Operator’s Manual ST-120S Automatic Torque Tester...Phone: (303) 987-8000 • Fax: (303) 987-8989 • E-mail: [email protected] • Web: torque.mesalabs.com Operator’s Manual

Mesa Laboratories • 12100 6th Awe. • Lakewood, CO 80228

Phone: (303) 987-8000 • Fax: (303) 987-8989 • E-mail: [email protected] • Web: torque.mesalabs.com

Operator’s Manual

ST-120S Automatic Torque Tester



Page 2 of 82 Rev A 28-Aug-17

Table of Contents

For convenience, this manual is divided into several chapters. A brief description of each chapter follows. Chapter 1: Overview ………………........................................................ pg 6 This chapter provides a brief introduction, common uses, and brief description on content to follow. Chapter 2: Specifications and Description .......................................... pg 8 This chapter contains information about the ST-120S and a detailed picture describing parts to the torque tester. Chapter 3: Unpacking and Inspection ............................................... pg 12 This chapter is a guide to ensure that the ST-120S is received in proper condition and that all necessary components have been located. Chapter 4: System Power Up ............................................................. pg 15 This chapter contains the required information for electrically and pneumatically connecting the system components and then powering up the system. Chapter 5: Tooling Set Up …………..................................................... pg 17 This chapter contains the required information for installing and adjusting the tooling that will be used for testing. Utilizes he Manual Mode Menu Chapter 6: Quick Start ....................................................................... pg 23 This chapter contains a step-by-step procedure to help the user become familiar with the basic operation of the ST-120S Chapter 7: Tester Settings ................................................................. pg 27 This chapter contains instructions on how to navigate and edit the ST-120S settings including Data output, screen format and more Chapter 8: Test Types and Their Menus ............................................. pg 30 This chapter contains a description of the ST-120S test types and the menus that are used to select and program them.




Chapter 9: Product Management ……............................................... pg 37 This chapter contains instructions on how to navigate and edit the Product

Management Menu so that the operator can enter/modify product specific variables.

Chapter 10: Example Product Management Setups .......................... pg 39 This chapter contains several examples of common product set-ups including cap tightening and release testing with CR, TEB, and CT caps. Chapter 11: Password Management ………........................................ pg 47 This chapter contains instructions on how to navigate and edit the administrative

passwords for setup and recalibration actions.

Chapter 12: Timers ………………………...…......................................... pg 48 This chapter contains instructions on how to navigate and edit the delay timers

during testing for all test modes.

Chapter 13: Data and Communication ..…......................................... pg 50 This chapter contains information stored and recalled in the Data Log Menu as well

as the data management and communication types of the ST-120S

Chapter 14: System Calibration......................................................... pg 52

This chapter is intended to acquaint the user with the required Calibration

Equipment, the Calibration Verification Process, and the process for performing a

User Calibration.

Chapter 15: Gold Bottle Verification .................................................. pg 63

This chapter describes the Gold Bottle and the procedure for using it to verify the calibration of the ST-120S.

Chapter 16: Troubleshooting ............................................................ pg 66

This chapter is a guide to assist in the recognition of any possible malfunctions, identification of their probable causes, and corrective actions to solve the problem.

Chapter 17: Preventative Maintenance ............................................. pg 68

This chapter is a guide to assist in the proper care and maintenance schedule to ensure long lasting quality and use.




Appendix 1: ST-120S Spare Parts Kit ................................................. pg 72

This addition is to show the operator common spare parts associated with the

ST-120S

Appendix 2: Torque Transducer Specifications ................................. pg 74

This addition contains information and specifications about the Torque Transducer

Appendix 3: Variables in Torque Testing ........................................... pg 76

This addition is to inform about the many variables that can affect torque readings

Appendix 4: Torque Testing Standards ….......................................... pg 81

This addition is a quick reference for the various standards including the ones

developed by ASTM and ISBT




Conventions The following conventions are used in this manual.




Chapter 1: Overview

What’s Inside This manual is designed to provide the user with a step-by-step procedure from receipt of the system through operation, maintenance and calibration.

Introduction

Mesa Laboratories, Inc. is an industry leader in the manufacturing of precision torque measuring equipment. Over forty years of experience in the torque-testing field is reflected in every automated system. The SureTorque ST-120S Automated Torque Tester by Mesa Labs is a test instrument intended to be incorporated into a quality control program of bottle packaging companies. The ST-120S is a motorized testing equipment with a strain gage based torque transducer used to measure the removal/applied torque of threaded closures. The equipment was developed in accordance with various ASTM D10.31 and ISBT voluntary bottle testing standards. Mesa Labs recommends the user to obtain copies of the standards developed by the ASTM D10.31 subcommittee and ISBT (International Society of Beverage Technologists) for reference.




Common Uses The automated test system can be used for the following purposes: Cap tightening: The unit may be used as a portable precision cap tightener in low volume production facilities. Closure integrity testing: The torque required to remove the cap from the container threads is an indicator of packaging quality. Low removal torque values may indicate a poor cap product design or bad capping process which may result in product contamination or leakage. Testing the thread break torque within a quality control program (combined with accelerated aging and leak testing) will ensure that your packaged products are consistently and reliably closed and product leakage/contamination is minimized or eliminated. Package Development: Thread break/tamper evident band break/strip and applied torque testing can be utilized for package development and marketing. New materials and designs can be evaluated by comparing the value and repeatability of test results. Validation: The test results from the SureTorque tester can be used to validate and set the limits of the packaging process. Packaging Machinery Troubleshooting: The torque testing results can aid in troubleshooting a packaging machine configuration or operation.




Chapter 2: Specifications and

Description

What’s Inside This chapter contains information about the ST-120S and a detailed picture describing parts to the torque tester.

Technical Specifications

Testing

Torque Tests Cap release test, Final application, Fatigue, Tamper evident break

Torque Range 0-88 lbf•in (0-10N•m)

Torque Transducer Strain gauge

Accuracy +/- 0.5% for static loads over full scale

Repeatability +/- 0.2 lbf•in for one set up

Resolution Min 0.1 lbf•in

Maximum Overload 150%

Rotation 0-60 RPM, CW and CCW, Infinite

Modes Position, Speed or Torque control

Torque Units d•Nm, N•m, kg•cm, kg•m, oz•in, lbf•in

Calibration Certifiable (NIST)

Standards Meets or exceeds NIST, ASTM, FDA, GMP

Electrical

Control PLC-based system

Analog Signal 16bit/12.5ms conversion

Response Time (avg) <12.5ms

HMI Display 3.5” 256-Color Touch panel

Communication RS-232/RS-485 (USB, Ethernet optional)

Real-Time Clock 7-year typical battery backup

Utilities

Air Source 80-125 PSI, 5 SCFM

Power Source 100-240VAC, ~2.5A, 50-60 Hz




Environment

Temperature Range 32-122°F (0-50°C)

Relative Humidity 10% to 95% (non-condensing)

Mounting Flat surface or desktop

Container Sizes

Height Range 1.0” (with base adapter) to 16.75”

Diameter Range 0.25” to 7.50” (with 10” platform)

Dimensions

Dimensions 31” x 12" x 16” (HxWxD)

Weight 65 lbs.

Materials of Construction

Exterior Anodized Aluminum and Stainless Steel

Hardware Stainless Steel

Tooling Anodized Aluminum, Nickle Plated Steel, Polyurethane, Acrylic, HDPE, UHMW

Tooling and Options

Tooling

Collet CT Standard threaded cap collet

Collet CR Child resistant cap collet

Angular Gripper Spray type or odd shaped cap gripper

Spring Loaded Serrated or non-threaded closures (beer cap)

Standard Clamp Set Round container clamps (left and right)

Clamp Adapter Set Adapts legacy tooling to new design

“V” Clamp Set Clamps for square or glass containers

Top load Chuck Chuck housing with adjustable spring top load fixture (5- 25 lbf). Use for child-resistant and push-to-turn closures.

