161 counts 12.5V Channel Shunt: OFF : Toggle Channel Shunt : Exit. CHANGE PASSWORD Password: **** New Password: **** Verify: **** Password Change Successful! Figure 46 – TRANSDUCER INPUTS Screen Figure 47 – CHANGE PASSWORD Screen

MODEL 962 RECORDER OPERATION MANUAL 22 View Only: Select this to just receive the data and view it. View and Upload: Select this to receive the data, view it, and upload tool definitions and test setups to the Model 962 View, Save, Upload: Select this to receive data and view it, save the data to a computer drive, and upload tool def- initions and test setups to the Model 962. NOTE: The password for being able to View and Upload is “379”, and the password for being able to View, Up- load, and Save is “157”. Auto Save Options: This feature lets you assign a location for saving data file when they are sent to the PC using FastPlot2. Checking any of the options will store the respective file in the location entered into the location field using the browse function. Test Setup: Stores the Model 962 test setup. Tools: Stores the transducer definitions currently saved in the Model 962. Results: Stores the numerical results from the Model 962. Test Curve: Stores the data that makes up the test curve. Saving the XY Plot data using this selection stores the file in a compressed format that can- not be read by standard spread sheet programs Test Curve (CSV For- mat: Stores the data that makes up the test curve. Saving the XY Plot data using this selection stores the file in a csv (comma separated value) format that can be read easily by most spread- sheet programs About: Provides version information about the FastPlot2 soft- ware and technical support. It also provides information about the Model 962 you are connected to and also the means to upload a firmware update. NOTE: The password to update the firmware is “12345”. 5.3 ToolsView Tab This view lets you set up the torque transducers and load cells that you will be using with your Model 962. See Figure 49. There is a separate library for all of the transducer and load cell data. Once the tools are entered here, they can be selected for use in the SetupView tab. The data for the transducers and load cells is entered on the right side of the screen and all of the tools entered into the FastPlot2 library are listed on the left side of the screen. There is a Context Menu that can be displayed by right-clicking anywhere on the window. From this menu you can do the fol- lowing: • Load a previously saved tool definition file (*.xdf) • Save the displayed tool definitions to the PC • Upload the displayed tool definitions to the Model 962 • Upload a previously save tool definition file to the Model 962 Figure 49 – ToolsView Tab Tool Editor: Provides a method of defining transducers using the FastPlot2 software. Name: Define the transducer with a model number (up to 5 digits) Serial Number: Define the transducer with a serial number (up to 8 digits) Full Scale: Input the full scale torque or load value of the transducer. This value can be found on the unit’s calibration certificate. Calibration: Input the calibration torque or load value of the transducer. This value can be found on the unit’s calibration certificate. PPR: Input the pulses per revolution to define the an- gle encoder of the torque transducer. This value can be found on the unit’s calibration certificate. This value is not applicable to load cells. 5.4 SetupView Tab This tab lets you enter the information needed to set up a test in the Model 962. See Figure 50. There is also a Context Menu that you can display by right-clicking at any place on the win- dow. From the Context Menu you can do the following: • Load a previously saved setup file (*.stp) • Set default values • Save the displayed setup to the PC • Upload the displayed setup to the Model 962 • Upload a stored setup file to the Model 962

