Deprag ME 5600 User manual

015128en
Operating instruction booklet
- Translation of the original instructions -
Electronic Torquemeter
Type: ME 5600
Order No.: 201440 A
NOTICE ALL DOCUMENTATIONS !
Before beginning work this operating instruction booklet and the enclosed
safety instructions (no. 016000, pink-colored booklet) have to be read through
carefully. Always follow the instructions during operation. Give this operating in-
struction booklet and the appropriate safety instructions to the operator.

Contents
1Definition of signal words and symbols .....................................................................5
2Safety Instructions.....................................................................................................6
3Intended Use.............................................................................................................6
4Scope of Delivery ......................................................................................................6
5Short Description.......................................................................................................7
6Definitions .................................................................................................................8
7Front and rear panel..................................................................................................9
7.1 Front panel of ME5600............................................................................................9
7.2 Rear (connector) panel of ME5600 ......................................................................10
8Interface Description ...............................................................................................11
8.1 Strain Gauge (DMS) and Inline Rotating Shaft Transducers.............................11
9Required Accessories .............................................................................................12
10 Optional Equipment.................................................................................................12
11 Operation ................................................................................................................14
11.1 Installation and Connection.................................................................................14
11.2 General Measurement Technique Information...................................................14
11.3 Machine Capability Study.....................................................................................14
11.3.1 Machine Capability Index (Cm)............................................................................15
11.3.2 Machine Capability Index (Cmk)..........................................................................15
11.4 Operation of the Electronic Torque Measurement System ...............................16
11.4.1 Piezo Electric Effect.............................................................................................16
11.4.2 Operation of the Piezo Transducer......................................................................16
11.4.3 Drift (with Piezo-Transducers) .............................................................................16
11.4.4 DMS-Bridge.........................................................................................................16
11.5 The Main Screen....................................................................................................17
11.5.1 DMS Setting ........................................................................................................17
11.5.2 Piezo Setting .......................................................................................................20
11.5.3 Header Settings...................................................................................................22
11.5.4 Additional Settings...............................................................................................23
11.5.5 Measurement Procedure .....................................................................................29
11.5.6 Direct Help...........................................................................................................35
12 Measuring Ranges ..................................................................................................36
12.1 Strain Gauge Transducer (DMS)..........................................................................36
12.2 Piezo Electric Transducer ....................................................................................36
12.3 Torque Transducer with Rotating Shaft..............................................................37
13 Remote Control of ME5600 Using the Serial Port...................................................38
13.1 Configuration of the Serial Port...........................................................................38
13.2 Special Properties of the Remote Control ..........................................................38
13.3 Start and Stop of Remote Control .......................................................................38
13.4 Command Format .................................................................................................39
13.5 Communication Protocol .....................................................................................39
13.6 Error Handling.......................................................................................................39
13.7 List of Available Commands................................................................................40
13.8 Description of Commands ...................................................................................41
13.8.1 End of Remote Control ........................................................................................41
13.8.2 Transducer Setup ................................................................................................41
13.8.3 Type/Measuring Range Setup .............................................................................42
13.8.4 Notes for Piezo measuring ranges ......................................................................43
13.8.5 Set Calibration Value...........................................................................................44
2

