Enerpac MCS7500 User manual

Instruction Sheet
L4370
Rev. B 01/20 Mobile
Calibration
System
MCS7500

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TABLE OF CONTENTS
1.0 INTRODUCTION......................................................................................................................................... 3
1.1 System Overview.................................................................................................................................... 3
1.2 Main Components .................................................................................................................................. 4
1.3 Electrical Connections........................................................................................................................... 5
1.4 CE Declaration of Conformity ............................................................................................................... 6
2.0 SAFETY ..................................................................................................................................................... 7
2.1 Introduction .............................................................................................................................................. 7
2.2 General Safety ........................................................................................................................................ 7
2.3 Mobile Calibration System Safety......................................................................................................... 8
2.4 Use and Care .......................................................................................................................................... 8
2.5 Disconnect Electrical Power ................................................................................................................. 8
3.0 SETUP AND ADJUSTMENTS.................................................................................................................... 9
3.1 Mount the Torque Wrench ..................................................................................................................... 9
3.2 Adjust the Run Down Fixture and Reaction Stop.............................................................................. 10
3.3 Torque To Spreadsheet Software (TTS).............................................................................................. 11
4.0 OPERATION.............................................................................................................................................. 12
4.1 Check Torque with Digital Display...................................................................................................... 12
4.2 Using the TTS Software ....................................................................................................................... 13
4.3 Performing a Calibration and Producing a Calibration Certificate for Corded Electronic tools .. 14
4.4 Performing a Calibration and Producing a Calibration Certificate for Pneumatic tools ............... 20
5.0 DIGITAL DISPLAY MODULE.................................................................................................................... 27
5.1 Digital Display Buttons ........................................................................................................................ 27
5.2 Digital Display Window ........................................................................................................................ 27
5.3 Battery Indicator................................................................................................................................... 27
5.4 Mode of Operation ............................................................................................................................... 28
5.5 Engineering Units ................................................................................................................................. 28
5.6 Filter....................................................................................................................................................... 29
6.0 MAINTENANCE........................................................................................................................................ 30
7.0 RECALIBRATION...................................................................................................................................... 31
8.0 TROUBLESHOOTING .............................................................................................................................. 32
8.1 Digital Display....................................................................................................................................... 32
8.2 Joint Run Down .................................................................................................................................... 32
8.3 Repair and (Re)Calibration .................................................................................................................. 32
9.0 TECHNICAL SPECIFICATIONS ............................................................................................................... 33

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1.0 INTRODUCTION
1.1 System Overview
The MCS7500 Calibration System allows users to check torque accuracy, run calibration tests, and create
calibration certificates for bolting tools. The MCS7500 is designed for corded electric, hydraulic and
pneumatic tools, such as the Enerpac PTW- and ETW-Series Torque Wrenches, as well as similar controlled
bolting fastening systems.
Not Suitable for use with battery or impact tools
The calibration system is a calibrated instrument qualified in a UKAS certified laboratory. The accuracy of
the MCS7500 is calibrated to meet or exceed: 1% of Full Scale Deflection (FSD) from 2% to 8% of torque
range and 1% of reading from 8% to 100% of torque range.
Upon delivery, all components must be inspected for damage incurred during shipping. If damage is found,
the carrier should be notified at once. Shipping damage is not covered by the Enerpac warranty.
Please read the full Instruction Sheet before using the MCS7500”.
The MCS7500 includes:
• 1 Dynamic run down fixture with 1.5” female square drive, and the following adapters (1):
- 1.5” to 1” x 2” tall
• 1 Base plate (2)
• 1 Standard reaction stop, and secondary reaction post (3)
• 1 Digital LCD display module with global outlet adaptor (4)
• 1 Calibration software with USB plug (not shown)
• 1 standard hard case (not shown)
• 1” x 1-1/2” adaptors available as an accessory on request
• ¾” x 1” adaptors available as an accessory on request.
• Drawings of the Special Reaction block and adaptors designed for usage in combination with Enerpac
S-Series and RSL-Series hydraulic wrenches available upon request.
Fig. 1
1
3
2
4