MODEL 962 RECORDER OPERATION MANUAL 23 Figure 50 – SetupView Tab The following describes the SetupView options. Channels: For Channel 1, select the type of transducer be- ing used, torque or force; if the torque transducer has an angle encoder, turn the angle measure- ment ON or OFF, and select TWOWAY or ONEWAY angle recording. The same options are available for the Channel 2 load cell or trans- ducer, when enabled. The data for the transduc- er/load cell will be indicated in the Assigned Transducer box. Reference Section 4.3.1 Analog Output: Click the button to toggle between OFF, Chan 1 (Torque), Chan 2 (Load), or Angle. NOTE: Only one of these signals can be pro- vided. Enabling allows you enter a full scale value for the selected output. (This may not necessarily be the full scale of the torque or load sensor.) Recording Direction: Click the button to toggle between CW and CCW. Reference Section 4.3.3. Engineering Units: Click the button to toggle between the various selections that are available. Reference Section 4.3.2. Torque Limits: Input values to setup the recording parameters. Reference Section 4.3.4. Recording Time: Input values to setup the length of the test. Reference Section 4.3.5. Options: Select the automatic options for resetting the Model 962 after a test, storing the data and plot data automatically, and sending an End Of Test data packet after each test is complete. Reference Section 4.3.6. Test Points: Select either torque values at which to record clamp load or force points at which to record torque values. Those torque/force points are set in the space below the Point Type. Reference Section 4.3.7. Analyses: Click the button to toggle between the optional analytical features available with the Model 962. Set the set the measurement window, the M- Alpha point, and enter the geometry of the fas- tener to obtain the Reference Friction. Reference Section 4.3.8. M-Alpha: If M-Alpha is selected in Analyses then input the percentage of Peak. Reference Section 4.3.8.2. Reference Friction: If Reference Friction is selected in Analyses then input the calculation points and joint geometry. Reference Section 4.3.8.3. Reports: Select the data that will be included in the nu- meric data report. Reference Section 4.3.9. Test Mode: Click the button to toggle between the Standard Test mode and the GMPT mode. This mode should be set to STANDARD unless a GMPT controller is being used. Reference Section 4.6.6. 5.5 RundownView Tab The RundownView Tab lets you view the rundown data that has been uploaded from the Model 962. See Figure 51. Figure 51 – RundownView Tab

MODEL 962 RECORDER OPERATION MANUAL 24 As with the other views, you can obtain a Context Menu by right-clicking on the window. See Figure 52. Figure 52 – Rundown with Context Menu From the Rundown Context menu you can perform several other important options including the following: Show Cursor: Displays a crosshair that follows the displayed plot data and allows for a data point to be marked by clicking the mouse. Up to 5 data points can be marked. The data points are dis- played in the upper left corner of the plot, and can be referred to as the Legend. Once the cursor is selected, you can display the Context Menu and choose to hide it. Hide Legend: Removes the labeling from the plot. Once the legend text is removed, it can be re-displayed by selecting Show Legend from the Context Menu. Mark Point: Marks a point on the plot. Clear Point/Clear All Points: Clears any or all of the marked data points on the plot. Set Scale: Displays a box into which scaling and division boundaries for the plot can be input. This pro- vides the ability to zoom in to view a particular section of the data. Restore Scale: Restores the plot to the original display axis scaling. Y-Axis: Select which of the recorded or calculated data will be displayed on the Y-axis of the plot. X-Axis: Select which of the recorded or calculated data will be displayed on the X-axis of the plot. Load: Open up and display a previously saved plot file. Save: Save the displayed data to the PC. Export: Exports and saves the data in a *.CSV format that can be accessed by another program such as Microsoft Excel. Print: Brings up the computer’s print window so that the printer and other print options needed to print out the data can be selected. 5.6 ReportView Tab This view lets you display the numeric test results recorded by and uploaded from the Model 962. See Figure 53. Figure 53 – ReportView Tab The Context Menu for this tab provides for the following op- tions: Load: Displays a previously saved numeric data file. Remove Results: Allows for the removal of a selected line of data from the results file. Note: Once a line of data is removed it cannot be restored. Save: Saves the displayed numeric data report to the PC. Export: Saves the displayed numeric data report in a format (*.CSV) that can be imported by anoth- er program such as Microsoft Excel. Print: Displays the computer’s Print window so that the numeric report can be printed. 5.7 Exit FastPlot2 To exit the program, click on the red Exit button in the upper right corner.