13.8.6 Start Measurement ..............................................................................................44
13.8.7 End Measurement ...............................................................................................44
13.8.8 Set Language ......................................................................................................44
13.8.9 Set Measurement Units .......................................................................................45
13.8.10 Select Measurement Method ...........................................................................45
13.8.11 Set Series length..............................................................................................45
13.8.12 Set Audible Alert ..............................................................................................46
13.8.13 CMK-Adjust Limits ...........................................................................................46
13.8.14 Request Results...............................................................................................47
13.8.15 Request Statistics ............................................................................................47
13.8.16 Example of a measurement using remote commands .....................................48
14 Service and Maintenance........................................................................................49
15 Troubleshooting ......................................................................................................50
16 Technical Data ........................................................................................................51
17 Placing Out of Operation.........................................................................................52
18 EG-Declaration of Conformity .................................................................................53
19 Service Locations and Authorized Partners ............................................................54
List of figures
Image 1: Front panel of ME5600 ......................................................................................9
Image 2: Rear (connector) panel of ME5600 ..................................................................10
Image 3: The Main Screen..............................................................................................17
Image 4: Main Screen for DMS Transducer...................................................................17
Image 5: DMS-Type Setting............................................................................................18
Image 6: DMS Calibration Value.....................................................................................18
Image 7: Entry of the DMS Nominal Value .....................................................................19
Image 8: Setting the DMS Sensitivity..............................................................................19
Image 9: Main Screen for Piezo Transducer...................................................................20
Image 10: Setting the Piezo Measurement Range........................................................20
Image 11: Entry of the Piezo Calibration Value.............................................................21
Image 12: Main Screen for Transducer/header.............................................................22
Image 13: Setting the Transducer/Header Type ...........................................................22
Image 14: Setting the nominal Value for the Transducer/Header..................................23
Image 15: The Setting Menu .........................................................................................23
Image 16: Setting the language ....................................................................................24
Image 17: Setting the Torque Unit ................................................................................24
Image 18: Setting the Signal Recognition .....................................................................25
Image 19: Setting the Measurement Method ................................................................25
Image 20: Setting the Number of Measurement per Series ..........................................26
Image 21: Printer Settings.............................................................................................26
Image 22: Signal Tone Setting ......................................................................................27
Image 23: Selecting the CmK-Limit Values Setting.......................................................27
Image 24: Setting the CmK Upper Limit ........................................................................28
Image 25: Setting the CmK Limits as percentage of the average .................................28
Image 26: Display during Measurement........................................................................29
Image 27: Timeout cancellation ....................................................................................29
Image 28: Manual cancellation of a single measurement by automatic signal recognition
30
Image 29: Measurement results display........................................................................30
Image 30: Security query at start of Series ...................................................................31
Image 31: Single Measurement in a Series...................................................................31
3

Image 32: End of a Series.............................................................................................32
Image 33: Selection menu for Results Display..............................................................32
Image 34: Display of the Series Results as a List .........................................................33
Image 35: Display of the Measurement Series Results as a Diagram ..........................33
Image 36: Display of the Measurement Range Statistics ..............................................34
Image 37: Current Value Measurement ........................................................................35
Image 38: Online-Help ..................................................................................................35
List of tables
Table 1: Strain Gauge (DMS) and Inline rotating shaft transducer ................................11
Table 2: Connector Cable ..............................................................................................12
Table 3: Optional Equipment .........................................................................................12
Table 4: Equipment........................................................................................................13
Table 5: -Value..................................................................................................15
mkm CC /
Table 6: Units of Measurement Range Display..............................................................21
Table 7: Command Format ............................................................................................39
Table 8: Error Handling..................................................................................................39
Table 9: List of Available Commands ............................................................................40
Table 10: End of Remote Control.................................................................................41
Table 11: Transducer Setup.........................................................................................41
Table 12: Type/Measuring Range Setup......................................................................42
Table 13: Factors for measuring range calculation on Piezo transducers ....................43
Table 14: Conversion factors for torque units...............................................................43
Table 15: Set calibration value .....................................................................................44
Table 16: Start Measurement.......................................................................................44
Table 17: End measurement ........................................................................................44
Table 18: Language Setup ...........................................................................................44
Table 19: Set measurement units ................................................................................45
Table 20: Select measurement method........................................................................45
Table 21: Set Series length ..........................................................................................45
Table 22: Set audible alert ...........................................................................................46
Table 23: CMK-Adjust Limits........................................................................................46
Table 24: Request Results. ..........................................................................................47
Table 25: Request statistics .........................................................................................47
Table 26: example of single measurement using remote commands ..........................48
4