Axial Float Chuck Chuck housing with floating mechanism. Use to minimize top load during testing for standard thread caps.

Height Base Adapter Platform base for short containers

Locating Base Adapter Locating base for square or round bottom containers




Options

DAQ Option 1 Captures peak torque, time and date stamp. Windows based software, version 1.10 – 1.12.

DAQ Option 2 Captures Realtime Torque vs. Time or Angle vs. Torque. Windows based software, version 3.1.

DAQ Custom Consult factory

TorqueIQ SPC Software

FDA 21 CFR Part 11 compliant record keeping and Statistical Process Control Software

Serial Printer For all torque tester models. Interface: RS-232. Paper dimensions: 57.5, 69.5, or 76.0 mm (W) x 83.0 mm dia. Reliability: MTBF-180,000 hour

Laboratory Kit ASTM Calibration kit in protective case with 3 weights and 4 pulleys for 25 points of calibration.

Portable Kit ASTM Calibration kit in protective case with 1 weight and 2 pulleys for 3 points of calibration

Gold Bottle For daily “Quick Check” of calibration, 0-20 lbf•in range.

Safety Enclosure 1” frame with ¼” thick clear abrasion resistant polycarbonate for protection

Top load Monitoring Electronically controlled and monitored top load system

Automatic Product Detection

Automatic storage and recall of test formulas for fast switchover

Indicator Light System Red, Amber, and Green Indicator lights for easy pass/fail indication




Description The ST-120S is a precision test instrument utilizing a unique torque and speed

controlled servo motor, a patented pressure controlled closure gripping

mechanism and a strain gage based torque transducer to measure the opening

and closing torque of threaded closure systems. Test methods were developed

based on various ASTM, ISBT standards and current testing practices at the

world’s largest bottle packaging companies. For general arrangement and change

part descriptions please refer to the pictures below.

Base

Dual Activation Start Buttons

Collet

Chuck

Self-Centering

Clamp Assembly

Clamps

NEMA power enclosure

(Optional)

Column

Back panel with pressure

regulators and air filters E-Stop

Touch Screen HMI+PLC

Head Assembly

Column height

Adjustment handles

Locating Base (Optional)

Air Filters

Quick Release Pin

Platform




Chapter 3: Unpacking and

Inspection What’s Inside This chapter is a guide to ensure that the ST-120S is received in proper condition and that all necessary components have been located.

Packaging Your Torque meter was carefully inspected, both electrically and mechanically before shipment. Follow the unpacking procedure to carefully remove the tester and check for any signs of damage that may have occurred during shipment.

Immediately report any shipping damage to the shipping agent.

Unpackaging Procedure Step 1: Remove outer shipping shell. Retain and use the original packing materials in case reshipment is necessary. Step 2: Move inside box and place to side for later use.

Contains all change

parts purchased

along with standard

equipment




Step 3: Unscrew 4 wing nuts securing machine to shipping frame.

Step 4: Carefully move the ST-120S to table top or testing platform.

Replace foam frame parts and wing nuts on bottom shipping frame.

Step 5: Remove lock screw for the Column Cable. Located on the

bottom of the Base plate of the ST-120S. (3/16” Hex)

IMPORTANT!! Lock screw for column cable must be

removed before any testing can be done.




Check List The following items are shipped with all ST-120S testers:

Input power cable

Input power supply

USB cord

Air hose with fitting

Operator’s manual

A Certificate of Calibration for your new ST-120S is included behind the front cover of the manual.




Chapter 4: System Power Up

What’s Inside This chapter contains the required information for electrically and pneumatically connecting the system components and then powering up the system.

Powering the ST-120S The system is energized by first inserting the external power supply into the receptacle on the back panel of the head (see Below) and then plugging the input power cable into an AC OUTLET.

Now by actuating the red rocker power switch located on the back panel, the system will be energized and ready for use.

The ST-120S is supplied for use with 100 - 240 VAC 50 - 60 HZ. Consult factory or your local sales representative for operation with other voltages. The use of a surge protector or power conditioner with the ST-120S is recommended as a protective measure against electrical noise.




Pneumatic Set Up The system is properly connected to an air supply by first connecting the air fitting supplied to a clean, dry, air supply of 80 psi at 4 cfm. Next connect the airline to the 1/8” NPT fitting at air filter on the back panel.

Initial Display After Power-up The following Main Menu will appear on the touch screen display whenever the system is turned on. The manufacturer and software version information is shown on the first “splash” screen during the boot-up procedure. Startup/Support Display Main Menu




Chapter 5: Tooling Set Up

What’s Inside This chapter contains the required information for installing and adjusting the

tooling that will be used for holding the bottle, gripping the cap and positioning

the platform.

The tooling pictured here may not necessarily be the tooling shipped with your system however the descriptions for installing this tooling is still applicable for most other tooling packages.

Installing Tooling for Holding the Bottle

SureTorque testers require the use of product specific tooling, it is important to

use the correct change parts for the testing. Usually change parts are labeled for

easy identification.

To allow safe pneumatic actuations, lower the platform to the bottom of the

vertical support then release the locking handle. Lower the platform assembly to

the bottom of the column. Secure the platform assembly with the locking handle.

Now slide the clamps into the clamp bracket and secure the clamps by tightening

the thumb screw.




Custom Printed locating bases, including

those used for Automatic Product detection,

should be mounted on the platform before

adjusting the height. This is to incorporate the

added height of the base and ensuring

accurate placement to secure the container.

Installing Tooling for Gripping the Cap

All Mesa supplied chucks are mounted on the drive shaft and secured by tightening 2 hex set screws

If utilizing a standard, axial/floating, or top load chuck, a

pneumatic tube is needed and attached to the drive shaft. A

Collet is also needed to grip the closure. The collet is

inserted into the chuck, and secured with the quick release

pin.




Adjusting the Platform

The Platform was designed to position the container at a convenient height for loading and unloading test samples while providing for the minimum amount of vertical motion.

Step 1: Once the clamps, chuck, and collet are installed, adjust the platform

height by lowering/raising the platform until the clamp profile matches the

container profile. When the correct clamping position is found, secure the platform

by tightening the adjustment knobs.

Step 2: On the PLC, navigate to the Manual Mode by selecting Setup on the

Main Menu. The tester will prompt the operator for a password. (default

password is 1111). The operator will then select Manual Mode




Step 3: Activate the platform cylinder by selecting the PLATFORM U/D key on

the HMI.

Step 4: Release the platform assembly locking handle and, using the crank

handle, raise the assembly with one hand while centering the bottle with the

other ensuring that the cap slides inside the collet.

Step 5: Make sure the collet does not interfere with any part of the container or

the tamper evident band. Generally, it is the best to insert approximately 3/5 of

the cap (excluding the TEB) in the collet, then secure the platform assembly with

the locking handle.




Step 6: Press the CHUCK key to squeeze the cap. This will also center the

container. The squeezing pressure may be adjusted with the mini regulator on the

rear panel. Try to manually rotate the container body to confirm that the collet is

holding the cap securely.

If the cap is slipping in the collet, make sure that:

A. the chuck cylinder or airline is not leaking (listen for the sound of

leaking air, or remove the collet and look at the actuating plastic ring

lowering and raising inside the chuck assembly).

B. the correct collet is used and is not excessively worn.

C. the air pressure controlling the squeezing force/pressure of the collet

is not too low.




Step 6: Press the CLAMP key to activate the self-centering clamp cylinder.

Inspect the setup for possible alignment issues. To make sure the clamps are

holding the container securely, deactivate the platform and chuck cylinders by

pressing the appropriate keys on the screen, then manually apply torque on the

cap while the container is clamped. If the container is slipping, make sure that:

A. the clamp cylinder or airline is not leaking (listen for the sound of

leaking air).

