Sure Torque ST-LAB Bedienungsanleitung

rev. 08.15.2006. 1-1

Read This First!

TO UNPACK AND SET UP YOUR SURE TORQUE BENCHTOP TORQUE TESTER, PLEASE PERFORM THE

FOLLOWING STEPS:

Tools needed: Screwdriver, Allen wrench set.

1. Carefully remove the crating box cover to expose the machine, which is mounted on the crate’s base. Then using an

Allen wrench set, unscrew four screws in the machine’s base.

2. Next, unscrew the screws holding the machine tight in the crating box then identify the other components and

assembly hardware.

3. Connect the main air supply to the rear air plug (refer to section 2.5.1 in the manual for specifications).

4. Attach the provided CE marked power supply to the rear of the system.

5. Run unit in manual cycle first to check component operation and alignment before running automatic cycle.

rev. 08.15.2006. 1-2

Corporate Overview

Sure Torque (ST) began the development of the first electronic torque tester in 1985 in response to the needs

of manufacturing and quality control engineering departments for precision torque testing instrumentation, capable of

accurate, NIST certifiable torque measurement. Our equipment line offers rigorous testing of closure integrity, and is a

necessary requirement to meet today’s stringent specifications for quality control and data collection.

Our torque testers are currently an invaluable part of the production and quality control departments for major

corporations such as Abbott, Eli Lilly, Schering, Upjohn, Procter & Gamble, Coca Cola, S.C. Johnson, Gerber,

Seagram, Hershey, Warner Lambert, and Kraft General Foods, to name a few.

Container cap torque is important, not only for package appearance and product integrity, but mainly for

customer satisfaction and consumer safety. We fully support a total commitment to quality control at ST; after all, we

developed this advanced technology in response to the needs of our customers. ST continues to respond to our

customers’ needs by developing and manufacturing the most sophisticated, up to date electronic torque testers

available in the world today.

We know today’s consumers judge product quality based on many criteria, which include packaging,

appearance and overall effectiveness of the product. Cap torque not only impacts the package’s appearance, but more

importantly, the customer’s perception of the manufacturers’ level of quality and concern.

In today’s competitive market, the consumer avoids buying products if there is detectable evidence of product

leakage, product tampering or something as simple as a difficult to remove closure.

Quality control of the filling operation is concerned with possible product loss due to loose caps on liquid

products and the stability of both liquid and dry products. Stability is of particular concern with moisture sensitive

products, which require that the integrity of the container cap and the internal seal be maintained. Stability

considerations are critical since product loss due to evaporation or moisture absorption can cause significant changes

in potency and thereby the efficacy of the product.

Container closure application can significantly affect the success of a product and closure application defects

are detectable with the correct torque testing protocols in place, thus assuring closures meet certain specifications,

thereby assuring product integrity.

To achieve the desired level of product quality, manufacturers set certain specifications for acceptable torque

values, based upon container closure testing conducted on each container type.

At ST, our line of torque testing equipment is designed to not only conduct precise closure torque testing, but

to also provide data necessary for evaluation of a closure system’s compatibility to a container, efficiency of tamper

evident bands and closure or liner durability. This data will help determine a closure’s conformance to performance

specifications, and evaluate a capper’s capability.

Our customer service and parts departments are always willing to help you with ordering the proper parts, and

will answer any questions you may have about operation and maintenance of your machine.

ST invites you to attend a guided tour of our manufacturing facility including demonstrations of our laboratory

torque testing equipment. Please feel free to contact ST for information, brochures and specification literature for our

quality, state of the art, precision instrumentation.

Thank you for your interest in Sure Torque

We look forward to supporting your closure testing requirements.

Dan Delzer

President

Sure Torque

2532-34 Trailmate Drive

Sarasota, Florida 34243

Office: (941) 753-1095

Fax: (941) 756-8425

http://www.suretorque.com

rev. 08.15.2006. 1-3

Preface

Thank you for the confidence you have shown in Sure Torque, as demonstrated by your purchase of our

equipment.