1 Definition of signal words and symbols
The signal words and symbols used in the technical documentation (safety instructions,
operating instruction booklet, etc.) have the following meaning:
DANGER
Indicates an immediate danger which causes serious injuries or even
death if not avoided.
WARNING
Indicates a threatening danger which can cause serious injuries or even
death if not avoided.
CAUTION
Indicates a danger or unsafe procedure which can cause injuries to a per-
son or material damages if not avoided.
NOTICE
Indicates a potentially dangerous situation which can cause damage to
the product or its surroundings if not avoided.
IMPORTANT
Indicates tips and other useful information.
In each case the symbol used does not replace the safety text. The text must always be
read fully. In some cases other symbols will be used with the signal words.
5

6
2 Safety Instructions
Reading the enclosed safety instruction booklet no. 016000 (pink-coloured booklet) is
essential for working with the equipment.
WARNING
Fires, electric shocks and other injuries, or damages to components can be
caused if the safety guidelines are ignored.
WARNING
Risk of fatal injury due to electrocution!
Disconnect the electric equipment from the power supply before starting
any work on the tool (e.g. installation, changing of accessories or machine
tools, removal of covers prior to longer downtimes, maintenance works,
etc.).
Switch off the mains switch and pull out the mains plug!
3 Intended Use
This Measurement equipment is designed and constructed for industrial measurement of
torque using Strain gauge platform, Strain gauge inline and Piezo transducers.
The use of this instrument in any other way is not permissible. Furthermore, DEPRAG is
not liable for damages, resulting from the misuse of the instrument; the user alone is liable.
The correct use of the instrument includes compliance with all Operating-, Maintenance-,
and Repair Instructions, which are considered an integral part.
4 Scope of Delivery
Check that the shipment is complete and that there have been no damages in transit.
Quantity Name Order No.
1 Operating instruction booklet 015128en
1 Safety Instructions 016000
1 Electronic Torquemeter ME5600 201440 A
1 Power Supply Cable (230V EU) 812587
1 Power Supply Cable (115V US) 812295
1 Calibration Certificate -

5 Short Description
The ME5600 is a measuring device, which is designed for measuring using strain gauge
(DMS) measuring platforms and strain gauge (DMS) torque wrenches, piezo measuring
platforms and external transducers. Strain gauge (DMS) platforms and external transduc-
ers, either from DEPRAG or from other manufacturers can be connected.
The device is operated using a touch screen. The interface can be set to various lan-
guages.
The calibration value can be set for the chosen transducer. There are three measurement
methods available: single measurement, series measurement and instantaneous value
measurement. For single or series measurement, individual measurements can be ended
by hand or with automatic end recognition. However instantaneous measurement can only
be ended by hand.
The measurement unit for the display of measurement results can be set.
The procedure of a measurement series can be portrayed graphically or in a list form, and
printed as a list.
The average, the standard deviation and the standard deviation as percentage of the av-
erage are calculated for statistical analysis. The machine performance indices (Cm and
Cmk) are calculated according to the set tolerance in reference to the average. The toler-
ance is stated in percent. Alternatively the upper and lower limits can be altered by you.
7

6 Definitions
Parameter Description
Measuring Value: Submitted torque from transducer.
Calibration Value: Sensitivity of transducer.
Measurement
Series:
The torque values are stored. At the end of a measurement
series, the average torque and standard deviation is being
calculated.
Average Values:
Mean value is calculated from a specific number of previously
stored values.