MODEL 962 RECORDER OPERATION MANUAL 25 5.8 Installations of Software Upgrade Software upgrades are installed by uploading the new firmware from a remote laptop or desktop computer, via the USB port and FastPlot2 software. From the MainView tab of FastPlot2 click on the Update Firmware button and follow the prompts. When prompted for a password, enter “12345”. 6.0 M-ALPHA ANALYSIS The Model 962 is ideal for threaded fastener joint analysis. One of the best tools is our patented M-Alpha analysis that lets you estimate fastener tension simply by recording and analyzing torque-angle signatures. This section provides a brief overview of how the Model 962 can be used for M-Alpha analysis. 6.1 M-Alpha Overview There are three basic steps to conducting an M-Alpha analysis on a problematic bolted joint. The first step is to qualify the joint components by performing some preliminary tests to determine the relationship between torque, angle, and tension. Once a con- sistent relationship between angle and tension is established, you can calculate the angle-tension coefficient in terms of tension per degrees of turn. Finally you can audit the assemblies and esti- mate the tension on the fastener by analyzing the torque-angle curve. 6.2 M-Alpha Analysis Procedure Use the following steps to conduct an M-Alpha Analysis using the Model 962. NOTE: The M-Alpha analysis method can be used for analyz- ing test data recorded in the elastic tightening region of the torque angle curve. Therefore the Peak Torque and the Lower Tangent Torque value must both lie within this region for the analysis calculation to be accurate. 1. Using your Model 962, rotary torque sensor, and clamp force sensor run a series of torque-angle-tension tests. Make sure that you have set the Lower Tangent Torque properly as described in Section 4.3.8. After the tests are done, print out the numeric and graphic data. 2. Examine the torque-angle graphs to determine if you are recording data in the elastic clamping zone. This means that the slope of the torque-angle curve is a straight line leading up to the final torque being reached. A bend or curve in the line means that embedment or thread strip or some other fac- tor is adversely affecting the joint. 3. Examine the numeric data and locate the data listed in the column labeled Elas Pk. This is the tightening angle or the amount of turn of the fastener that went directly into clamp- ing the parts together. 4. To determine the angle-tension coefficient, divide the aver- age tension by the average tightening angle (Elas Pk). The result will be in terms of clamp load vs. degrees. For exam- ple, if your average tension is 7500 N and your average tightening angle is 40 degrees, your angle-tension coefficient is 187.5, meaning for every degree of turn, 187.5 N of clamping force is generated. 5. Subsequently, when you conduct torque-angle audits of the bolted joint using your Model 962 and a rotary torque-angle sensor, estimate your clamp load by multiplying the result- ing tightening angle (Elas Pk) by the angle-tension coeffi- cient. NOTE: The effectiveness of the M-Alpha analysis method is affected by yield in the fastener and by the state of fric- tion in the joint. The presence of yield or differences in friction can produce errors in the estimation of clamp load. Slight differences in the plating finish or protective coating on the fastener may produce error as well. More complete information on the M-Alpha process and other possible uses for the Model 962 recorder can be found in the Knowledge Library on the PCB Load & Torque website at the following link: https://www.pcb.com/WhitePaperLibrary.aspx#Fastening 7.0 MAINTENANCE Routine maintenance of the Model 962 should include inspection and cleaning of the electrical connectors, housings, and mounting surfaces. Since the Model 962 instrument is computer equipment, use the same cleaning routine as you would for a laptop comput- er, iPad, tablet, or cell phone. 7.1 Battery Use & Re-Charging The Model 962 is a portable instrument. It can operate for up to 8 hours on a fully charged internal battery. NOTE: It is recommended that you take data while using bat- tery power only. This will minimize the interference of electrical noise in the acquired data. Keep solvent-type cleaners away from the front panel dis- play and keyboard as they may damage those components. CAUTION The Model 962 is not watertight, so do NOT submerge the unit, pour liquids poured on it, or let the unit get wet. Never use a pressure washer on the Model 962 or the torque transducers and load cells typically used with it. CAUTION

MODEL 962 RECORDER OPERATION MANUAL 26 7.2 Handling & Placement Please observe the precautions contained in the following para- graphs. In general, since the Model 962 is computer equipment, take the same precautions with it as you would a portable or laptop per- sonal computer. Allow adequate air circulation to prevent internal heat buildup. Do not set up or operate in close proximity to heat sources such as radiators or air ducts. Do not use in a corrosive environment or place near equipment such as salt-spray cabinets, etc. The cast aluminum housing of the Model 962 makes the instru- ment a durable design, but you should avoid conditions that will induce vibration, and avoid dropping the instrument. Since the Model 962 is computer equipment, use the same clean- ing routine as you would for a personal computer. The Model 962 is NOT watertight so do NOT let the instrument get wet. Keep solvent-type cleaners away from the front panel display and keypad. Care for the keypad as you would for a personal computer. 