Although many machine concepts and subsystem operations may be common to several different Sure Torque

machine models, this Operation and Maintenance Manual (O&M) applies to your specific packaging system.

This manual is intended to provide a comprehensive description of your system’s machine concepts, safety

precautions, operation, basic maintenance, and adjustments necessary to assure optimum performance. A

troubleshooting and replaceable parts section is included (section 5) to aid in prolonging maximum machine

productivity and packaging line “up-time.” We at ST take great pride in you, our customer, and dedicate this manual to

support your goal of prolonged system productivity throughout the years.

ST machines normally require little special attention other than routine lubrication and cleaning. Routine

preventative maintenance procedures, however, should always be followed, especially those recommended in this

manual. In particular, component contact areas should be inspected regularly for proper alignments and for possible

wear or damage. The handy “Replaceable and Spare Parts List” (optional) will aid in rapid replacement of worn, or

damaged parts, and will help return your machine to on-line productivity in the shortest possible time.

It is also extremely important to observe good shop safety practices in all aspects of installation, lubrication,

operation, maintenance, and adjustments of all ST packaging equipment. Safety instructions given in this manual

should be followed strictly, without exception under all circumstances.

If this manual does not answer a particular question, or leaves doubts in the proper operation of your machine, do

not hesitate to contact our Customer Service department in Sarasota, Florida (941) 753-1095.

Your ST representative is eager to help you get the most production possible out of your torque tester. Our staff

can ensure that you receive any additional information you may need. We will work with you in solving interfacing or

mechanical problems, and will guide you in ordering the proper equipment, or replacement parts.

Again, thank you for becoming another loyal ST customer.

Sincerely,

Dan Delzer

President

SURE TORQUE Worldwide Torque Testing Equipment Specialists!

rev. 08.15.2006. 1-4

rev. 08.15.2006. 1-5

Safety Comes First With ST

Throughout this manual, ST will emphasize safety precautions that should be adhered to by all personnel setting

up, operating, maintaining and repairing all ST equipment. Machine and personal safety depends on adherence to ALL

CAUTIONS and WARNINGS. Since actual working environments vary greatly, it is impossible to mention ALL

precautions that should be taken in any particular situation. It is your responsibility to be alert while working with any

machinery. Failure to do so will cause personal injury or equipment damage.

All precautions and warnings should be discussed with All personnel operating, working on, or near any packaging

equipment or production lines.

Follow All Safety Precautions In This Manual

NOTE:

Generally, CAUTION conditions refer to equipment damage, whereas WARNING conditions alert personnel to the

possibility of bodily injury. One hazardous condition, however, could easily cause the other.

WARNING

Personal Injury Or Equipment Damage May Result If The

Following 10 Safety Precautions Are Not Observed At All Times.

1. DO NOT operate any machine until you have completely read the manual.

2. DO NOT operate machine without safety guards in place. Stop the machine if guards are opened.

3. STAY CLEAR of all moving parts, AND NEVER wear baggy clothes around machines. Protect long hair with a

hair net.

4. STOP the machine before clearing container jams.

5. STOP the machine before cleaning.

6. STOP the machine before performing maintenance or lubrication procedures.

7. Disconnect power BEFORE changeovers or adjustments.

8. ENSURE machine is properly grounded.

9. Permit ONLY qualified personnel to open the electrical enclosure.

10. Ensure that All personnel are clear of the machine BEFORE starting.

REMEMBER!