N
ii
X
N
X1
_1
Standard Deviation:
Standard deviation is calculated from a specific number of
previously stored values.
s
XX
N
i
i
N




()
_
1
2
1
C
m
The machine capability index C
m
indicates how large the
dispertion of values is.
 6ueMinimumValueMaximumVal
Cm


C
mk
The machine capability index C
mk
is a statement how the mean
of the sample is located to the predetermined tolerance.
)
3
,
3
min(

ueMinimumValAverageAverageueMaximumVal
Cmk



Ber factor Range dependent factor for the calculation of the
measurement limits
Serial Connection Part of a system which allows external communication
8

7 Front and rear panel
7.1 Front panel of ME5600
Image 1: Front panel of ME5600
9

7.2 Rear (connector) panel of ME5600
Connection for
strain gauge
and/or external
rotary transducer
Connection for
piezo transducer
Not used
Serial port
ON / OFF switch Power supply
Image 2: Rear (connector) panel of ME5600
10

8 Interface Description
8.1 Strain Gauge (DMS) and Inline Rotating Shaft Transducers
Connection: Round Connector 8-pole
Connector Series 712, Order Number: 99-0425-00-08
Pin Signal Used for
1 VCC Power Supply of the Inline Transducer (+12V)
2 GND GND Inline Transducer
3Signal Measurement current Inline Transducer (0 – 5V)
4 U+ Positive current Strain Gauge (DMS) Transducer (+2,5V)
5 Ud- Negative Measurement signal Strain Gauge (DMS) Transducer
6 Ud+ Positive Measurement signal Strain Gauge (DMS) Transducer
7 U- Negative current Strain Gauge (DMS) Transducer (-2,5V)
8 GND GND Inline Transducer
Table 1: Strain Gauge (DMS) and Inline rotating shaft transducer
11

9 Required Accessories
Connection Cable Selection - Electronic Torquemeter ME5600 with respective transducer.
Measuring Transducer Connector Cable Order No.
MP 25 PE
MP 200 PE or
MS 25 PE-W
810675 (5m)
MP 1000 PE 810629 (1 m)
MP 2 DMS,
MP 7 DMS,
MP 25 DMS or
MP 160 DMS
385493 A (2 m)
385493 B (4 m)
385493 C (6 m)
MP 500 DMS 385486 A (2 m)
385486 B (4 m)
385486 C (6 m)
MS 2 DMS
MS 7 DMS,
MS 7 DMS-W or
MS 25 DMS-W
385493 A (2 m)
385493 B (4 m)
385693 C (6 m)
V002-E6,3/F6,3
V005-E6,3/F6,3
V010-E6,3/F6,3 or
V020-E6,3/F6,3
385486 A (2 m)
385486 B (4 m)
385486 C (6 m)
Table 2: Connector Cable
10 Optional Equipment
Charge Calibrator
(for functional test)
349960 A
Software: upon request
Printer Type ND 40 ND 100
Order No. 200715 A823476
Print Method
Digits per Line
8-pin Printer
40
9-pin Printer
>100
Print Speed
Print Storage
approx. 2 lines/sec.
0.5 KB
approx. 2 lines/sec.
2 KB
Interface Port
Electrical Power Supply
RS 232
5 V
RS 232 / parallel
230 V / 50 Hz
Dimensions
(W x H x D) (mm)
(in.)
160 x 42 x 106
65/16 x 111/16 x 43/16
385 x 135 x 300
155/8x 55/16 x 1113/16
Weight (kg / lbs) 0.35 / 0.8 4 / 8.8
Table 3: Optional Equipment
see leaflet D 3022 E
12