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1.2 Main Components
Run down fixture and transducer – The run down fixture and transducer are designed specifically for the
testing of constant rotation controlled bolting tools. The MCC7500 features a 1.5” female square drive that can
accommodate other size square drive tools with the use of adaptors. The dynamic fixture provides a fastening
solution that is similar to real life applications. An integrated transducer measures the torque and communicates
the results to the digital display module. The run down fixture can be adjusted vertically to accommodate
various tool designs.
Base plate - The base plate houses the run down fixture, reaction stop, and digital display module. It features
three sturdy legs, end slot to transport the unit, and can be fastened down to a flat surface.
Reaction stop – The reaction stop functions as a counterpoint to the reaction arms of the wrench. The
torque wrench being calibrated is positioned with the reaction arm in between the wings of the reaction stop.
The MCS7500 features a standard reaction stop that will accommodate most pneumatic and electric tools,
including the PTW-, ETW-Series and many competitive tools. It also features a special reaction post for tools
with configurations that won’t work with the standard reaction stop.
Digital display module –The digital display module facilitates the display, collection, archiving, and processing
of torque readings. The module can run o battery power or plugged into an outlet. Each MCS7500 is equipped
with a global outlet adaptor that allows the tool to be used with many electrical systems.
Fig. 2 - Digital Display
When used with the Torque To Spreadsheet (TTS) software, the digital display module can be attached to a
computer with a USB plug (see Section 1.3).
The TTS software is included with the standard MCS7500 package. The MCS7500 can interface with the test
stand using a USB cable. The software facilitates the calibration testing of torque wrenches and can be used to
create calibration certificates. Windows 7/8/10 is required to install the TTS software. Microsoft Excel is required
to export and display the torque readings.

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1.3 Electrical Connections
The digital display module includes a USB/battery charger port as shown in Figure. 3.
Fig. 3 - USB/ Battery charge port
1.3.1 DC Interface
The interface for the 5V DC USB AC adapter is supplied with the MCS7500. Use the adapter if you plan on using
the main power source.
Use only the AC adapter provided with the MCS7500. If another power source is used it will void
the warranty and may cause severe damage to the digital display module.
1.3.2 USB Connections
The USB interface cable shown below is used when downloading to a computer, or other device. The values
are sent every time a reading in Peak mode is taken on the MCS7500 (see Figure 7).
Replacement USB cable and Power Supply Cable can be ordered using part numbers:
• USB Cable: VSSPX-0000-ENXXUS,
• Power Supply Unit: VSSPX-0000-ENXXPS.
Fig. 4 - Standard USB Cable ICBL-USB

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1.3.3 Charging the Battery
Follow the standard operating procedures in your workplace and be sure to observe all communicated safety
precautions.
• The battery for the MCS7500 should last approximately 12 hours when fully charged.
• The battery is charged any time the MCS7500 is plugged-in. The charge time is between 2 and 4 hours
depending on the battery charge level. It is recommended that the user unplug the unit when it is not in use.
This will not harm the unit and will increase battery life.
NOTE: If the MCS7500 is stored for several months make sure the battery is completely charged prior to
storage.
1.4 CE Declaration of Conformity
Enerpac declares that the MCS7500 Mobile Calibration System meets the applicable standards
and directives issued by the European Union. A copy of the EU Declaration of Conformity is
shipped along with this Unit.
Follow the standard operating procedures in your workplace and be sure to observe all communicated safety
precautions.

