Sturtevant Richmont TCV User manual

TCV Torque Control Verifier
2.4GHz FM Torque Control Verifier Owners Manual
Sturtevant Richmont
Worldwide: 1-847-455-8677
US Only: 1-800-877-1347
www.srtorque.com
Part Number: 10467
Rev A 09/30/14
LIT-123 1 43009

2TCV / Owners manual • www.srtorque.com • [email protected]
Introduction.......................................................................................... 3
2 Safety Precautions.................................................................4
2.1 Warnings................................................................................6
2.2 Installation..............................................................................7
2.3 Mounting ................................................................................7
2.4 Source Power ........................................................................7
2.5 Connecting Peripherals ......................................................... 8
2.6 Options for Relay Function and Assignability ........................8
3 Device Programmer 1.3 software ..........................................8
3.1 Programmable Tool Functions ...............................................9
3.2 Programmable and Assignable 24 V I/O Relay circuit ........... 10
3.3 Programming the 24 Volt I/O Circuit ......................................11
3.4 TBC (Time Between Cycles)..................................................11
3.4.1 Relay Mode............................................................................11
3.4.2 Beeper ...................................................................................12
3.5 RF Channel............................................................................13
3.6 Wrench Radio ID....................................................................13
4 Operation ...............................................................................14
4.1 Power Up ...............................................................................14
4.2 Normal Operation .................................................................. 14
4.3 Adding a Wrench or Wrenches ..............................................14
4.3.1 Changing Channels ...............................................................15
4.3.1.1 Method 1 For older boards or for mix of new and old ............ 16
4.3.1.2 Method 2 For Newest boards only......................................... 16
4.4 LED Functions .......................................................................17
TABLE OF CONTENTS
Safety FIRST: To avoid possible
injury, always follow these
recommended precautions:
• Wear safety glasses or goggles at
all times. The TCV and AC Adaptor
are for dry location use only.
• Do not stand in water when using
the TCV or allow the TCV to get wet.
• Be sure torque wrench properly
engages fastener prior to
applying torque.
• Maintain rm footing and balanced
body position when applying torque.
TCV
Owners Manual

TCV / Owners manual • www.srtorque.com • [email protected] 3
1 Introduction
The TCV/Switch Wrench System is designed to assist the manufacturer in
closing several loops in the quality system which have been, until now,
gaps in their quality improvement efforts. The key capabilities this system
enables are as follows:
1. The ability to integrate hand torque tools into the automated line
control system.
2. Process control of the actual torque wrench use process, not just the
wrench calibration process.
3. Rapid and effective training in proper torque wrench use, with
reinforcement of proper technique provided with every wrench click.
This chapter will cover the system, starting with the concepts involved
in the use of the TCV-FM and FM Switch Wrench system.
The TCV-FM works with the FM Switch Wrench to bring systematized
control to the use of manual torque wrenches. The control is applied as follows:
1. The FM Switch Wrench is a preset clicker-type torque wrench. The
torque is preset using a torque tester to assure the wrench is
accurately set, then the torque setting is locked in.
2. The joint is tested with the FM Switch Wrench and an indicating
torque wrench to determine the proper duration of a click on the joint.
3. The maximum and minimum duration of a click is programmed into
the TCV-FM.
4. The FM Switch Wrench is used to tighten a fastener. As soon as the
wrench clicks, the electronics on the wrench begin to time the
duration of the click.
5. When the pressure is released on the wrench, the timer is stopped
and the duration of the click is transmitted to the TCV-FM. The TCVFM
compares the time to the minimum (TMIN) and maximum (TMAX)
allowable times for signal duration.
6. The TCV-FM communicates immediately to the operator the
acceptability of that use of the wrench. Front panel LED’s and a
buzzer inform the operator whether or not the fastener was accepted.
7.The 24 Volt I/O circuit (Input/Output) will report the results of the tool(s)
operation. With the TCV the PLC could be used as a part of a SCADA
system.