ADHERE TO ALL SAFETY PRECAUTIONS LISTED ABOVE

AND THROUGHOUT THIS MANUAL

SURE TORQUE Worldwide Torque Testing Equipment Specialists!

rev. 08.15.2006. 1-6

Electronic Torque Tester: Model ST-LAB

Operation and Maintenance Manual

With Appendix A containing:

• Machine Tuning Sheet

• Certification Records

• Closure Records

• Top Load Setup Procedure – Optional

• Sure Torque DAQ Software – Optional

• Sure Torque DAQ Plugin Torque-Time/Angle Analysis – Optional

• Instructions for Optional Sure Torque Test Methods – Optional

• Instructions for Decay, Alarm, four level Password Protection,

Adaptive Torque application features – Optional

Information provided in this document contains proprietary data on patented products and systems. This

information is furnished for the exclusive use of the customer to install, maintain, repair, and operate the

equipment covered in a specific purchase agreement. Disclosure of the data contained herein to any individual or

organization not a party to the specific purchase agreement and all other uses, including reproduction by any

means, is strictly prohibited without the express written consent of Sure Torque Acceptance and use of this

manual constitutes acceptance of these terms and conditions.

PREPARED BY:

SURE TORQUE

2532-34 Trailmate Drive

Sarasota, Florida 34243

Tel: (941) 753-1095 Fax: (941) 756-8425

SURE TORQUE Worldwide Torque Testing Equipment Specialists!

rev. 08.15.2006. 1-7

Table of Contents

Read This First!...............................................................................................................................................1-1

Preface.............................................................................................................................................................1-3

Safety Comes First With ST............................................................................................................................1-5

Electronic Torque Tester: Model ST-LAB .....................................................................................................1-6

1. General Information..............................................................................................................................1-10

1.1. System Overview ..........................................................................................................................1-10

1.1.1. Control Interface....................................................................................................................1-10

1.1.2. Mechanical Assembly ...........................................................................................................1-10

1.1.2.1. Stand Assembly.............................................................................................................1-12

1.1.2.2. Chuck Assembly............................................................................................................1-12

1.1.2.3. Change-Parts .................................................................................................................1-12

1.1.2.4. Pneumatic Assembly.....................................................................................................1-12

1.1.3. Electronic Assembly..............................................................................................................1-14

1.1.3.1. Transducer.....................................................................................................................1-14

1.1.3.2. Programmable Logic Controller....................................................................................1-14

1.2. Operational Sequence of the Test Cycle Functions.......................................................................1-14

1.2.1. Clamping Sequence...............................................................................................................1-14

1.2.2. Head Lowering Sequence......................................................................................................1-14

1.2.3. Chuck Actuation Sequence ...................................................................................................1-14

1.2.4. Torque-Test Sequence...........................................................................................................1-14

2. Installation Instructions.........................................................................................................................2-15

2.1. Receiving the Unit.........................................................................................................................2-15

2.1.1. Inspecting ..............................................................................................................................2-15

2.1.2. Unpacking .............................................................................................................................2-15

2.2. Positioning the Unit.......................................................................................................................2-16

2.3. Pre-Run, Sure Torque Check-out..................................................................................................2-16

2.4. Electrical Installation.....................................................................................................................2-16

2.4.1. Precautions ............................................................................................................................2-17

2.4.2. Connections...........................................................................................................................2-17

2.5. Pneumatic Installation...................................................................................................................2-17

2.5.1. Air Supply .............................................................................................................................2-17

2.5.2. Plumbing ...............................................................................................................................2-17

2.5.3. Air Pressure Settings.............................................................................................................2-17

2.6. Machine Tuning Sheet...................................................................................................................2-17

3. Operating Instructions...........................................................................................................................3-18

3.1. Controls and Indicators .................................................................................................................3-18

3.2. Machine Setup...............................................................................................................................3-19

3.2.1. Mechanical Setup..................................................................................................................3-19

3.2.2. Electronic Setup ....................................................................................................................3-20

3.2.2.1. Timer configuration.......................................................................................................3-21

3.2.2.2. Speed Settings ...............................................................................................................3-22

3.2.2.3. Miscellaneous................................................................................................................3-23

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3.2.2.4. Load/Save Presets..........................................................................................................3-24