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2.0 SAFETY
Read all introductions carefully. Follow all recommended safety precautions to avoid personal injury as well
as damage to the product and / or damage to other property. Enerpac cannot be responsible for any damage
or injury from unsafe use, lack of maintenance, or incorrect operation. Do not remove warning labels, tags, or
decals. In the event of any questions or concerns arising, contact Enerpac or a local Enerpac distributor for
clarification.
This manual follows a system of safety alert symbols, signals, words, and safety messages to warn the user of
specific hazards. Failure to comply with these warnings could result in death or serious personal injury, as well
as damage to the equipment or other property.
2.1 Introduction
The Safety Alert Symbol appears throughout this manual. It is used to alert you to potential physical injury
hazards. Pay close attention to Safety Alert Symbols and obey all safety messages that follow this symbol
to avoid the possibility of death or serious injury.
Safety Alert Symbols are used in conjunction with certain Signal Words that call attention to safety messages
or property damage messages and designate a degree or level of hazard seriousness. The Signal Words used
in this manual are WARNING, CAUTION, and NOTICE.
Indicates a hazardous situation that, if not avoided, will result in death or serious personal injury.
Indicates a hazardous situation that, if not avoided, could result in death or serious personal injury.
Indicates a hazardous situation that, if not avoided, could result in minor or moderate personal injury.
Indicates information considered important, but not hazard related (e.g. messages relation to property
damage). Please note that Safety Alert Symbol will not be used with the signal word.
2.2 General Safety
Observe the following safety precautions. Note that under some circumstances, additional safety precautions
beyond those described in this manual may be required.
• Be sure you have read and understood the instruction manual prior to using the tool.
• Make sure you have completed safety training specific to the work surroundings. The operator should be
thoroughly familiar with the proper use of the calibration system.
• The operator must be at least the minimum age required by applicable local regulations, laws, and the
facility’s standard operating procedures.
• Make sure your workplace is safe.

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2.3 Mobile Calibration System Safety
The following hazard messages are specific to the Mobile Calibration System (MCS).
Failure to observe and comply with the following precautions could result in death or serious
personal injury. Property damage could also occur.
• Always wear appropriate personal protection equipment such as protective head wear, eye protection,
footwear, and gloves suitable for safe operation of the MCS. The protective clothing must not interfere with
safe operation of the system or restrict the ability to communicate with co-workers.
• Prior to use, check reaction stops for cracks and replace if any sign of deterioration is found. Check reaction
stop mounting bolt torque regularly. Bolts should be tightened to 50-55 Ft.lbs (68-75 Nm).
• Do not stand in the line of movement of the tool when it is in operation. If the reaction stop should break, it
will detach in that direction.
• Keep loose clothing, hair, and other items from being caught in any rotating part of the tool being calibrated.
Failure to comply with the following precautions could result in minor or moderate personal
injury.
• Do not place any objects between the reaction arm and the reaction stop. Keep the cords away from the
reaction stop.
• When operating, ensure full contact is achieved between the reaction arm and the reaction stop.
• The maximum torque rating of the MCS7500 is 7375 Ft.lbs (10,000 Nm). Never exceed the torque rating of
the MCS7500.
2.4 Use and Care
• Do not operate the equipment with a damaged cord or plug, or after the equipment malfunctions, or is
dropped or damaged in any manner. Return the equipment to the nearest Enerpac Authorized Service
Center for examination or electrical and mechanical repair.
• Store the MCS7500 in a secure, dry location. Keep out of reach of children.
2.5 Disconnect Electrical Power
To disconnect, turn the On/O switch to the OFF (“O”) position, then remove plug from the outlet.
• Do not unplug by pulling on cord. To unplug, grasp the plug not the cord.
• Unplug from 5V DC outlet when not in use and before servicing or cleaning.

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3.0 SETUP AND ADJUSTMENTS
3.1 Mount the Torque Wrench
• Remove the MCS7500 components from the packaging and place on a flat surface. Ensure that the digital
display module is plugged in or suciently charged to operate.
• Select and position an appropriate adaptor onto the run down fixture to allow the proper mounting of the
torque wrench.
• Mount the torque wrench vertically onto the run down fixture, positioning the reaction arm between the
reaction stop wings, and lower the wrench into position. For safe operation, the square drive of the wrench
must fit into the run down fixture, with the wrench reaction arm positioned to fully engage the reaction stop
as shown in Figure 5:
Fig. 5 - Fitting torque wrench

