HEX CHUCK User manual

CHUCK
Bolting Data Processor
Operations Manual
HEX TECHNOLOGY
2021

CHUCK Bolting Data Processor
Operations Manual
CHUCK and all materials within copyright HEX TECHNOLOGY (2021)
i
Contents
Video Guide to Setup............................................................................................................................................. 1
Welcome to CHUCK ............................................................................................................................................... 2
Hardware Check: Procuring Bolts for CHUCK............................................................................................................2
Required Equipment for Use .....................................................................................................................................2
Unboxing Your CHUCK ..............................................................................................................................................3
Powering Up Your CHUCK .........................................................................................................................................3
Installing CHUCK to Your Bolting Skid.......................................................................................................................4
Setting Up CHUCK’s Software ................................................................................................................................ 5
Connect to CHUCK.....................................................................................................................................................5
Getting Started in the Software ................................................................................................................................6
Status Setup ..............................................................................................................................................................6
Other Uses for the Status Window............................................................................................................................8
Using CHUCK.......................................................................................................................................................... 9
Navigation Buttons ...................................................................................................................................................9
Configure Your CHUCK ............................................................................................................................................10
Bay Setup ................................................................................................................................................................13
Calibrating, Connecting and Zeroing Your Bolts .....................................................................................................14
A. Connect Cables to Brain.................................................................................................................................15
B. Calibrate Cables and Brain .............................................................................................................................16
C. Connecting Cables to Studs............................................................................................................................16
When to Calibrate (And Why it Matters) ................................................................................................................17
Shutting Down ........................................................................................................................................................18
Using CHUCK with Flanges ................................................................................................................................... 19
Pro Tip: Zeroing and Elastic Interaction ..................................................................................................................20
Using CHUCK with a Torque Stand ....................................................................................................................... 21
Torque Stand Quick Reference................................................................................................................................22

CHUCK Bolting Data Processor
Operations Manual
CHUCK and all materials within copyright HEX TECHNOLOGY (2021) 1
Video Guide to Setup
In addition to the written manual, you can follow these step-by-step guides to unboxing your
CHUCK, connecting it to your training skid, and performing the initial software setup. Click on
the links to view our video library.
1. Unboxing CHUCK: What’s Inside
2. Connecting CHUCK to the Grounding Wire
3. Connecting CHUCK to the Training Skid
4. Connecting the Server to CHUCK and the Skid
5. CHUCK’s Cable Bays: An Overview
6. Connecting CHUCK to Cables and Bolts
7. CHUCK Initial Software Setup

CHUCK Bolting Data Processor
Operations Manual
CHUCK and all materials within copyright HEX TECHNOLOGY (2021) 2
Welcome to CHUCK
CHUCK pairs with instrumented bolts to
provide accurate bolt load readings in real
time.
These readings are useful for training and
testing personnel involved with the assembly
of bolted flange joints.
With CHUCK, the complicated physics of
bolting become clear as day, with each
reading displayed clearly on any wi-fi enabled
laptop, smartphone or tablet.
The following guide walks you through the setup and use of CHUCK.
Hardware Check: Procuring Bolts for CHUCK
CHUCK must be paired with instrumented bolts from
manufacturer James Walker.
The unit is compatible with studs sized from 5/8” to 1-1/4”.
(Additional sizes available upon request.)
If you have not already, contact James Walker
representative John Carr at john.c[email protected] to
order your bolts.
Required Equipment for Use
•CHUCK data processor (contents listed below, see “Unboxing Your CHUCK”)
•Instrumented bolts (4 to 16 bolts total, size range 5/8” to 1-1/4”).
•Matching nuts for bolts
•RG-316 coaxial with SMB connectors
•Flange compatible with bolt configuration
•Torque stand unit (optional) (requires 4x3/4” bolts)

CHUCK Bolting Data Processor
Operations Manual
CHUCK and all materials within copyright HEX TECHNOLOGY (2021) 3
Unboxing Your CHUCK
The package you receive will contain 6 items:
CHUCK Brain
(Hexagonal box)
Server
(Black box)
Ground Wire
Micro B USB Cable Power Supply with USB-C
connector
Four (4) #10 machine screws
for mounting CHUCK Brain.
(Packaged in red bubble
wrap.)
You will find a label on the underside of the CHUCK Brain with the WiFi network name, the WiFi
password, and the CHUCK serial number. You will need those items to connect to your CHUCK.
If you discover an item is missing, contact [e-mail].
Powering Up Your CHUCK
1. Connect the CHUCK Brain to Server using USB cable.
a. Connect the USB cable to the Chuck Brain using the Micro B USB port centered
on one edge of the box.
b. Connect the other end of the USB cable to any of the four USB ports on the
Chuck Server.
2. Power up Server and Brain.
a. Connect the power supply cable to the USB-C port on the side of the Server.