8.0 TROUBLE SHOOTING Proper performance of the Model 962 with the connected torque transducers and load cells requires careful attention to both electrical and mechanical aspects of the equipment as a measurement system. A basic understanding of the electrical and mechanical installa- tion requirements is recommended. For basic trouble-shooting guidance, please refer to the following table. Problem Description Action Model 962 does not power up Battery pack fully discharged Recharge the battery pack Battery will not charge Charging LED not ON Defective or improper charging wall adapter Battery pack defective Return to factory for evaluation Battery charge does not last Battery not fully charged Charge battery until LED is OFF Battery pack weak/defective Return to factory for evaluation Channel values random and floating after power ON Model 962 not calibrated to the transducers Calibrate Model 962 to transducers Recorded signal “Noisy” Charging battery pack during test Remove charger for testing Transducer cable is loose Tighten cable firmly to Model 962 Cable has intermittent connection Replace or repair cable Transducers and cables near high energy equip- ment or wires Route/move transducers and cables away from electro-magnetic radiating wires and equipment Transducer may need service Contact support for assistance Recorded signal is saturated Transducer cable is loose Tighten cable firmly to Model 962 Cable not attached to transducer Attach cable to transducer Cable intermittent or defective Replace or repair cable Transducer may need to be serviced Contact support for assistance Calibration Error – Low Output Calibration resistor not installed on Model 962 Install proper calibration resistor Calibration resistor is loose Tighten firmly Calibration resistor has a broken wire Replace calibration resistor Cable has open or shorted wires Replace or repair cable Transducer may need service Contact support for assistance Calibration Error – Zero Offset Transducer cable is loose Tighten firmly to Model 962 and transducer Cable has open or shorted wires Replace or repair cable Transducer may need service Contact support for assistance Scaling Errors Selected transducer not calibrated to Model 962 Calibrate Model 962 to transducer Wrong calibration resistor is installed Install proper calibration resistor, the resistor is called out in the calibration certificate

MODEL 962 RECORDER OPERATION MANUAL 27 Problem Description Action Display not showing Peak values Model 962 is in “Track” mode Press the “TASK” button to toggle peak mode to ON Error saving limit values Cycle End not < Cycle Start Adjust parameter value Low Limit not > Cycle Start Adjust parameter value Target not > Low Limit Adjust parameter value High Limit not > Target Adjust parameter value Rundown status always “In-Cycle” Cycle Start value set too low Adjust parameter value Transducer cable is loose Tighten cable firmly Model 962 not calibrated to transducer Calibrate Model 962 to transducer Readings are not being saved to Limits memory Auto save is disabled Enable auto save if desired Manual save mode is enabled Press the “STORE” button after recording has completed Cannot connect to PC via USB Model 962 not connected to PC USB Connect USB to PC Model 962 not on MAIN SCREEN when connecting to FastPlot2 Put Model 962 on the MAIN SCREEN, then run FastPlot2 Model 962 – SiLabs USB drive not installed or is not working Re-install driver from software CD, Drivers folder USB port on PC not working Try a different USB port USB flash drive not working Flash drive not compatible or defective Try another flash drive 9.0 CALIBRATION / REPAIR SERVICES A yearly calibration cycle is recommended to ensure that the unit’s performance matches the factory specifications. PCB Load & Torque offers calibration and repair services. The PCB Calibration Laboratory in Farmington Hills, Michigan is A2LA Accredited per ISO/IEC 17025. Standard calibration certificates list ten load points ascending. Additional data points are available at extra cost upon request. Certificate information includes tabulated measurements, devia- tions of nonlinearity, a Best Fit Calibration Equation, specifica- tions for accuracy, standard deviation, and uncertainty, and traceability statements. If an initial evaluation shows that a transducer requires repair, PCB will provide the customer with an estimate prior to taking any corrective action. Before sending a load cell back to the factory for any reason, please contact PCB Load & Torque Customer Service to request a return material authorization (RMA). For calibration services, if possible, a copy of the purchase order covering the requested services should be included with the returned instrument. 10.0 WARRANTY Standard warranty on the Model 962 covers parts and workman- ship. For full details, refer to the Warranty Statement supplied with each instrument. If the Model 962 is defective for any reason, please contact PCB Load & Torque to request technical assistance. If we are unable to assist you, return it to the factory for detailed evaluation. Fac- tory evaluation may show that the instrument is repairable or non-repairable, and if repair or replacement will be under war- ranty. If not under warranty, the customer will be contacted with the cost of repair and recalibration. Once authorization to pro- ceed is received, a delivery date will be provided. 11.0 SAMPLE TEST SETUPS The following paragraphs provide information on some of the most common ways the Model 962 is set up and used. 11.1 Torque-Tension Testing Torque-tension testing is typically used to test the coating or plat- ing on a surrogate test bolt or test part. Torque-tension testing is a common means of estimating the frictional characteristics of the plating or coating process. 11.1.1 Scope Testing consists of installing a test bolt, washer, and nut into a clamp load cell and applying torque until a shutoff value is reached. Torque-tension points are set to either pick off the ap- plied torque values at specified fastener tension values, or pick off fastener tension values at specified applied torque values. It is also possible to calculate the Reference Friction (or Total Fric- tion) value at a specified torque or tension value. Figure 54 illustrates a typical set of torque-tension test equipment using a Model 962 for data acquisition.