3.2.2.5. Serial communication, Data table setup........................................................................3-25

3.2.2.6. Unlocking operation modes, optional features..............................................................3-26

3.2.2.7. Alarm settings................................................................................................................3-27

3.2.2.8. Calibration.....................................................................................................................3-28

3.3. Displayed messages, options and instructions. .............................................................................3-30

3.3.1. Display...................................................................................................................................3-30

3.3.2. Power On...............................................................................................................................3-30

3.3.3. The Mode Screens.................................................................................................................3-31

3.3.3.1. Manual Mode ................................................................................................................3-31

3.3.3.2. Applied Mode................................................................................................................3-33

3.3.3.3. Release Mode................................................................................................................3-34

3.3.3.4. Multiple Applied Mode.................................................................................................3-34

3.3.3.5. Applied then Release Mode ..........................................................................................3-35

3.3.3.6. Multiple Release Mode .................................................................................................3-35

3.3.3.7. Release and Applied Mode............................................................................................3-35

3.3.3.8. Reverse Ratchet Mode...................................................................................................3-35

3.3.3.9. Shelling Mode ...............................................................................................................3-35

3.3.3.10. Strip Test .......................................................................................................................3-35

3.3.3.11. Nondestructive Release Mode.......................................................................................3-35

3.3.3.12. Various Dispenser Pump Head Tests............................................................................3-35

3.3.3.13. Sealed closure torque testing methods ..........................................................................3-36

3.3.3.14. Precision Applied and Release tests..............................................................................3-36

3.3.3.15. Topload measurements..................................................................................................3-36

3.3.4. Historical Data Screens.........................................................................................................3-36

3.3.5. Serial Communication...........................................................................................................3-37

3.3.5.1. Sure Torque Data Acquisition.......................................................................................3-37

3.3.5.2. Customisation of the communication string..................................................................3-37

4. Maintenance ..........................................................................................................................................4-38

4.1. Cleaning.........................................................................................................................................4-38

4.2. Preventive Maintenance................................................................................................................4-38

4.3. Pneumatic Maintenance ................................................................................................................4-39

4.3.1. Air Leaks...............................................................................................................................4-39

4.3.2. Air Filter................................................................................................................................4-40

4.3.3. Solenoid Valves.....................................................................................................................4-40

5. Troubleshooting Guide..........................................................................................................................5-41

6. Sure Torque Warranty, Limitation of Liability and Service Information.............................................6-43

7. Sure Torque Options List......................................................................................................................7-44

7.1. Software Mode List.......................................................................................................................7-44

7.1.1. Release Mode........................................................................................................................7-44

7.1.2. Applied Torque Mode...........................................................................................................7-44

7.1.3. Multiple Applied Mode.........................................................................................................7-44

7.1.4. Applied then Release Torque Mode......................................................................................7-44

7.1.5. Release then Re-Apply Mode................................................................................................7-44

7.1.6. Non-Destructive Release Mode.............................................................................................7-44

rev. 08.15.2006. 1-9

7.1.7. Non-Destructive Release and Re-Apply Mode.....................................................................7-45

7.1.8. Repetitive Applied then Release (Fatigue) Mode .................................................................7-45

7.1.9. Multiple Peak Mode..............................................................................................................7-45

7.1.10. Reverse Ratchet Mode...........................................................................................................7-45

7.1.11. Shelling Fixture Mode...........................................................................................................7-45

7.1.12. Strip Test ...............................................................................................................................7-45

7.1.13. Various Dispenser Pump Head Tests....................................................................................7-45

7.1.14. Sealed closure torque testing methods ..................................................................................7-45

7.1.15. Precision Applied and Release tests......................................................................................7-45

7.1.16. Topload measurements..........................................................................................................7-46

7.2. Other Options list..........................................................................................................................7-46

7.2.1. 360°/720° Degree Test Mechanism.......................................................................................7-46