CHUCK Bolting Data Processor
Operations Manual
CHUCK and all materials within copyright HEX TECHNOLOGY (2021) 4
b. Plug power supply into a wall socket. (CHUCK
comes with a universal power supply that will
operate on 120 VAC 60 Hz power or 240 VAC 50
Hz power.)
3. Ground the CHUCK Brain.
a. Connect ground wire to grounding stud on
CHUCK Brain (shown, right).
b. Connect opposite end of ground wire to an
appropriate grounding point. The ring terminal is
sized for the #10 machine screws that are used
to mount the CHUCK Brain. We recommend you
ground at one of the mounting screws.
IMPORTANT: CHUCK box MUST be grounded to a point that is electrically connected to the
flange containing the instrumented bolts. Failure to establish a ground connection will result in
erratic bolt stress readings.
Installing CHUCK to Your Bolting Skid
Both the CHUCK Brain and its companion server can be attached to your skid.
If you’ve fabricated your skid according to the spec provided by Hex Technology, there will be
mounting brackets for both the CHUCK Brain and Server.

CHUCK Bolting Data Processor
Operations Manual
CHUCK and all materials within copyright HEX TECHNOLOGY (2021) 5
Setting Up CHUCK’s Software
For the following steps, you will need a Wi-Fi enabled laptop.
You should have received an email (Subject line: “CHUCK License Key”) with a license key for
your new CHUCK application. Make sure you have that email handy on your laptop before you
connect to CHUCK. The license key will look like…
EXAMPLE LICENSE KEY:
key/eyJleHBpcmF0aW9uRGF0ZSI6IjIwMjItMDEtMjEiLCJzZXJpYWxOdW1iZXIiOiIxMDEifQ==.KS1dSXrsDcnKRBmdDReLo1ChZX9Y/2vbkOQvpQ3
7ZM3T5o5soXmLQgcPQCtpHYwxDuR2BzAHDIDSXCaHpxSJXmeUAEqjE5iBYUPVh3SDmVFpqUwe8A9Rfm4Qj2Zp14QAOanpuHqrYYX2fsHdZhV
XOK1cAHTNJswxQZJCStEj1iVDhnust9oLnzvVbseRkXZ/C/k52nQVNbsgF/dg+ub2xoe0oWd552guCzABh2BDD/stYk/UwDmt+W98ITF9eY1cJRQY
3ly/3cAKR5/Uu5ujSX2X8b6ZK0lbiUgaY9+6+q5NWk73dpICjiUtyi1UxKvKTeITwsdu4u7LJsMsojV4WA==
Connect to CHUCK
1. Connect your laptop to Chuck:
a. Find the label attached to the underside of the CHUCK Brain with the WiFi
Network ID and password.
b. From your laptop’s wi-fi selector (or the “Network Preferences”), look for the
CHUCK wireless network.
c. To connect, enter the WiFi password.
2. Open your internet browser.
3. Type “http://chuck/” into the navigation bar.
a. Note: On some computers and browsers, you won’t need to type the “http://”.
b. Some computers and browsers will think you are searching for a friend named
“Chuck.” If you have that problem, key in the Server IP address
(http://192.168.4.1) into the navigation bar.
c. You will arrive at CHUCK’s user interface and see a Welcome message:

CHUCK Bolting Data Processor
Operations Manual
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Getting Started in the Software
Press “OK” in the Welcome Message.
You’ll see the user interface consists of 3 main areas:
1) Top navigation buttons
2) A “Status” section presenting license and serial number
3) A section housing four Bays (Bay 1, Bay 2, etc.)
We will discuss each of those items later. During startup, your first step is to provide the
necessary information in the Status window.
Status Setup
The “Status” block provides 6 pieces of information on how your CHUCK is operating.
You’ll see a welcome message like this when you first connect to CHUCK.
An example of the information you’ll see in CHUCK’s Status Bar.

CHUCK Bolting Data Processor
Operations Manual
CHUCK and all materials within copyright HEX TECHNOLOGY (2021) 7
During the initial setup, you need to:
1. Click on “Description,” then enter a short name for your Chuck. The name can be
anything you like, using any characters or capitalization you wish.
2. The “Server” field is pre-set with “Chuck.” If you had to enter the IP address in the
browser’s navigation bar when connecting, you’d use that instead.
3. The Serial No field needs to match the serial number that you will find on a sticker on
the CHUCK Brain. Click on the “0” and enter the serial number.
4. In the License Status box, click on “No key” to open that dialog.
a. You’ll have received your license key by email. Find that email on your laptop,
copy the license key, and paste it into the window. (You will need to copy
everything from “key/” to the two equals signs at the end.)
b. Click on the link for the End User License Agreement and read the terms.
c. If you are satisfied with the terms, click the “Submit” button.
That completes the initial connection and configuration.
Congratulations! You are now ready to begin training and testing with CHUCK.

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Operations Manual
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Other Uses for the Status Window
The Status window also shows the elapsed time since your CHUCK Brain connected to the
CHUCK Server. This field will continue to tick off seconds letting you know your system is
operational.
Finally, the status window shows the software version number. If you click on the version
number, you will see a window to upload an update file. From time to time, we will make
updates to the program available and send you a zip file to upload. We will provide detailed
instructions when that happens.