Name Type Measuring Range Part No.
V002-E6,3/F6,3 0,2 - 2 Nm 385481 B
V005-E6,3/F6,3 0,5 - 5 Nm 385481 C
V010-E6,3/F6,3 1 - 10 Nm 385481D
External Rotary Type
Transducer / Header
(strain gauge, non-contact
signal transfer)
V020-E6,3/F6,3 2 – 20 Nm 385481 E
MP 25 PE ± 25 Nm 360850 A
Piezo Electric (PE)
Transducer:
(Measuring Platform) MP 200 PE ± 200 Nm 373205 A
MP 2 DMS ± 0,1 to ± 2 Nm 385200 B
MP 7 DMS ± 1 to ± 7 Nm 385200 A
MP 25 DMS ± 4 to ± 25 Nm 385200 C
Strain Gauge
(DMS) Transducer:
(Measuring Platform)
MP 160 DMS ± 20 to ± 160 Nm 385200 D
Piezo Electric
(PE) Transducer:
(Torque Wrench)
MS 25 PE-W ± 25 Nm 346217 A
MS 2 DMS ± 0,1 to ± 2 Nm 387798 B
MS 7 DMS ± 1 to ± 7 Nm 387798 A
MS 7 DMS-W ± 1 to ± 7 Nm 388050 A
Strain Gauge
(DMS) Transducer:
(Measuring Platform)
MS 25 DMS-W ± 4 to ± 25 Nm 388050 C
Table 4: Equipment
see leaflet D 3020 E
13

14
11 Operation
11.1Installation and Connection
Please set the electronic measurement system on a clean flat surface
Attach connection cable to measurement platform and ME5600
Plug into mains voltage
Switch on with ON/OFF switch at rear
11.2General Measurement Technique Information
The Torque Transducer should be at rest when the start signal is applied.
At the moment the start signal is given there should be no external forces, side loads or
vibrations applied to the transducer (e.g. via pressure hoses or cables on the screwdriver
or tension applied to the transducer by improper mounting).
With each start signal there is a zero point adjustment of the transducer. External forces,
torques or vibrations can lead to false measurement results .
To insure quality assurance and traceable documentation upon an audit, we recommend
that the measuring instruments undergo calibration at least once per year.
For our torque measuring equipment, transducers and the complete measurement chain
we offer the possibility of factory calibration at our main facilities .
We are always at your disposal to answer questions.
11.3Machine Capability Study
Before an industrial device or system is placed into service it should be tested to prove
that it meets the requirements of its task.
The goal of a machine capability study is to demonstrate that:
a) The tested machine or system completes its task with a definable repeatability.
When there is no definable repeatability then the machine or system has no reliable
Capacity. In particular, it is then not possible to assign the machine or system a
statistically calculated machine capability index .
b) The machine or system is able to produce parts within the specified tolerances. The
necessary proof can only be derived from point a) a defined repeatability.
The machine capability study is a short-term study, whose aim is to uncover only machine-
related influences on the manufacturing process.
During the performance of the cmk test there may be no
interruptions or system interference (e.g. machine adjustments).
The Study is based upon the Gaussian distribution curve.

15
11.3.1 Machine Capability Index (Cm)
Cm = Total specific torque tolerance of the screw joint : 6 Sigma (s)
This index represents only information about the spread of the torque values.
sitLoweritUpper
Cm*6 limlim  
11.3.2 Machine Capability Index (Cmk)
Is defined as the minimum of:
1.
svalueAverageitUpper
Cmk *3
lim 

or
2.
sitUppervalueAverage
Cmk *3 lim 
Ths index provides information about the setting as well as the spread of of the torque
values.
IMPORTANT
The average value should not drift more than 3% from the target
value otherwise a reliable confirmation as to the capability of the
system is not possible.
The lowest acceptable - value for a screwdriver is 1.33 (equivalent to a calculation of the
limits of 4 sigma (s)).
mkm CC /
Limit Values
Within the
Limit values
Failure Rate
0,30 ± s 68,3 > 30%
0,70 ± 2s 95,4 ~ 5%
1,00 ± 3s 99,7 3 ‰
1,33 ±4s 99,994 60 ppm
1,63 ±4,891s 99,9999 1 ppm
1,66 ±5s 99,99994 0,6 ppm
2,00 ± 6s 99,9999998
210
9
*
Table 5: -Value
mkm CC /