MODEL 962 RECORDER OPERATION MANUAL 28 Figure 54 – Basic Model 962 Torque vs. Tension System The setup selections for a torque-tension test for a M10 grade 10.9 surrogate bolt might resemble the following. Note that cer- tain setup values will differ depending on the size of the test bolt and the test specification being used. NOTE: Be sure to consult the test specification when setting up to perform torque-tension testing to ensure all of the values and procedures are accounted for. 11.1.2 Torque-Tension Testing Equipment Setup 1) Channels Setup CHANNEL 1 1) TYPE: TORQUE 2) ANGLE: ENABLED 3) ANGLE COUNT: TWOWAY 4) TRANSDUCER: 39250 CHANNEL 2 5) INPUTS: ENABLED 6) TYPE: FORCE 7) TRANSDUCER: 59810 2) Units Nm, N, mm 3) Direction CW 4) Set Torque Limits Cycle Start (Nm): 20.00 Cycle End (Nm): 10.00 Cycle End Time (sec): 0.10 Low Torque (Nm): 40 Target Torque (Nm): 70 High Torque (Nm): 160.00 5) Set Recording Time Full Scale (sec): 5.00 Advance Time (sec): 0.50 6) Set Auto Options Enable desired options: 1) Auto Reset: ENABLED 2) Reset Time (sec): 10 3) AutoStore Results: ENABLED 4) AutoStore XY Data: ENABLED 5) AutoSend at EOT: DISABLED 7) Torque Force Points Select Point Type: FORCE-PT0 (N): 20000 FORCE-PT1 (N): 30000 FORCE-PT2 (N): 36100 FORCE-PT3 (N): 0 FORCE-PT4 (N): 0 8) Analysis Setup 1) Measurement Window 2) M-Alpha 3) Friction Coefficient Calc Friction at: FORCE Clamp (N): 36100 Nominal Dia (mm): 10 Pitch (mm): 1.5 Bearing Dia (mm): 15.0 Thru Dia (mm): 10.4 9) Set Report Format Enable desired report data: 1) Enabled Channels: ENABLED 2) Test Setup: ENABLED 3) Standard Results: ENABLED 4) Torque-Force: ENABLED 5) Friction Data: ENABLED 6) M-alpha Data: DISABLED The test setup for a torque vs. tension example would be dis- played in FastPlot2 as follows: 11.1.3 Test Procedure 1. The test bolt, washer, and nut are installed in the clamp force load cell and tightened close to finger-tight. Refer to Figures 56 and 57. 2. The socket on the drive motor is engaged with the bolt head. 3. The Model 962 is placed in the “READY” mode. 4. The drive motor is started and run at a precise speed (typi- cally 30 RPM) to its shutoff point (typically a torque value greater at or around the High Torque value). 5. The data from the test is stored automatically or manually as programmed. 6. When all fasteners have been tested, the limit results report is printed from the Model 962 or uploaded to the PC via FastPlot2 for printing or storage. Figure 55 – FastPlot2 Torque-Tension Test Setup

MODEL 962 RECORDER OPERATION MANUAL 29 11.2 Power Tool Testing Ensuring the proper operation of assembly tools in an important part of building quality assemblies. PCB Load & Torque can provide the equipment needed to verify the performance charac- teristics of most electric and pneumatic power torque tools. 11.2.1 Scope This test procedure provides the basic steps necessary to verify the performance characteristics of most hand held electric and pneumatic power tools. NOTE: This is provided as an example only. There are several established tool testing specifications so be sure to refer to the required specification for precise settings. Figure 56 – Typical Power Tool Audit Setup 11.2.2 Power Tool Testing Equipment Setup A typical set of equipment for testing power tools is listed below. 1. Model 962 Instrument: Displays peak torque values for power tools and torque wrenches. 