4TCV / Owners manual • www.srtorque.com • [email protected]
TCV
Owners Manual
2 Safety Precautions
For your safety and the safety of others, read and understand the safety
recommendations before installing or operating the TCV.
TCV are designed and constructed to provide the user with a safe
and reliable means of calibrating torque wrenches and power tools.
Should a fault occur which impairs its function and/or compromises its
safe use, immediately disconnect the unit from its power source and
secure against unintended operation. Under no circumstances should
repair be attempted by persons not qualied in the service of electronic
instrumentation. Please contact our customer service department at
[e-mail] to schedule a return.
When testing a tool torque, always wear protective equipment:
For additional information on eye and face protection, refer to Federal
OSHA Regulations, 29CFR § 1910.133, Eye and Face Protection,
and American National Standards Institute, ANSI Z87.1, Occupational
and Educational Eye and Face Protection. Z87.1 is available from the
American National Standards Institute, Inc., 11 West 42nd Street, New
York, NY 10036.
Hearing protection is recommended in high noise areas of 85 dBA
or greater. The operation of other tools and equipment in reective
surfaces, process noises and structures can substantially contribute
increase the noise level in the area. Excessive air pressure above 90
PSI or worn motor components can also increase sound level emitted
by the tool. Proper hearing conservation measures, including annual
audiograms and training in the use and t of hearing protection devices
may be necessary. For additional information on hearing protection,
refer to CFR § 1910.95, Occupational Noise Exposure, and American
National Standards Institute, ANSI S12.6, Hearing Protectors.

TCV / Owners manual • www.srtorque.com • [email protected] 5
TCV
Owners Manual
TCV should be securely mounted and located such that inadvertent
movement will not allow the unit to be dislodged, possibly causing
personal injury or damage to the unit. Should the unit be dropped,
it should be checked by someone qualied in the service of
electronic instrumentation.
WARNING: Shock Hazard. Disconnect power to
the unit before attempting to service. Any internal
adjustments should be carried out only by skilled
persons who are aware of the hazards of dealing
with live circuitry. The cabinet which houses the
circuitry provides protection against dust and
falling dirt. This unit should be used only indoors.
Do not use in explosive atmospheres.
WARNING: Shock Hazard. Damaged cords or
plugs are dangerous, and should be repaired or
replaced as necessary.
CAUTION: Tripping Hazard. Electrical cords and
tool cables must be organized and located in such
a manner as to reduce the likelihood of the user
and others from tripping or becoming entangled in
electrical cords and cables used with this product.
Route electrical cord so that it is not subject to
chang, crushing, or severing.

6TCV / Owners manual • www.srtorque.com • [email protected]
TCV
Owners Manual
2.1 Warnings
The enclosed device complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions:
(1) this device may not cause harmful interference and (2) this
device must accept any interference received, including
interference that may cause undesired operation.
2.1.1 This equipment has been tested and found to comply
with the limits for a Class B digital device, pursuant to
Part 15 of the FCC Rules.
2.1.2 These limits are designed to provide reasonable
protection against harmful interference in a residential
installation. This equipment generates, uses and can
radiate radio frequency energy and, if not installed
and used in accordance with the instructions, may
cause harmful interference to radio communications.
2.1.3 However, there is no guarantee that interference
will not occur in a particular installation. If this
equipment does cause harmful interference to radio or
television reception, which can be determined by
turning the equipment off and on, the user is
encouraged to try to correct the interference by one
or more of the following measures:
Re-orient or relocate the receiving antenna, Increase
the separation between the equipment and receiver.
2.1.4 Connect equipment and receiver to outlets on
different circuits.
WARNING: To satisfy FCC RF exposure requirements for mobile
transmitting devices, a separation distance of 20 cm or more should maintained
between the antenna of this device and persons during device operation. To
ensure compliance, operations at closer than this distance is not recommended.
The antenna used for this transmitter must not be co-located in conjunction with
any other antenna or transmitter.