B. the correct clamps are used and they are not excessively worn.

C. the air pressure controlling the clamping force/pressure is not too low.

The clamp pressure can be adjusted with the “clamp” mini regulator

on the rear panel.

Step 7: The final step, check the overall setup, deactivate the clamp, the chuck

and the platform cylinders by pressing the corresponding keys and then activate

them again one by one in the correct order: first the clamps, second the platform,

third the chuck. If clearances, positions and pressures look good, the setup is

done. Press the BACK key to navigate to the Main Menu

It is always a good idea to document platform and column

heights for future reference. This will allow for quick and easy

adjustment for multiple container heights.




Chapter 6: Quick Start

What’s Inside This chapter contains a step-by-step procedure to help the user become familiar with the basic operation of the ST-120S.

Main Menu

The Main Menu allows the user to navigate to the main areas of the control system. This screen may be accessed from any of the displays by pressing the BACK key a couple of times.) Press the appropriate icon to test caps, calibrate the machine, explore historical measurement data or setup the machine.

SETUP: Manual operation and general electronic setup CALIBRATE: Calibration, linearity check and recalibration TEST: Torque Test, up to 20 pre-configured test profiles DATA LOG: Historical measurement data

Testing Navigate to the Test screen from the Main Menu by selecting the Test icon. Applied (clockwise) and Release (counterclockwise) testing may be initiated from here to determine the torque required to rotate a cap both in CW and CCW directions. By adjusting the rotational speed, torque ramp, maximum rotation and other variables, various torque tests may be performed. The sequence of operation and the operating principles are detailed below.




Test Settings:

BACK: Return to “Main Menu” PREV RECORD: Select previous test recipe NEXT RECORD: Select next test recipe SETTINGS: Displays test recipe settings screen COUNTER RESET: Resets batch counter COUNTER DETAILS: Displays counter results

Step 1: Place a container on the platform then press the dual activation safety start buttons. During this process, and anytime when pneumatic cylinders activate, keep yourself and others clear of the moving parts. Step 2: Once the clamps are closed and the chuck is activated, pinch points are eliminated and the product is firmly supported from all sides. You may release the start buttons now. The chuck starts rotating at the predefined velocity, torque ramp and acceleration. Check the display during the cycle to analyze the torque/ angle trend real-time. Step 3: During the test cycle, observe the container/collet for indication of concentricity, excessive side load or downward pressure, and fine-tune the mechanical setup if required.

Anytime during the operation, you may press the BACK key to stop the automatic test if the unit is not able to measure the torque/angle properly, mechanical or electrical adjustments are required, or if there is an emergency.

Step 4: Depending on the selected testing method, either when the maximum rotation is exceeded, or when the peak torque is measured, the chuck stops and the screen displays the peak value. The actuators return to home position and the product is ready for removal.




Default Settings SETUP: Default Password:1111

Product Management: Name: 1. Product

Cap ID: NA

Collet ID: NA

Container ID: NA

Clamp ID:: NA

Head height: 0.00

Left clamp: 0.00

Clamp height: 0.00

Right clamp: 0.00

Product Management 2/2: Cap type: CT

Cap material: #1: PET

Cap color: NA

Container type: ROUND

Container material: #1: PET

Container color: NA

TEB: NO

Liner: NO

Cap OD: 0.00

Cap ID: 0.00

Cap height: 0.00

Container OD: 0.00

Container ID: 0.00

Container height: 0.00

Container length: 0.00

Container width: 0.00

Passwords: Setup: 1111

Calibration: 1113




Miscellaneous: Screen format: Data and Graph

Serial data: Result only - PC

Data entry: Enabled

Date/time: mm/dd/yy hh:mm:ss

Timers: Clamp on: 00:00:40

Chuck on: 00:00:50

Test start: 00:01:00

New cycle: 00:01:00

CALIBRATION: Default Password: 1113

Torque: Preferred Unit: 1 lbfin

Pulley Radius: 02.00 in

Weight: 010.000 lb

Pressure: Preferred Unit: PSIG

Reference Low: 0

Reference High: 80.0




Chapter 7: Tester Settings

What’s Inside This chapter contains instructions on how to navigate and edit the ST-120S

settings including Data output, screen format and more

Navigation to Menu To view/edit the tester settings, first navigate to the Other Settings menu by

selecting Setup from the Main Menu. The tester will prompt the operator for a

password. (default password is 1111). Next select Other Settings




Other Settings Menu More Settings Menu

From the Other Settings menu’s, the operator can specify:

Screen Format: Select from 3 display representations

Data Only: Displays only the numeric angle and torque

values.

Graph and Data: Provides not only numeric values on

the screen but also the angle vs. torque graph of the

measurement.

Pass/Fail: The most basic of the result representations, it

only displays whether the test passed or failed the

specifications.

Serial Data: The data output may be set to the following:

Result only – PC: Data output is formatted for

compatibility with the ST-DAQ software.

Result only – Printer: Data is formatted for printout on

a 3” wide paper roll.

Real-time – Angle vs. Torque: The data output is a

continuous stream containing the angle and corresponding

torque values.

Real-time – Angle vs. Time: Data output is a

continuous stream of the time and the corresponding

torque values.

No Output: When this option is selected, there is no

automatic data output from the torque tester.




Test Settings: The editing of test variables may be enabled/disabled by

changing this variable. See Chapter 8

Date and Time: Change the system date and time.

Start Switches: Determines what procedure happens when start buttons

are pressed.

Press Only: Machine begins testing when both switches

are pressed simultaneously

Press and Hold: Machine begins testing when both

switches are pressed simultaneously. Both start buttons

must be continuously held throughout testing otherwise

tester immediately stops running and realigns to starting

position.

Number of Test Controls Test recipes being displayed when Test Settings

are

Recipes to Display: disabled. Up to 49 test recipes. Test Recipes can be

navigated through on the Test Screen through the Next

Record and Previous Record buttons.

Run Offset CCW: Controls Dead band cutoff for calibration in CCW direction

Run Offset CW: Controls Dead band cutoff for calibration in CW direction

Pressure Alarm: Enable/Disable audible alarm due to Low Air Pressure




Chapter 8: Test Types and Their

Menus

What’s Inside This chapter contains a description of the ST-120S test types and the menus that are used to select and program them.

Test Types The St-120S was designed to perform 5 test modes and can be selected in the Test Settings screen. To get to this screen from the Main Menu, Select the Test Option. The test mode can be selected and changed by pressing the TEST MODE: on the Navigation Screen

The 5 test modes include:

A. Release (counter-clockwise) B. Applied (clockwise) C. Release then Applied D. Applied then Release E. Strip

(other test modes are available upon customer customization)




Enabling Test Settings In order to edit test settings for each test mode, the operator must first enable

the option by navigating to the Other Settings menu. The test settings for each

test mode are intentionally disabled due to minimizing operator error without first

applying the administrative password. To enable the test settings, first navigate to

the Other Settings menu by selecting Setup from the Main Menu. The tester

will prompt the operator for a password. (default password is 1111). Next select

Other Settings

In the Other Settings Menu, press the toggle switch for TEST SETTINGS to

enable editing of the test setting for each test mode.




Release and Applied Settings

After enabling the test settings, the operator can now edit product specific test

settings in the Test Settings. Navigate to the Test Settings by selecting Test from

the Main Menu. Next, toggle the Test Mode selection to display the product

specific Test Mode.

Product Name: Select from the list of available products.

Test Mode: Select from Applied, Release, Release then Applied or

Applied then Release test modes

Unit: Select from ozfin, lbfin, lbfft, gfcm, kgfm, or Nm

Platform U/D: Enable/Disable platform actuation. When doing a quick

accuracy verification with the Gold Bottle verification tool

or when testing a pump dispenser head, it is necessary to

disable the platform actuation.

NO of Cycles: For fatigue testing enter a number between 1 and 32,000.