2. Rotary Torque Transducer: Measures the amount of torque that is supplied by the tool. 3. Power Tool Joint Simulator: Provides mounting and posi- tioning for tool, and a series of Belleville-type washers that can be set up in various arrangements to simulate hard, me- dium, or soft joint rates. 4. Transducer Cable: Connects rotary torque sensor to Model 920 instrument. 5. Printer (optional): Prints out data and statistics recorded by the data acquisition. Not shown. 6. Power Tool and Controller: The tool to be tested and its controller. Not Shown. 11.2.3 Setup Menu for Power Tool Testing The setup selections for testing a power tool designed to shutoff at 50 Nm ±5% might be set as follows. 1) Channels Setup CHANNEL 1 1) TYPE: TORQUE 2) ANGLE: ENABLED 3) ANGLE COUNT: TWOWAY 4) TRANSDUCER: 39250 CHANNEL 2 5) INPUTS: DISABLED 6) TYPE: FORCE 7) TRANSDUCER: 59810 2) Units Nm, N, mm 3) Direction CW 4) Set Torque Limits Cycle Start (Nm): 7.00 Cycle End (Nm): 5.00 Cycle End Time (sec): 2.00 Low Torque (Nm): 45.00 Target Torque (Nm): 50.00 High Torque (Nm): 55.00 5) Set Recording Time Full Scale (sec): 10.00 Advance Time (sec): 2.00 6) Set Auto Options Enable desired options: 1) Auto Reset: ENABLED 2) Reset Time (sec): 10 3) AutoStore Results: ENABLED 4) AutoStore XY Data: ENABLED 5) AutoSend at EOT: DISABLED 7) Torque Force Points 8) Analysis Setup 9) Set Report Format Enable desired report data: 1) Enabled Channels: ENABLED 2) Test Setup: ENABLED 3) Standard Results: ENABLED 4) Torque-Force: DISABLED 5) Friction Data: DISABLED 6) M-alpha Data: DISABLED Figure 56– Torque-Tension Test Fixturing Stack-up At least 2 threads should be protruding from the nut when fully tightened. Figure 57– Torque-Tension Test Proper Thread Engagement

MODEL 962 RECORDER OPERATION MANUAL 30 The test setup above would be displayed in FastPlot2 as shown in Figure 57. Figure 57 – Tool Testing Setup View 11.2.4 Power Tool Verification Procedure The following procedure outlines the steps required to verify power tool performance. NOTE: Be sure to refer to the required specification for precise settings. 1. Connect the instrument to the torque transducer and power it up. 2. Perform a transducer calibration and clear the memory. 3. Make sure that the Measurement Mode of the instrument is set to read Peak torque. Refer to the Model 920 instruction manual. 4. Set up the joint simulator to emulate the desired joint rate. 5. Position the tool on the joint simulator with the output drive of the power tool inserted into the input end of the rotary torque sensor. Then position the rotary torque sensor on the input drive of the joint simulator. Adjust the tool as needed. Refer to the photo above as needed. 6. Activate the power tool and run it until it shuts off or stalls. 7. Back off the joint simulator and return it to the start position. 8. Repeat steps 6 and 7 until the number of runs required by the test procedure are recorded. Typically, 10 to 25 rundowns are recommended. 9. If the tool does not meet the required torque shutoff specifi- cation, make the necessary adjustments to the tool or the tool controller, and repeat Steps 6 and 7. 10. If necessary, repeat Step 9 until the tool is performing within specification. 11. Print out the final test data or upload it to a computer as de- sired. 