TCV / Owners manual • www.srtorque.com • [email protected] 7
TCV
Owners Manual
2.2 Installation
It is mandatory that the national, state, and local safety and
wiring standards be followed during installation. These standard
would take precedence over any information presented in
this section
2.2.1 To avoid the hazard of electrical shock or burn, the
following instructions must be adhered to. Failure to
follow these instructions may also cause damage to
your unit and void existing warranties.
2.2.2 Do not energize the unit until all connections have
been properly made.
2.2.3 Equipment must be properly grounded before
applying power. Units energized by cord and plug must
be connected to an approved and properly
grounded receptacle.
2.2.4 Ensure the power switch is in the “off” position before
applying power.
2.3 Mounting
This unit may be wall mounted, table mounted, beam mounted,
suspended overhead, pedestal mounted. Mounting tabs have
been provided on the base of this unit.
2.3.1 Locate the unit in a stable, secure area so as to avoid
damage to the unit and avoid injury to the operator due
to inconvenient mounting. Locate the unit so that
ambient air can circulate freely around the box.
The TCV should be located to allow access to the front
panel and connectors. The location should allow for
unrestricted and comfortable viewing of the front panel.
The unit may be remotely mounted, but should still
be accessible.
2.4 Source Power
CAUTION! This unit is capable of being powered by 115VAC or
230VAC (both 50 and 60Hz). Before powering up the unit for
 thersttime,makesurethevoltageselectiononthepower
entry module matches the type of power being applied.
The TCV is fused at 1 Amp for 115VAC.
The TCV is fused at 1 Amp for 230VAC.

8TCV / Owners manual • www.srtorque.com • [email protected]
TCV
Owners Manual
2.5 Connecting Peripherals
The TCV has relay outputs and an optically isolated RESET
input. All can be accessed through the 5-pin connector on the
bottom of the box. The TCV also has a serial port labeled “RS232”.
The serial port may be used to connect to a personal computer in order to
program the TCV’s various settings.
2.6 Options for Relay Function and Assignability
The TCV has the ability to work with 2 tools simultaneously. As
a result the outputs are programmable and assignable to
accommodate working with 1 or 2 wrenches.
3.0 Device Programmer 1.3. Software
This manual was provided on a USB removable drive that also
has our utility program, Device Programmer V 1.3.3. The
software is Windows XP and Windows 7 compatible. We
recommend following standard Windows installation procedures.
The TCV has many parameters that may be adjusted using a
personal computer running the Device Programmer software and
the RS-232 programming cable. Custom congurations can also
be saved and duplicated on other TCV units.
After installing and running the Device Programmer software:
1. Connect the serial cable provided to the TCV and
to your PC’s COM port.
  2. MakesurethecorrectCOMportisselectedatthe 
bottom of the screen.

TCV / Owners manual • www.srtorque.com • [email protected] 9
TCV
Owners Manual
3.1 Programmable Tool Functions
As of the writing of this manual the current code is P317_6. This version
is backward compatible with older transceiver code P317_5. The
following functions can be programmed via the software;
1. Radio ID
2. Code Type
3. Code Revision
4. Low Battery alarm
5. Transmit attempts (not functional with P317_5 and earlier code)
6. Tmin
7. Tm a x
8. Time between cycles

10 TCV / Owners manual • www.srtorque.com • [email protected]
TCV
Owners Manual
3.2 Programmable and Assignable 24 V I/O Relay circuit
The TCV has the ability to work with 2 tools simultaneously. As a
result the outputs are programmable and assignable to
accommodate working with 1 or 2 wrenches. The following
functions can be programmed and assigned for this circuit:
1. Relay output 1 can be assigned for a specic tool (A or B) or
assigned to both.
2. Relay output 2 can be assigned for a specic tool (A or B) or
assigned to both.
3. Relay outputs functionality can be congured to send a signal
for the following events;
a. Cycle OK
b. Cycle NOK
c. Low battery alert
d. TBC*
e. None**
4. Relay mode (Latching or Momentary)
5. Relay On Time
6. Relay Off Time
7. Beep Settings (On or Off)
8. Indicator Lamps (Accept or Reject lamps time to be illuminated)
*One purpose of this relay assignation would be to have a light stack notify the operator that the TCV tool
communication is suspended.
*For Large multiple installations where the cables can be made the same for any operation.