This is the number of tests the machine will automatically

conduct on the supplied container/cap. For example, in an

applied then release test the number of cycles may be set

to 1000 in order to evaluate the torque degradation over

several repetitive opening/closing cycles.




To edit the test mode settings, press the Settings button to enter the Settings

Menu.

Release Settings Menu Applied Settings Menu

The operator can toggle between the Release Settings menu and the Applied

Settings Menu when the test mode selected is either Release then Applied or

Applied then Release.




From the Settings menu, the operator can specify:

Applied Set-point: The torque applied in a cap tightening cycle.

Torque Limit: The maximum permissible torque in a removal cycle.

Applied Fallback: Only applicable in Strip Test mode when the torque based

validation method is selected. This variable defines the

amount of drop in the torque that validates a peak as a

strip torque. One may also consider this variable as the

sensitivity of the strip test.

Release Fallback: When sensitivity based testing is enabled this variable

allows the automatic determination of thread break torque

(or other characteristic drops in torque). In other words,

the release fallback defines how sensitive the control is to

the torque variations/transients during a cycle.

Please note that the fallback values have no effect on the

operation when rotation based test methods are active.

Max rotation: The maximum allowed rotation during a test cycle.

(Degrees)

Ramp time (s): This is a timer defining the speed of the torque ramp up.

60s means the maximum torque is reached in 60s. When

the timer is set to 0, the torque applied during a cycle is

constant and defined by the starting torque value.

Starting torque: The torque applied at the beginning of the test. Default

value is 2.5%-5%, approximately 0 lbfin. 100% is

approximately 80 lbfin. (Units are in %)

Speed (rpm): The angular speed of the rotation during a test cycle.




Method: Torque: Recommended in Applied mode to immediately

stop the test upon reaching the set-point.

Rotation: Recommended in removal cycle where rotation

based validation is required. CR and TEB closures

Top load: Optional: It is possible to adjust the amount of force the

platform cylinder applies vertically while the product is

being tested.

High pressure: Recommended for most CT (continuous

thread) closures to determine the thread break torque or

apply torque to a set-point.

Low pressure: Recommended to measure the thread

break torque on CR (child resistant) caps. By adjusting the

platform height and the pressure in the platform actuator

(with the mini regulator on the rear panel) it is possible to

optimize the top load, making CR cap engagement

repeatable and minimizing the introduced friction.

“Zero”: Recommended when both the thread break and

the tamper evident band break torque must be measured

in one test cycle. This method allows a low adjustable

pressure to compensate for the weight of the platform

assembly and “float” the platform as the cap is being

unthreaded. The “floating platform” effect minimizes top

load and allows the accurate measurement of both thread

break and tamper evident bridge break in one test cycle.

Warning Limits: Configure these variables to display warning and error

& Error Limits: messages on the screen. (low error < low warning < pass

< high warning < high error). For example: if the

permissible removal torque range on a cap is 14-18lbfin,

set the low error and warning to 14lbfin, the high error

and warning to 18lbfin. When required, allow a separate

range for the warnings.




Operational Modes

Many different test modes may be created by selecting Rotation-based or

Torque based measurements and/or changing the adjustable platform

pressure/top load.

In Rotation based measurement, the chuck moves until the angle exceeds the

predefined limit, as opposed to the torque based measurement where the break

torque is automatically determined because the torque dropped after the thread

break or other distinctive break point (for example the engagement torque of a

child-resistant cap’s outer shell) is reached.

When the Torque based measurement is enabled the unit can automatically

determine the break torque with the help of the Release Fallback parameter. The

Fallback is the amount of drop in the torque the machine must measure in order

to qualify the peak torque as the thread break torque. The Fallback may be also

considered as the sensitivity of the automatic torque test.

When testing products with multiple “break” points, increasing the Fallback value

will eliminate the possibility of measuring a local force drop as the absolute thread

peak torque. On the other hand, when the Fallback is increased too much, the

tester may lose its ability to consistently recognize the real thread break torque.

Under these circumstances it may be preferable changing to the rotation based

testing method. This will allow the tester to rotate the chuck to the angle defined

by the maximum rotation variable and then display the peak.

To achieve repeatable and accurate results, we recommend that

the customers analyze every cap/container system and configure

the runtime variables accordingly.




Chapter 9: Product Management

What’s Inside This chapter contains instructions on how to navigate and edit the Product

Management Menu so that the operator can enter/modify product specific

variables.

Navigation to Menu These variables are for documentation purposes only; their use is optional and the

settings/values stored in these fields do not have any effect on the operation of

the machine. To navigate to the Product Management menu, first select Setup

from the Main Menu. The tester will prompt the operator for a password.

(default password is 1111). Next select Product Management




Product Management Product Management Menu Product Management More Menu

Description of the product management data fields:

Name: Customer specified product name

Cap ID, Container ID: Customer specified cap and container IDs.

Collet ID, Clamp ID: Identification entry for each product specific tooling.

Platform height: The position of the top of the platform

Clamp height: The position of the top of the clamp slide

Left clamp, right clamp: When applicable, these fields can be used to

document the right and left clamp positions.

Cap, Container type, The type, shape, material and color of the

shape, material, color: cap/container system.

TEB, Liner: These fields may be used to document the presence

of a liner or tamper evident band.

Cap, Container Document product dimensions in these fields.

Dimensions:




Chapter 10: Example Product

Management Setups

What’s Inside This chapter contains several examples of common product set-ups including cap tightening and release testing with CR, TEB, and CT caps.

Example 1: Cap Tightening Cycle This example is to demonstrate the process of setting up a new product in the product management menu and then assigning that product to a specific test profile. For this example, we will test a generic closure and assign it to a cap tightening recipe. Step 1: Navigate to the Product Management menu, first select Setup from the Main Menu. The tester will prompt the operator for a password. (default password is 1111). Next select Product Management. Step 2: Rename the Product to: Cap Test 1 Step 3: Return to Setup Menu and select Other Settings Step 4: In the Other Settings Menu, press the toggle switch for TEST

SETTINGS to enable editing of the test setting for each test mode. Set test

recipes to 1 then return to Main Menu by pressing the Back button twice.




Step 5: Navigate to the Test Menu

Step 6: Edit the Product selection by toggling the menu and selecting Cap Test

1. Toggle the Test Mode to Applied and Ensure Platform U/D is Enabled and

NO of Cycles is set to 1. Toggle the Unit to lbfin.

Step 7: Navigate to the Settings Menu and apply the following settings:

Applied Set-point: Based on closure specs (Usually ½ Diameter in mm)

Max rotation: 180

Torque Ramp: 30s

Start torque: 5%

Speed (rpm): 5 rpm

Method: Torque

Top load: High pressure

Low Warning: 0.000

High Warning: 80.000

Low Error: 0.000

High Error: 80.000

Step 8: Press the start switches to perform the Applied test




Example 2: Release torque testing of a CT closure This example is to demonstrate the process of setting up another product in the product management menu and then assigning that product to a different test profile. For this example, we will test a CT (Continuous Thread) closure and assign it to a Release test recipe. A standard chuck is used in this example. Step 1: Navigate to the Product Management menu, first select Setup from the Main Menu. The tester will prompt the operator for a password. (default password is 1111). Next select Product Management. Step 2: Rename the Product to: Cap Test CT Step 3: Return to Setup Menu and select Other Settings Step 4: In the Other Settings Menu, press the toggle switch for TEST






Step 5: Navigate to the Test Menu. Cap Test 1 is still associated to Test 1. Press

the Next Record to edit Test 2.


CT. Toggle the Test Mode to Released and Ensure Platform U/D is Enabled

and NO of Cycles is set to 1. Toggle the Unit to lbfin.