7.2.2. Metric/US Measurement .......................................................................................................7-46

7.2.3. RS-232 Interface....................................................................................................................7-46

7.2.4. Real Time Clock (RS-232 serial port required) ....................................................................7-46

7.2.5. Verification Kits....................................................................................................................7-47

7.2.6. STDA Software.....................................................................................................................7-47

7.2.7. Password Protection Feature.................................................................................................7-47

7.2.8. Time Decay Feature..............................................................................................................7-47

7.2.9. Historical Data Option...........................................................................................................7-47

8. Glossary.................................................................................................................................................8-48

9. Data Acquisition Program for the ST-LAB Bench Top Torque Tester................................................9-51

9.1. General ..........................................................................................................................................9-51

9.2. System Requirements....................................................................................................................9-51

9.3. Installation.....................................................................................................................................9-51

9.3.1. Hardware Installation............................................................................................................9-51

9.3.2. Software Installation..............................................................................................................9-51

9.4. Operation.......................................................................................................................................9-51

SURE TORQUE Worldwide Torque Testing Equipment Specialists!

rev. 08.15.2006. 1-10

1. General Information

Sure Torque recommends that all operators and service personnel scan the Table of Contents to familiarize

themselves with the contents and layout of this technical manual. Since certain modifications have been made or

requested by our customers, this is a general guide and all of the technical information in this manual may not pertain

to your specific machine. Changes in machine design or specifications are a result of continual machine improvement

and Sure Torque reserves the right to change specifications without prior notice.

The following chapter gives a brief description of the operational philosophy of your fully automated ST-LAB, Sure

Torque Electronic Torque Tester System.

Major components and assemblies are called out on Figure 1-1, ST-LAB Torque Tester General Arrangement,

and referred to in this chapter, and throughout this manual as well. Any optional equipment included with your

machine is listed on the Owners Fact Sheet. Any Changeover specifications are listed on the Machine Tuning Sheet

for the particular closure and container being tested.

Your ST-LAB, “Sure Torque” Electronic Torque Tester, is a fully automated precision instrument designed for a

wide array of container closure test functions. The ST-LAB electronically measures the forces required to apply or

remove threaded screw caps from the containers. Your ST-LAB, with available options, will also apply downward

forces to a childproof closure for the required protocol tests under the Poison Prevention and Packaging Act. The ST-

LAB can also be used for any other test that requires the measurement of an increasing rotary, or linear force to a

peak point, closure container compatibility or failure analysis.

The Sure Torque’s modular design assures minimum maintenance, ease of operation in a minimum of space, and

wide-range of container acceptance capabilities.

ST offers an optional 360° degree test mechanism (refer to section 7.2.1 in this manual) for our ST-LAB unit. This

option measures the largest release torque sensed during a full 360° degree turn of a closure.

1.1. System Overview

The following paragraphs are intended to give an outline of the major components and operational sequences

required to perform the ST-LAB, Sure Torque functions. Major components and assemblies are called out on Figure

1-1, ST-LAB Torque Tester General Arrangement.

The basic ST-LAB Torque Tester System consists of:

1. Control Enclosure.

2. Sturdy mechanical assembly.

3. Integrated pneumatic systems.

4. Electronic components and assemblies required to perform various operational test functions.

The following four sections give a detailed description of each of these assemblies:

1.1.1. Control Interface

The operator’s interface with the Sure Torque unit is controlled through the PLC mounted in the head of the ST-

LAB that regulates the operational cycles, processes the input/output data, and acts as the overall communications

link with the line operator or test engineer. This PLC can easily interface with an on-line or remotely operated host

computer for data collection. Sure Torque will gladly integrate this host computer interface controller PC in your

system.

1.1.2. Mechanical Assembly

The Mechanical System consists of a Base, Chuck and Change Part Components. Please refer to Figure 1-2, ST-

LAB Torque Tester Mechanical Components (Chuck Assembly).

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