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3.2 Adjust the Run Down Fixture and Reaction Stop
If the tool will not fit as indicated, the run down fixture can be adjusted vertically, and the reaction stop can be
adjusted in a straight line perpendicular to the run down fixture (see Figure 6).
3.2.1 Run Down Fixture
• To vertically adjust the run down fixture, use the appropriate adapter that provides the required positioning
to achieve full reaction arm engagement. It is important to reverse (loosen) the run down fixture for testing.
3.2.2 Reaction Stop
• To adjust the reaction stop, loosen the handle as shown in Figure 6.
• Slide the reaction stop to properly position the reaction arm and fully engage the reaction stop per
manufacturer’s recommendation.
• Slide the reaction stop to the desired position. Lock into place by rotating the lock handle located directly
under the reaction stop.
Once the MCS7500 unit has been appropriately adjusted, complete the mounting of the tool.
Fig. 6 - Securing reaction arm
Handle

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3.3 Torque To Spreadsheet Software (TTS)
The Torque To Spreadsheet (TTS) software is an intuitive application that allows users to connect to an MCS7500
or digital transducer through a USB cable. This application facilitates the display, collection, archiving, and
processing of torque readings. Microsoft Excel is launched by the application.
3.3.1 Software Requirements
• Windows 7/8/10
• Microsoft Excel is required for the exporting and graphing function.
3.3.2 Installing the Software
• Install the TTS software by extracting the file EnerpacVSES.exe provided by Enerpac, onto a PC.
• The EnerpacVSES.exe can also be downloaded at the following link:
https://www.enerpac.com/en-us/calibration-systems/mobile-calibration-system/MCS7500.
• Please read the Readme file before extracting files and installing the software.
• Follow the instructions on the screen to finish installing.
• The driver for the cables can be installed by running CP210x USB to UART Bridge Virtual COM Port.
NOTE: Install the driver for the USB cable only if the software fails to recognize the cable.

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4.0 OPERATION
4.1 Check Torque with Digital Display
• Activate the wrench, ensure that all safety precautions are being followed. Take note of potential pinch
points when handling the torque wrench during calibration testing.
• After the wrench stalls, the peak reading will momentarily appear on the display module, and then is saved.
For the next cycle it is important to reverse the tool and loosen the run down fixture.
NOTE: The default setting for the torque reading is peak. To take a peak reading, ensure that the “Peak” icon
appears under the torque reading on the display module (see Figure 7).
4.1.2 Digital Display Overview
The digital display has five main buttons: ON/OFF, MENU, PEAK/TRACK, LEFT AND RIGHT (Figure 7, Items
1-4).
Fig. 7 - MCS7500 Digital Display
The display module can be set up to perform other functions, such as tracking the torque. The amount of time
that the reading is displayed cannot be adjusted. For a detailed description of the available functions, see
Section 5.
1
3
4
2

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4.2 Using the TTS Software
The TTS software can be used to check torque values, collect and export torque readings, and generate
calibration certificates. The calibration certificates can also be generated from predefined or custom-made
calibration tests.
After properly completing the setup, the MCS7500 must be connected to a computer via the USB cable. The
computer must feature Windows 7/8/10 and include Microsoft Excel®. This allows the torque readings to be
transferred and calibration forms to be generated.
• Launch the EnerpacVSES software. The “Start spreadsheet export” Tab is displayed.
NOTE: The TTS software should detect the MCS7500 under “Available COM Ports”. If the TTS is launched prior
to attaching the cable, the user must select “Rescan COM ports” to prompt the TTS to identify the MCS7500
as an available COM Port.
• Verify that the digital display module is showing the desired output, and correct functions, such as Peak and
Ft.lbs. Adjust the settings as needed following the instructions in Section 5.