R Limit: Based on closure specs (Usually ½ Diameter in mm)

Fallback: .5

Speed (rpm): 5 rpm

Torque Ramp: 30s

Method: Torque

Start torque: 5%

Max Rotation: 360

Top load: High pressure

Low Warning: 0.000


Low Error: 0.000

High Error: 80.000

Step 8: Press the start switches to perform the Release test




Example 3: Release torque testing of a CR closure This example is to demonstrate the process of setting up another product in the product management menu and then assigning that product to a different test profile. For this example, we will test a CR (Child-Resistant) closure and assign it to a Release test recipe. A top load chuck is used in this example. Step 1: Adjust the platform to engage the CR Cap. This will make the test repeatable and minimize the introduced friction. To Adjust the Platform, please refer to Chapter 5. Step 2: Navigate to the Product Management menu, first select Setup from the Main Menu. The tester will prompt the operator for a password. (default password is 1111). Next select Product Management. Step 3: Rename the Product to: Cap Test CR Step 4: Return to Setup Menu and select Other Settings Step 5: In the Other Settings Menu, press the toggle switch for TEST






Step 6: Navigate to the Test Menu. Cap Test 1 and Cap Test CT are still

associated to Test 1 and 2 respectively. Press the Next Record to edit Test 3.


CR. Toggle the Test Mode to Released and Ensure Platform U/D is Enabled




Fallback: .5

Speed (rpm): 5 rpm

Torque Ramp: 30s

Method: Rotation

Start torque: 5%

Max Rotation: 360

Top load: Low pressure

Low Warning: 0.000


Low Error: 0.000

High Error: 80.000

Step 9: Press the start switches to perform the Release test on a CR cap




Example 4: Release torque testing of a TEB closure This example is to demonstrate the process of setting up another product in the product management menu and then assigning that product to a different test profile. For this example, we will test a closure with a TEB (Tamper Evident Band) and assign it to a Release test recipe. An axial floating chuck is used in this example. Step 1: Adjust the platform to engage the cap and ensure the platform is at a height that both the TEB and release torque can be measured (Float). The “floating platform” effect minimizes top load and allows the accurate measurement of both thread break and tamper evident bridge break in one test cycle. To Adjust the Platform, please refer to Chapter 5. Step 2: Navigate to the Product Management menu, first select Setup from the Main Menu. The tester will prompt the operator for a password. (default password is 1111). Next select Product Management. Step 3: Rename the Product to: Cap Test TEB Step 4: Return to Setup Menu and select Other Settings Step 5: In the Other Settings Menu, press the toggle switch for TEST






Step 6: Navigate to the Test Menu. Cap Test 1, Cap Test CT and Cap Test CR

are still associated to Test 1, 2, and 3 respectively. Press the Next Record to edit

Test 4.


CR. Toggle the Test Mode to Released and Ensure Platform U/D is Enabled




Fallback: .5

Speed (rpm): 5 rpm

Torque Ramp: 30s

Method: Rotation

Start torque: 5%

Max Rotation: 360

Top load: Zero pressure

Low Warning: 0.000


Low Error: 0.000

High Error: 80.000

Step 9: Press the start switches to perform the Release test on a TEB closure




Chapter 11: Password Management

What’s Inside This chapter contains instructions on how to navigate and edit the administrative

passwords for setup and recalibration actions

Navigation to Menu Passwords are implemented to safe guard against accidental changes in the setup

as well as protecting the calibration from inadvertently being overwritten with

invalid measurements. To navigate to the Passwords menu, first select Setup

from the Main Menu. The tester will prompt the operator for a password.

(default password is 1111). Next select Password. Passwords can be edited here

and up to 4 numeric digits.




Chapter 12: Timers

What’s Inside This chapter contains instructions on how to navigate and edit the delay timers

during testing for all test modes.

Navigation to Menu To navigate to the Passwords menu, first select Setup from the Main Menu. The

tester will prompt the operator for a password. (default password is 1111). Next

select Timers.




Timers Menu Timers are in the format (mm:ss:hh) and can range from .5 sec up to 99 minutes.

Each timer can be selected to change the actuation delays.

Timers / Delays

Timers:

Clamp On: This timer is used to delay the clamp activation.

Chuck On: This timer delays the chuck cylinder after starting a test.

Test Start: Delays the rotation at the beginning of the test.

New cycle: Delay after a test is finished.

Suggested Delay:

Clamp On: 00:00.40

Chuck On: 00:00.50

Test Start: 00:01.00

New cycle: 00:01.00




Chapter 13: Data and

Communication

What’s Inside This chapter contains information stored and recalled in the Data Log Menu as

well as the data management and communication types of the ST-120S

Data Log Menu The Data Log Menu can be accessed by pressing the Data Log icon from the

Main Menu.

The Data Log section contains both the Historical Data log as well as the Statistics

Log. Data can be sent to a PC for either a single record or for all stored data.

Historical Data Statistics




Data Management and Communication Several communication options may be selected in the Setup/Other Settings

submenu. For more info on the selection please see Chapter 7: Tester Settings.

The serial communication is set to RS232, configured for 9600/8/n/1. Available

output options:

• The data output may be formatted to ASCII characters to be printed on 3”

roll paper.

• It may be formatted to ASCII strings, including peak torque value, date and

time stamps, etc. This is compatible with the previous SureTorque data

acquisition software.

• Data may be configured for real-time data acquisition to analyze torque

transients (analog data is sampled in approximately 10ms intervals at min.

16-bit resolution).

• Data may be saved in PLC memory without sending any data out on the

com port.

For more information on communication, contact the manufacturer.




Chapter 14: System Calibration

What’s Inside This chapter is intended to acquaint the user with the required Calibration

Equipment, the Calibration Verification Process, and the process for performing a

User Calibration.

General Calibration Information

The ST-120S is supplied with a factory calibration that is stored on the PLC.

Checking the calibration of the ST-120S at least once a year

is recommended when the system is used frequently.

Required Calibration Equipment

The following list of equipment is required to perform a Calibration. When ordering this equipment please provide the Model Number and Serial Number of the machine that the equipment will be used on. Minimum Required Equipment:

1. 2” Calibration Pully with wire 2. Chuck to house calibration pully 3. Calibration Frame 4. 10 lb. Calibration Weight (NIST Traceable)

All equipment can be found in the ST-120S calibration kit, 000-1413: Kit Includes:

1. Calibration Pullies: 0.5”, 1”, 1.5”, 2” Radius 2. Calibration Frame 3. Calibration Weights: 2 lb., 5 lb., 10 lb. (All weights NIST Traceable)

4. Protective Carrying Case




Calibration Pully Set

The calibration pully set include a 0.5”, 1”,

1.5”, and 2” Radius pullies. The different sizes

are designed to allow for multiple calibration

points with the weight set. (see chart below)

Calibration Frame

The calibration frame is designed to be fixed to

the ST-120S column during calibration. It

includes a frictionless bearing that allows for

the most accurate calibration.

Calibration Weight Set

The calibration weight set consists of three weights that including 2 lb., 5 lb., and 10 lb. All weights are NIST traceable.

Protective Carrying Case

The Protective carrying case is designed to hold all calibration equipment in a foam designed insert.




Torque Calibration Weight Chart

The required calibration point in lbfin is produced by selecting the appropriate

weight to pully ration. This can be computed by multiplying the weight by the

pully radius to acquire a desired torque value.

This chart shows the weights and pullies that Mesa Supplies when a calibration kit

is purchased. The resulting field represents the lbfin the ST-120S should read.

Calibration Weights (lbs.)

Pully

Radius (in) 2 5 2 + 5 10 2 +10 5 +10

2 +

5 +10

0.5 1

lbfin

2.5

lbfin

3.5

lbfin

5

lbfin

6

lbfin

7.5

lbfin

8.5

lbfin

1 2

lbfin

5

lbfin

7

lbfin

10

lbfin

12

lbfin

15

lbfin

17

lbfin

1.5 3

lbfin

7.5

lbfin

10.5

lbfin

15

lbfin

18

lbfin

22.5

lbfin

25.5

lbfin

2 4

lbfin

10

lbfin

14

lbfin

20

lbfin

24

lbfin

30

lbfin

34

lbfin

Calibration Menu The Calibration Menu can be accessed by pressing the Calibrate icon from the

Main Menu.




Torque Calibration Equipment Set Up Procedure This procedure is used to detail how the calibration equipment is connected to the

system to perform a calibration verification as well as a user calibration.

Step 1: Release the platform assembly locking handle and, using the crank

handle, drop the assembly to its lowest point.

Step 2: Remove clamps, and the collet from the chuck. Insert desired calibration

pully and wire into chuck.

Quick Release Pin Location




Step 3: Remove the platform by loosening the adjustment knobs and replacing

the platform with the calibration frame.

Step 4: Adjust the height of the column and calibration frame until top of bearing

is aligned with the center of the calibration pully wire. This is to ensure no

additional friction is added to the system.

Wire is parallel with benchtop




Torque Calibration Verification Procedure This procedure is used to detail how to perform a calibration verification. To start

a verification, ensure the calibration equipment has been set up properly and the

calibration menu is shown on the PLC.

Step 1: Rotate the chuck so that the pulley is in a position that allows the wire to

wrap around the pulley a min. of 90 degrees. The wire must run parallel to the

base between the two pulleys).

Step 2: Lock the shaft by pressing the Lock or Unlock Shaft button. If it’s not

locked the chuck is free to rotate and the weight may fall or drive the chuck until

a hard stop.

Wire Connection Location in Back




Step 3: With no weight added to the pully, press the Zero Offset and the Reset

Peak buttons to zero out the system for an accurate verification.

Step 4: Hang a weight from the pully wire and verify that the torque readout

matches the Calibration chart for the pully and weight used. The torque readout is

considered within range for a +/- 0.5%.

If the torque readout is out of tolerance, follow the User Calibration Procedure

below to recalibrate the display.




Torque User Calibration Procedure

This procedure is used to detail how to perform a Torque User Calibration to

recalibrate the tester. To start a torque calibration, ensure the calibration

equipment has been set up properly and the calibration menu is shown on the

PLC.

Step 1: Rotate the chuck so that the pulley is in a position that allows the wire to

wrap around the pulley a min. of 90 degrees. The wire must run parallel to the

base between the two pulleys).



a hard stop.

Step 3: With no weight added to the pully, press the Zero Offset and the Reset

Peak buttons to zero out the system for an accurate verification.

Step 4: Press the RECAL button, the tester may prompt the operator for a

password. (default password is 1113).

Step 5: Accept or change the calibration variables (unit system [0-ozfin, 1-lbfin, 3-

kgfcm, 6dNm], pulley radius and weight). Use the numeric keypad to enter a

variable then press the ENTER key to accept the change. When all variables are

entered, follow the instructions on the bottom of the screen.

Step 3

Step 4 Step 2

Step 3




Step 5: Unload the pulley and press the NEXT key. This registers the zero offset

of the calibration.

Step 6: Hang a weight from the pully wire on the right side of the pulley, let it

settle, then press the NEXT key. This registers the gain of the calibration for

counterclockwise (CCW) direction.

Step 7: Hang the weight on the left side of the pulley, let it settle, then press the

Next key. This registers the gain of the calibration for clockwise (CW) direction.

Step 8: The display is now calibrated both CW and CCW directions, press the

NEXT key again to return to the calibration check screen and test linearity by

hanging different weights on the pulley, or just press the BACK key to return to

the Main Menu.

The SureTorque tester is a precision torque measurement

device. The torque is transformed to an electrical signal with a

strain gage based force transducer. As in the case of any other

strain gage based measurement device, it is recommended to

check the calibration and/or re-calibrate the device as often as

possible. Usually the recalibration timeframe is not more than 6

months, but proper determination depends on many factors,

such as the duty cycle and the average load on the transducer,

also the possibility of overloading the strain gage. On-site

calibration services, calibration kits and certified weights are

optionally available from Mesa Labs.




Pressure User Calibration Procedure This procedure is used to detail how to perform a Pressure User Calibration to

recalibrate the tester. To start a pressure calibration, ensure the calibration menu

is shown on the PLC.

Pay special attention to pneumatic actuators operating at 80 PSI,

as pressure may cause serious damage to operator, equipment

and product.

Step 1: Press the Calibrate Pressure button.

Step 2: Check the Pressure Readout if readings are not in tolerance, recalibrate by

pressing the RECAL button and follow the on-screen instructions.




Step 3: Adjust the Mini Regulator for the chuck on the back panel all the way out

to produce a Low reference point. Select Next.

Step 4: Adjust the Mini Regulator for the chuck on the back panel all the way in to

produce a Low reference point. Select Next.

Step 5: Adjust the Mini Regulator for the clamp on the back panel all the way out

to produce a Low reference point. Select Next.

Step 6: Adjust the Mini Regulator for the clamp on the back panel all the way in to

produce a Low reference point. Select Next.




Chapter 15: Gold Bottle Verification

What’s Inside This chapter describes the Gold Bottle and the procedure for using it to verify the calibration of the ST-120S.

Gold Bottle Description

The Model 1612 Gold Bottle is used to quickly verify the

calibration and operational repeatability of the Model ST-

120S Torque Tester. This bottle is pre-set at the factory

to a customer specified torque value.

Each Gold Bottle is labeled with its exact torque rating.

Since the cap torque of this bottle is the torque

produced

by a permanent magnet assembly, the value will always

be

the same. Therefore, when tested on the ST-120S, the

measured value should always repeat unless something

has been damaged.

The bottle is normally supplied with the customer’s cap,

or with a custom printed cap (optional), so that the

customer’s Collet can be used in the testing process.

These Gold Bottles are readily available and their torque

can be certified on an annual basis




Gold Bottle Verification

This procedure is used to detail how to perform a Gold Bottle verification. To start

a verification, Remove the clamps and ensure the calibration menu is shown on

the PLC.



a hard stop.

Step 2: Insert the cap of the Gold Bottle into the chuck. A min of 60% of the

closure should be inserted. Press the Chuck On/Off to close the chuck around

the cap

Step 3: While the Gold Bottle is stationary, press the Reset Peak and Zero

Offset buttons. The Peak Torque reading should display 0.000

Step 4: Slowly turn the Gold Bottle clockwise until the peak reading is displayed.

Record the peak reading for validation

Step 5: While the Gold Bottle is stationary, press the Reset Peak and Zero

Offset buttons. The Peak Torque reading should display 0.000

Step 6: Slowly turn the Gold Bottle counter-clockwise until the peak reading is

displayed. Record the peak reading for validation.




Step 7: Check the verification rating on the Gold Bottle and compare with the

peak readings recorded and verify they are within specified tolerance. To check

the specified tolerance, please refer to the specifications table. If peak readings

are not in specified tolerance, Repeat Test. If verification fails a second test, a

calibration should be done.

Step 8: While holding the Gold Bottle, release the chuck by pressing Chuck

On/Off

Step 9: Unlock the shaft by pressing Lock or Unlock shaft key. Ensure Shaft

Status displays “Unlocked”.

Gold Bottle Specifications

Small

Torque Range: .5 – 4 in-lbs

Gold Bottle Tolerance: +/- 0.2 in-lbs

ST-120S Machine Tolerance: +/- 0.5 in-lbs

Standard

Torque Range: 3 – 16 in-lbs



Large

Torque Range: 8 – 43 in-lbs






Chapter 16: Troubleshooting

What’s Inside This chapter is a guide to assist in the recognition of any possible malfunctions, identification of their probable causes, and corrective actions to solve the problem.

Troubleshooting

Refer to the Machine Tuning Sheet in the product manuals when making any

adjustments to the machine. This is a general troubleshooting guide; therefore,

some malfunction conditions and/or corrective applications may not apply to your

model Electric Torque Tester.

Only qualified personnel should troubleshoot this machine

All personnel should stay clear of moving parts

All guards and safety features must be replaced before this

machine is returned to service. Failure to comply with these

warnings may cause personal injury!

Mechanical Troubleshooting Guide

Malfunction Probable Cause

Unusually High

Torque Reading:

Check clearance between the top, inside surface of the Collet’s

relief cut counter bore, and the top of the container/closure.

Assure that this clearance is from .06” to .012”

Unusually Low

Torque Reading:

Check the rigidity of the container clamps

Container Must Not Rotate!!




Electrical Troubleshooting Guide

Malfunction Probable Cause Corrective Action

ST-120S will not

Power-Up:

a. No AC Power to main Panel

b. Main AC fuse missing/blown

c. Main disconnect not in “on”

position

d. “Power On” switch faulty

a. Check Power Connections

b. Replace fuses

c. Turn disconnect to “on”

position

d. Replace rocker-switch

ST-120S will not

Start:

a. No AC Power

b. Control or main fuse

missing/blown

c. Line voltage not within +/- 10%

a. Check connections and

disconnect. Reconnect

power supply

b. Replace fuse

c. Install isolation X-former

Pneumatic Troubleshooting Guide

Malfunction Probable Cause Corrective Action

Cannot Get Proper

Air Supply:

a. Air regulator defective

b. Air gauge defective

c. Leak in air system

d. Insufficient air supply

a. Replace air regulator

b. Replace air gauge

c. Locate leak and correct

d. Check for restrictive kinks or

leaks in air hoses and

connections

Discrete Air

Components Not

Reading/

Functioning:

a. Excessive moisture in system

b. Component defective

c. Defective rear panel fuse

d. Low air Pressure

a. Check System filter

b. Replace component

c. Replace fuse

d. Check air supply and insure

air pressure at main

regulator at 80 psi

Water in Air

Supply:

a. Filter defective

b. Filter dirty

a. Replace filter

b. Clean or Replace filter

Discrete Air

Components

Malfunctioning:

a. Excessive moisture in system

b. Air supply dirty

c. Leak in component or hose

connections

a. Check filtering system

b. Check filtering system

c. Locate leak and correct




Chapter 17: Preventative

Maintenance

What’s Inside This chapter is a guide to assist in the proper care and maintenance schedule to ensure long lasting quality and use.

Maintenance Schedule At every startup: Check for leaks

Optional: Verify the accuracy of the measurement system

using the Gold Bottle Verification, see chapter 15

Weekly: Check condition of change parts (asymmetric wear may

indicate setup/concentricity issues). If the polyurethane

surfaces in the change parts are hardened and/or dirty,

wipe them with a clean, soft cloth/paper towel and

isopropyl alcohol.

Monthly: Clean stainless-steel enclosures.

Clean all other parts with clean, soft cloth and Formula 409

Glass and surface cleaner or similar.

Check the air filter assembly for fluid/debris trapped inside

the bowl, replace cartridge and clean bowl if necessary.

Actuate the pneumatic cylinders in manual mode and

check for leaks (a drop in air pressure or hissing sound).

Check for worn/chafed/broken air hoses and electrical

power supply cords and replace if necessary.

Annual: Check calibration, see chapter 14. Recalibrate if necessary.




Cleaning Tips Stainless Steel Surfaces: To remove dust, use a clean, soft cloth.

To remove light soil, use a clean, soft cloth/sponge and

Formula 409 Glass and surface cleaner or similar.

To remove moderate and heavy soil, use a damp cloth

or sponge and clean with a non-abrasive cleaner such

as a baking soda paste then carefully rinse and dry.

To polish and prevent fingerprints, follow with Sheila

Shine or similar.

If the stainless steel enclosures show signs of rust, this

is typically only a surface discoloration and a mild,

nonabrasive stainless steel cleaner and a damp cloth

can be used to remove surface buildup and restore

shine.

Anodized Aluminum: Because anodizing is so hard, you want to use an

abrasive cleaning technique with a gentle soap.

Do not use harsh acidic or alkaline cleaners because

they may destroy the finish. Use solvents with care as

they may stain the finish. Regardless of the technique,

be sure to try a test area first.

One recommended technique is to use an abrasive

cleaning sponge with mild dish washing liquid. Always

try a test small area first to prevent a widespread

problem.




Acrylic Surfaces: Do not use cleaners containing ammonia. Cleaners such

as Windex or 409 will harm your new piece of acrylic.

Use only products specifically recommended for

cleaning acrylic such as Novus #1, or Brillianize, and a

soft cloth.

Never use a dry cloth or your hand to clean your acrylic!

This rubs the dirt and dust INTO the acrylic as much as

it rubs it OFF. First, blow the dust or dirt off, or use

water and a soft cloth to float the dirt off. Then use a

recommended cleaner to complete the job.

A mild solution of dish detergent and warm water takes

off stubborn dirt easily without harming the acrylic if

you've run out of Novus #1 or Brillianize.

Fine scratches can be removed with a mild abrasive

polish such as Novus #2, or Novus #3. Heavier

scratches, such that you can feel with your fingernail,

will require some elbow effort to remove with a bit of

sanding and buffing. A series of grits (150,400,600)

followed by a buffing wheel and available buffing

compound, will restore the acrylic surface.




Lubrication Tips Cylinders in SureTorque models can operate for years without lubrication. Generally all SMC cylinders in the machine (including CXSM and NCDG models) can operate without lubrication. The BIMBA “Pneu-turn” rotary actuator can operate without lubrication. Chuck cylinder: can operate without lubrication for years Should you decide to lubricate pneumatic components, please read the recommendations below. Lubrication of non-lube type SMC cylinders: These cylinders are lubricated at the factory and can be used without any further lubrication. Should you decide to lubricate, use class 1 turbine oil (without additives) ISO VG32. Stopping lubrication later may lead to malfunction due to the loss of the original lubricant. Therefore, lubrication must be continued once it has been started. Lubrication of a lube style SMC cylinders: Install a lubricator in the pneumatic circuit and use Class 1 turbine oil (with no additives) ISO VG32. Do not use machine oil or spindle oil. The Pneu-Turn Rotary Actuator is pre-lubricated at the factory for extensive, maintenance-free operation. However, the life of the rotary actuator can be lengthened by providing additional lubrication with an air-line mist lubricator or direct introduction of oil to the actuator every 500 hours of operation. Recommended oils for Buna N seals are medium to heavy inhibited hydraulic and general-purpose oil. If High Temperature seals, use Dow Corning #710. Other types of prelube are available upon request. The rack and pinion gear and ball bearings are pre-lubricated at the factory for extensive, maintenance-free operation. If additional lubrication should be required, use a high-grade bearing grease. Chuck cylinder: every 3 yrs. replace the rubber O-rings and apply a light coating of silicone based lubricant on the new O-rings. Only a thin film of lubricant should be used to prevent seal damage.




Appendix 1: ST-120S Spare Parts

Kit

What’s Inside This addition is to show the operator common spare parts associated with the ST-

120S

Spare Parts Kit

000-1022 Assy, Cable, Counter Balance, 15.56"

066-1637 Torque Transducer, 0-10Nm 066-1047 Motion

controller




066-0974 Expansion module 066-0975 Adaptor I/O

066-1046 Stepper motor 000-1446 PCA, Encoder Interface Circuit

066-0945 Solenoid Valve, 4 Port 066-1197 Filter, Air




Appendix 2: Torque Transducer

Specifications

What’s Inside This addition contains information and specifications about the Torque Transducer

Specifications This device utilizes an electronic strain gauge to measure very small amounts of

changes as it is flexed or strained in either CW or CCW directions. The mechanical

changes are measurable increases or decreases in electrical resistance. Our

transducer has the ability to compensate over a wide range of temperatures and

hold its accuracy for a cycle of over 1,000,000 measurements (under the specified

operating conditions).

Reaction type torque transducer




Transducer Specifications

Accuracy: 0.1% FS

Available Ranges: 5, 10, 20 Nm

Output: 2.0 mV/V ± 0.1%

Zero Balance: ±1% max.

Temperature Effect Zero: ±0.05% / 10K max.

Span: ±0.05% / 10K max.

Non-linearity: ±0.1% max.

Hysteresis: ±0.1% max.

Non-repeatability: ±0.03% max.

Creep over 30 minutes ±0.04% max.

Input Resistance: 350 ohm ± 2

Output Resistance: 350 ohm ± 2

Excitation (recommended): 6-10 V

Excitation (Max): 12 V

Insulation Resistance: 5 Gohm min.

Temperature Compensated: -10°C to +40°C

Operating: -20°C to +65°C

Storage: -50°C to +85°C

Overload, Safe: 150%

Breaking Load: 300% max

Protection: IP 65

Corrosion protection: Chem Nickel




Appendix 3: Variables in Torque

Testing

What’s Inside This addition is to inform about the many variables that can affect torque readings

Applied Torque In most cases, the higher the applied torque, the higher the thread break torque.

This is true up to the strip torque where the threads break/deform irreversibly in a

cap tightening cycle. Without the cap/container manufacturer’s guidance, it is

recommended to start with an application torque that equals to the cap outer

diameter in mm divided by two (in inch-pounds [in-lbs., lbf-in]). The release

torque / applied torque quotient depends on the specific cap design. It is usually

in the 0.6-0.9 range and higher for glass and lower for plastic bottles. It is not

uncommon to see values out of this range and dwell time usually decreases the

quotient over time.

Sensitivity of Automatic Thread Break torque measurement In the automatic detection of the thread break torque, two methods may be used

to validate the result.

A. Fallback based peak torque validation: this is the fastest and most cost-

effective way to measure thread break torque on a cap. In CR cap

applications, special attention must be made when fine tuning the fallback

value to avoid validating the shell engagement as the thread break torque.

B. Rotation based peak torque validation: to overcome the problem introduced

by the torque drop during the CR engagement an additional encoder can be

used to validate the thread break torque. The rotation limit must be set

according to the worst-case scenario of the shell engagement.




C. If fallback based validation is used during a measurement and the fallback is

set at <1.5lbfin, the tester will stop in <25 degrees and display the

engagement torque. To avoid the false readout, either the fallback must be

increased above 1.5lbfin (the recommended fallback for CR caps is 2.5lbfin),

or rotation based validation must be used and the rotation limit set at ~40

degrees.

D. See the top load vs. rotation and torque vs. rotation trends below to

understand the variations during a CR cap removal cycle. The vertical axis

represents both toque (lbfin) and top load (lbf) while the horizontal axis is

the rotation in degrees.




Cap and container squeezing pressure, top load The variation in cap/container squeezing pressure and the top load on the cap

may also affect the torque reading. The pressure variation is caused by either

force or contact area variation. The larger the contact area and/or the higher the

force compressing the cap and the container threads, the higher the torque

readout will be. Thus, in some applications it is important to monitor the container

and/or cap squeezing pressures and the top load force.

Speed of torque ramp, update rate of torque digitization There are two phenomenon a package engineer must be aware of when setting a

torque ramp setting:

A. When the torque ramp up is fast compared to the conversion time of the

digitizing device, the removal torque readout on the digital machine can be

considerably lower than the real peak due to the slow analog to digital

conversion speed. The error originating from the low sampling speed is not

to be confused with the quantization error. To understand the error

originating from inappropriate digitization, look at the graphs below and/or

find more information on the internet about the Nyquist-Shannon sampling

theorem and resolution/quantization noise.

Optimal chuck pressure:

The contact area is “minimal” and

the torque readout is not affected.

High chuck pressure and/or excessive

top load: The contact area is increased

resulting in higher torque readouts.




B. When the torque ramp up time is slower, the removal torque tends to be

lower because the gradually increasing fatigue lowers the peak force

required to finally break the threads. If the torque ramp is faster, the thread

break torque is usually higher.

Even if a manual torque tester had fast digitizer circuit, the lack of torque

ramp control may still cause considerable variation from one operator to

another, and even for one operator depending on how fast he/she manually

applied torque on a specific package.

Analog torque signal (red) sampled with a 12 bit, 100ms AD converter. The peak readout with this digitizer is ~4.9 lbfin at

200ms.

The same analog signal (red) sampled (green) with a 12 bit, 10ms AD converter. The peak readout with this

system is ~5.5 lbfin at 160ms.




Dwell Time In various experiments, it has been established that release torque levels are

highest immediately after application and then gradually decrease to a stable level

over a period of time (days/weeks). The rate of the release torque decay is

greatest in the first couple of hours/days and then reduces at a decreasing rate

before reaching its stable level. Production processes such as hot filling or those

using heat activated glue cap systems can produce a big difference in the release

torque readout when compared with results measured in a laboratory

environment.

Product Variations Minor changes in mold, material and liner can be also major contributing factors in

torque variations. See an example of different liner alignments and how it relates

to the contact surface area and the release torque.




Appendix 4: Torque Testing

Standards

What’s Inside This addition is a quick reference for the various standards including the ones

developed by ASTM and ISBT

ASTM Developed by D10.31:

• D2063-91(2002) Standard Test Methods for Measurement of Torque

Retention for Packages with Continuous Thread Closures

• D3198-97(2002) Standard Test Method for Application and Removal Torque

of Threaded or Lug- Style Closures

• D3469-97(2002) Standard Test Methods for Measurement of Vertical

Downward Forces to Disengage Type IIA Lug-Style Child-Resistant Closures

• D3470-97(2002) Standard Test Method for Measurement of Removal Lug

Strippage of Type IIA Child-Resistant Closures

• D3472-97(2002) Standard Test Method for Reverse-Ratchet Torque of Type

IA Child-Resistant Closures

• D3474-90(2002) Standard Practice for The Calibration and Use of Torque

Meters Used in Packaging Applications

• D3475-07 Standard Classification of Child-Resistant Packages

• D3481-06 Standard Test Method for Manual Shelling Two-Piece Child-

Resistant Closures That Are Activated by Two Simultaneous Dissimilar

Motions

• D3810-97(2002) Standard Test Method for Minimum Application Torque of

Type IA Child- Resistant Closures

• D3968-97(2002) Standard Test Method for Monitoring of Rotational Torque

of Type IIIA Child- Resistant Closures

• D7257-06 Standard Test Method for Automated Shelling Two-Piece Child-

Resistant Closures That Are Activated by Two Simultaneous Dissimilar

Motions




• D5094-90 Standard Test Methods for Gross Leakage of Liquids from

Containers with Threaded or Lug-Style Closures

• D5419-95 Standard Test Method for Environmental Stress Crack Resistance

(ESCR) of Threaded Plastic Closures

ISBT Voluntary Standard Test Methods for Plastic Flat Top Closures

• Top Closures

• Back-off

• Ball Impact

• Drop Impact

• Elevated Temperature Cycle

• Opening Performance

• Pressure Retention: Zahm Nagel

• Pull Up

• Removal Torque

• Secure Seal Test

• Security

• Strip Torque

• Top Load Vent

• Vacuum Retention

International Test Standards • DIN EN 12377:1998 Packaging - Flexible tubes - Test method for the

tightness of closures

• DIN EN 14401:2004 Rigid plastics containers - Methods to test the

effectiveness of closures

• SS-EN 12377 Packaging - Flexible tubes - Test method for the air tightness

of closures

USPC Test Methods • CHAPTER 671: Containers – Permeation

Documents

Operator’s Manual ST-120S Automatic Torque Tester...Phone: (303) 987-8000 • Fax: (303) 987-8989 • E-mail: [email protected] • Web: torque.mesalabs.com Operator’s Manual