TCV / Owners manual • www.srtorque.com • [email protected] 11
TCV
Owners Manual
3.3 Programming the 24 Volt I/O Circuit
3.4 TBC (Time Between Cycles)
The TBC timer starts at the completion of each torque operation
and must expire before the next torque operation occurs. If the
next torque operation occurs before the TBC time has expired,
the REJECT relay will close according to the relay conguration,
and the REJECT LED will light.
3.4.1 Relay Mode
If the relays are set to MOMENTARY, the duration of
the signal can be adjusted. For example, if the
ACCEPT RELAY TIME is 1.25, the ACCEPT relay will
close and remain closed for 1.25 seconds, then it will
open and remain open for 1.25 seconds. The REJECT
relay can be adjusted in the same manner.

12 TCV / Owners manual • www.srtorque.com • [email protected]
TCV
Owners Manual
3.4.2 Beeper
The TCV has an audible alarm or “beeper” that can be
programmed as follows:
Off – No beep
ON – Double beep for an ACCEPT, single long beep
for a REJECT

TCV / Owners manual • www.srtorque.com • [email protected] 13
TCV
Owners Manual
3.5 RF Channel
The TCV can operate on one of 12 channels. If the channel
is changed after a wrench has already been assigned
to this TCV, refer to section
4.3.1 under Add Wrench instructions.
The TCV uses channels from the IEEE 802.15.4 standard.
These channel numbers closely match the channels used
by the IEEE 802.11b/g wireless networking standard, so it
may be benecial to use channels that do not match the
channels selected for a nearby wireless network.
Center Frequency = 2.405GHz + (channel) (5MHz)
CH1 = 2.410GHz CH5 = 2.430GHz CH9 = 2.450GHZz
CH2 = 2.415GHz CH6 = 2.435GHZ CH10 = 2.455GHz
CH3 = 2.420GHz CH7 = 2.440GHz CH11 = 2.460GHz
CH4 = 2.425GHz CH8 = 2.445GHz CH12 = 2.465GHz
3.6 Wrench Radio ID
Each RF torque wrench has a unique four-character identication
number. When a wrench is assigned to a TCV using the Add
Wrench procedure, the wrench ID is acquired and saved by the
TCV. If this ID is changed using the Device Programmer
software, the assigned wrench will no longer be recognized by
the TCV. Conversely, If a wrench’s ID is programmed using
the Device Programmer software, the Add Wrench procedure is
not necessary

14 TCV / Owners manual • www.srtorque.com • [email protected]
TCV
Owners Manual
4 Operation
4.1 Power Up
During power up, all four LEDs will illuminate and a triple beep
will sound. After the triple beep has sounded, the TCV will be
ready for operation.
4.2 Normal Operation
During operation, the TCV will indicate the status of each
fastening cycle. If the cycle was within the user-dened
limits, an ACCEPT status will be issued, the ACCEPT LED will
illuminate, and the ACCEPT relay will close if so programmed.
4.2.1 If the fastening cycle did not conform to the user
dened limits, the REJECT LED will illuminate and the
REJECT relay will close if so programmed.
4.2.2 The status of the last fastening cycle persists until the
next cycle, the time set for illumination has expired or
the status may be cleared at any time using the
RESET input.
4.3 Adding a Wrench or Wrenches
Before a wrench can be used with the TCV, it must rst be
identied by the TCV. To do this, turn the key on the TCV to the
“PROG” position, then click the wrench. If the ACCEPT LED
turns on, the operation was successful.
4.3.1 If two tools are to be used with the TCV they both
must be identied by the TCV at the same time.
Turn the key back to the “LOCK” position. The TCV
will now respond only to the wrench(es) that it
has identied.
4.3.2 It is important to understand that when programming
multiple wrenches the rst tool clicked will be identied
by Device Programmer as Tool A and the second tool
to be clicked will be identied as Tool B.