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4.3 Performing a Calibration and Producing a Calibration Certificate for Corded Electronic
tools
1. Ensure the correct drivers and software are loaded onto the PC to be used for the calibration, as stated in
section 4.2
2. Connect the MCS7500 to the PC using the supplied USB type B to type A cable.
3. Run “EnerpacVses.exe” by double clicking the icon. The following window will be displayed:
Fig. 8 - Starting TTS Display (ETW)
4. Select the correct Com port by clicking the name of the required port (this can be found by going to Control
Panel\Hardware and Sound\Devices and Printers in windows and checking the port number allocated to the
CP210x USB to UART bridge in USB devices).

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5. Click the “Connect” button to connect the PC to the MCS7500 unit. The display window will now update
and show “Listening on COM2” in the top left of the window, see Figure 9:
Fig. 9 - TTS Display after connecting to PC (ETW)
6. Select the “Calibration Mode” tab. The window will update with fields which are used to specify the number
of data points, UUT info etc. :
Fig. 10 + 10b - Calibration Mode tab (ETW and Hydraulic)

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7. Enter in all the required information into the text fields. In “UUT Type” drop-down box select “Electric”. See
Figure 11:
Fig. 11 - Updating Calibration Mode (ETW)
8. Click the “Start Test Routine” button to start the calibration.
9. A spreadsheet will be created with the specified data points and limits, as set in the previous window.
10. Fit wrench to dynamic joint as specified in section 3.1. Ensure dynamic joint has been greased before use.
11. Set the target torque on the wrench controller, as specified in blue on the spreadsheet for data point 1. In
this case it is 1200 Ft.lbs. See Figure 12:
Fig. 12 - Test Routine Spreadsheet (ETW)

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12. Actuate the trigger on the wrench. The dynamic joint fixing will start to rotate and the wrench will shut
o when it hits its target torque. Once the cycle has finished, Sample 1 of data point 1 will be populated
automatically, with the reading taken during the run down. See Figure 13:
Fig. 13 - Test Routine Spreadsheet in use (ETW)
An average of the readings and status of reading will also be populated into the spreadsheet.
The last reading can be cancelled by clicking the “Cancel last sample” button. This may be necessary if the
joint was not backed o before the run down or an incorrect target torque was set.
13. Before preforming the second and after every subsequent run down, the dynamic joint must be undone by
setting the wrench to counter-clockwise and actuating the trigger.

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14. Continue performing run downs until all the data point samples have been populated, see Figure 14:
Fig. 14 - Completed Test Routine Spreadsheet (ETW)
15. On the main Enerpac VSES program, click the “Export to pdf” button to create the certificate. The program
will create a spreadsheet with an input tab and a certificate tab, at the bottom of the spreadsheet:
Fig. 15 - Calibration Certificate Input sheet (ETW)
Fill in the unpopulated fields with the relevant information. NOTE: Master equipment is the MCS7500
verification stand details. Calibration certificate number and calibration/due dates can be obtained from the
original calibration certificate supplied with the unit.

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16. Select the certificate tab to view the calibration certificate.
Fig. 16 - Calibration Certificate tab (ETW)
Calibration result, readings taken and a graph to show deviation from target (command torque) are all
displayed within the certificate in both Ft.lbs and Nm.
Fig. 17 - Completed Calibration Certificate (ETW)

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A copy can be printed, by selecting File, Print, and/or a copy can be saved to any preferred directory by
selecting File, Save as and selecting the directory in which the copy needs to be saved.
4.4 Performing a Calibration and Producing a Calibration Certificate for Pneumatic tools
1. Ensure correct drivers and software are loaded onto the PC in use, as stated in section 4.2
2. Connect the MCS7500 to the PC using the supplied USB type B to type A cable.
3. Run “EnerpacVses.exe” by double clicking the icon. The following window will be displayed:
Fig. 18 - Starting TTS Display (PTW)
4. Select the correct Com port by clicking the name of the required port (this can be found by going to Control
Panel\Hardware and Sound\Devices and Printers in windows and checking the port number allocated to the
CP210x USB to UART bridge in USB devices).
NOTE: If no COM ports are shown in the “Available COM port” box, click “Connect” and the unit will automatically
connect to the PC.