11.4Operation of the Electronic Torque Measurement System
The measurement system is designed and constructed for the industrial measurement of
torque using Piezo, Strain Gauge or Inline Rotating Shaft Transducers.
11.4.1 Piezo Electric Effect
In the case of torque measurement, the piezoelectric materials are polarized electrically
when they are mechanically deformed to change the dipole moments.
The associated changes in the polarization are exposed on the crystals surface in the form
of measurable electrical charges. The scale of the liberated charge depends only on the
deformation of the crystal and is not generated by the speed or acceleration of the
deformation.
11.4.2 Operation of the Piezo Transducer
The transducers (MP25 / MP200 / MS25 / MS10) have piezoelectric - Quartz - cells
installed. By the bias of the measuring cells during manufacturing the electrical charge
surrendered during application is determined (coulomb). Because different sizes of the
measuring cell are used, the electrical charge delivered from the transducer also varies.
The calibration value which is engraved on each transducer represents the delivered
charge (Coulomb) per Newton-Meter (Nm). i.e. when a force of 1Nm is applied to the
transducer measuring cells a specific charge is delivered as defined by the calibration
value.
Example of a calibration value : 172 pC / N.m
1 pico Coulomb = 0.000 000 000 001 C
The electronic measuring system (i.e. ME 5600) uses a charge amplifier to convert the
charge delivered by the transducer into volts. The voltage is dependant upon the input
measurement of an upstream capacitor. ie: For a range of 1000 pF a measured capacitor
charge is changed from 2 V to 2000 pC. Each measurement range is within + / - 5 volts.
11.4.3 Drift (with Piezo-Transducers)
A property of the charge amplifier is the Drift. This is caused by input resistance at the
input transistor. This causes the input current from the charge amplifier to drift in the
positive or negative direction. Therefore it is important that a measurment is started
(zeroed) as close to the start of the screwdriving cycle as possible.
11.4.4 DMS-Bridge
The electrical resistance of each conductor changes with deformation. The cause of the
deformation comes from, a force, pressure, torque, displacement, rotation angle and so
on. The resistance of a deformed strain gauge consists of its ground resistance R
(unloaded) and the deformation caused by the change in resistance ΔR together.
16

11.5The Main Screen
After switching on the device, first the start screen appears. After the software is fully loa-
ded, the main screen appears.
Image 3: The Main Screen
When you start the machine for the first time, the language may not be set correctly. In this
case press the button SETTINGS to select the required language
(see chapter 11.5.4.1 Language).
Press the on/off switch on the rear of the machine to switch the machine off again.
11.5.1 DMS Setting
If you want to use a DMS measuring platform, select DMS on the top bar.
Image 4: Main Screen for DMS Transducer
Next set the correct type of DMS. The chosen type is displayed on the type button, the
calibration value on the calibration button.
17

To set the type press the type button and select the relevant transducer from the list. If you
want to use a transducer from a different manufacturer select OTHER. Use the BACK but-
ton to return to the main screen.
Image 5: DMS-Type Setting
After pressing the calibration button you can enter the calibration value. Enter the required
value using the number buttons. The arrow button (<-) can be used to delete the last digit.
Press CANCEL to discard the last value. To save an entered value and return to the main
screen press OK. If the entered value is outside the set limits then either the upper or
lower limit is displayed without returning to the main screen. The value can then be
changed or confirmed with OK.
Image 6: DMS Calibration Value
18

If you want to use a DMS platform from a different manufacturer select “OTHER”. Next a
screen appears where you can enter the nominal value of the transducer in N·cm. Then a
screen appears where you can enter the sensitivity in mV/V. Once both these values have
been entered you return to the selection menu and can return to the main screen from
there.
Image 7: Entry of the DMS Nominal Value
Image 8: Setting the DMS Sensitivity
19

11.5.2 Piezo Setting
If you want to use a piezo platform, select PIEZO on the top bar.
Image 9: Main Screen for Piezo Transducer
Next the measurement range and the calibration value can be set. Remember that meas-
urement limits are dependent on the calibration value.
Image 10: Setting the Piezo Measurement Range
20