TCV / Owners manual • www.srtorque.com • [email protected] 15
TCV
Owners Manual
4.3.3 Note: Each wrench also stores the identication
number (ID) of the TCV to which it is assigned.
In order to assign a wrench to a TCV, any stored ID
must be cleared from the wrench. To do this, click
and hold the wrench until the LED ashes to indicate
a reset (about 5 seconds). The wrench will now be set
to perform an inquiry for available TCVs. Immediately
after a battery is installed on the wrench, the LED
will alternate between red and green several times
very quickly. This indicates a reset condition. This
reset indication will be followed by a red pulse if the
wrench has no stored ID and is ready to be added to
a TCV. If the reset indication is followed by a green
pulse, the wrench has already been assigned to a
TCV and is ready to perform torque operations. An
alternate way to add a wrench to the TCV is to
program the wrench’s radio ID using the Device
Programmer software.
4.3.1 Changing Channels
To change channels it is necessary to use Device Programmer
software. Since the TCV is backwards compatible with older
transceivers there are two methods for changing channels.

16 TCV / Owners manual • www.srtorque.com • [email protected]
TCV
Owners Manual
4.3.1.1 Method 1 For older boards or for mix of new and old.
4.3.1.2 Method 2 For Newest boards only.
Note: If there is a need to replace
one of two tools using a newer
board it is important to identify
what tool is being replaced (A or
B). As an example Tool B needs
to be replaced. Turn the Key to
programming mode and click tool A
(it does not need to be erased) then
click the new tool.

TCV / Owners manual • www.srtorque.com • [email protected] 17
TCV
Owners Manual
4.4 LED Functions
POWER – The POWER LED ashes on and off with a
two-second period (one second on, one second off) to indicate
that the TCV is powered up and the processor is functioning.
ACCEPT – The ACCEPT LED will illuminate after each torque
that results in an “OK” status.
REJECT – The REJECT LED will illuminate after each torque
that violates the Tmin or Tmax values. A Time Between Cycles
(TBC) violation will also cause the REJECT LED to illuminate.
STRENGTH/PROG - After each torque operation, the
STRENGTH/PROG LED will turn on for 2 seconds to indicate
the received signal strength from the wrench transmitter.
Green indicates a good signal. Yellow indicates a moderate
signal. Red indicates a poor signal.
The STRENGTH/PROG LED will continue to ash red after
each cycle until the Time Between Cycles (TBC) has
expired to indicate to the operator that a torque operation is not
permitted at this time. The next torque operation will be
permitted when the STRENGTH/PROG LED stops ashing red.
The STRENGTH/PROG LED stays solid red as long as the
key is in the “PROG” position.
Torq-Tronics 2
Even The Worlds Best Wrenches Need Calibration!

Sturtevant Richmont
555 Kimberly Drive
Carol Stream, IL 60188
Worldwide: 1-847-455-8677
US Only: 1-800-877-1347
www.srtorque.com
[email protected]
© 2014 Sturtevant Richmont All rights reserved. Specifications are subject to change without notice.
To nd your Sturtevant Richmont
sales professional use your smart
phone to follow the QR code.
Sturtevant Richmont
The Tools You Trust.
We set the bar for quality, standards, and
compliance in everything we do:
ISO 9001:2008 Certied
(First US Torque Tool Manufacturer to be ISO 9001)
ISO/IEC 17025:2005 Certied
(First US Torque Tool Manufacturer to be ISO 17025)
First in USA RoHS Compliant
A2LA Reference Lab
A2LA Pivot Lab