12.0 QUICK REFERENCE This section is designed to give a quick overview of common functions of the Model 962 recorder. The following functions are covered: 12.1 Add/Edit Transducers 12.2 Setup a Test 12.3 Calibrate Transducers 12.4 Perform a Test 12.5 Save Rundown 12.6 Update Report 12.7 View a Plot 12.8 Export Data 12.9 Clear Results 12.10 View Diagnostics 12.1 Add/Edit Transducers Reference Section 4.4.4 1. From the MAIN SCREEN press the CAL button. 2. From the CALIBRATION MENU: a. Press 4 to Add/Edit a Torque Transducer. b. Press 5 to Add/Edit a Force Transducer. 12.2 Setup a Test Reference Section 4.3 1. From the MAIN SCREEN press the SETUP button. 2. From the SETUP MENU go through selections 1 – 9 (reference Sections 4.3.1 – 4.3.9). 12.3 Calibrate Transducers Reference Section 4.4 1. From the MAIN SCREEN press the CAL button. 2. From the CALIBRATION MENU: a. Press 2 to perform an AUTO Calibration (ref- erence Section 4.4.2). b. Press 3 to perform a MANUAL Calibration (reference Section 4.4.3). NOTE: A ZERO operation should be performed immediately after a calibration operation (refer to Section 4.4.1).

MODEL 962 RECORDER OPERATION MANUAL 31 12.4 Perform a Test Reference Section 4.2 1. Press the ESC button until the MAIN SCREEN is visible (refer to Figure 8). 2. Make sure that “Ready” is displayed in the bottom left corner of the MAIN SCREEN (see Figure 9). If “Done” is displayed press the MAIN button. 3. Perform the test. 12.5 Save Rundown Reference Sections 4.5.2, 4.5.3, 4.3.6 1. If AutoStore XY Data is DISABLED then press the PRINT button (while still on the MAIN SCREEN). a. From the PRINT/DISK MENU: i. Press 2 to save rundown data to an at- tached USB flash drive (reference Section 4.5.2). ii. Press 3 to save rundown data to an at- tached host computer via the FastPlot 2 software (reference Section 4.5.3). 2. If AutoStore XY Data is ENABLED then the run- down data will be automatically stored to a USB flash drive (if connected). NOTE: Reference Section 4.3.6 to ENABLE/DISABLE the AutoStore XY Data function. 12.6 Update Report Reference Sections 3.8, 4.3.6 1. If AutoStore Results is DISABLED then press the STORE button (while still on the MAIN SCREEN, reference Section 3.8). 2. If AutoStore Results is ENABLED then the run- down data will be automatically stored to the Mod- el 962 memory. NOTE: Reference section 4.3.6 to ENABLE/DISABLE the AutoStore Results function. 12.7 View a Plot Reference Section 4.5.1 1. After a test is run, press the PRINT button (while still on the MAIN SCREEN). 2. From the PRINT/DISK MENU press 1 for the Printer. 3. From the PRINTER MENU press 2 to Print XY Plot. 4. From the SELECT XY PLOT menu select a plot to view on the screen. NOTE: A plot can only be viewed for the current rundown in memory. 12.8 Export Data Reference Sections 4.5.2, 4.5.3 1. From the MAIN MENU press the PRINT button. 2. From the PRINT/DISK MENU: a. Press 2 to export data to a USB flash drive (reference Section 4.5.2). b. Press 3 to export data to a host computer (ref- erence Section 4.5.3). 12.9 Clear Results Reference Sections 4.6.2 1. From the MAIN MENU press the UTILS button. 2. From the UTILITY MENU press 2 to Clear Re- sults. 3. From the CLEAR RESULTS screen press the EN- TER button to clear the results. 12.10 View Diagnostics Reference Sections 4.6.8 1. From the MAIN MENU press the UTILS button. 2. From the UTILITY MENU press 8 to view the Di- agnostics Menu from the TRANSDUCER INPUTS screen. Manual Number: 60809 Manual Revision: NR Revision Date: 1/26/15 ECO Number: 43769

MODEL 962 RECORDER OPERATION MANUAL 32 NOTES: