USER MANUAL - Flexible Assembly
Contents
1. USER MANUAL MODEL MZ 100 BOLT TENSION CALIBRATOR V SKIDMOREWILHELM 442 SOUTH GREEN ROAD SOUTH EUCLID OHIO 44121 USA VOICE 216 481 4774 FAX 216 481 2427 www skidmore wilhelm com TABLE OF CONTENTS IPMEOGUGUION METRE CHEER 2 Typical Testing 2 SalelV E 2 Principle OF 3 Calibrator Setup amp Operation esee 4 MOuUnTING Ine leer Ee eri ae el ae 4 Installing Optional Torque Reaction 5 Vc 6 Installing the Fastener Assembly to be Tested 7 How to Read the 8 Testing Procedures atr leto oe eee eRe 9 Special Testing 10 Testing Sport BOIS a nahen ia owe Deve ot iti forse 10 Testing LONGER aa lai iid 11 Testing Tension Control TC Twist Off Bolts 12 Testing F959 Direct Tension Indicating DTI Washers 13 Rotational Capacity ROCAP Testing 15 CANIDFATION p 16 T CU 16 Product Specifications 17 Reference2. Information ccccccecececececececececececececeuuauauauauauaenenes 18 Joa SKIDMOREWILHELM www skidmore wilhelm com Introduction Thank you for purchasing the Skidmore Wilhelm MZ 100 Bolt Tension Calibrator Our improved lightweight design builds on over 50 years of industry leading experience in bolt tension measurement and calibration while maintaining the accuracy reliability ease of use and technical support that you have come to expect from Skidmore Wilhelm Typical Testing Applications The calibrator can be used to measure fastener tension in a wide variety of applications including but not limited to e Calibration of tightening tools pre installation verification rotational capacity tests and other fastener tests e he calibrator is compatible with all tightening tools including manual and impact wrenches pneumatic hydraulic electric wrenches and hydraulic tensioners etc e Fastener elements that can be tested include hex bolts threaded studs tension control TC bolts Direct Tension Indicating DTI washers anchor bolts lock nuts etc Safety Safety First Read all instructions warnings and Q cautions carefully Follow all safety precautions to avoid personal injury or property damage during use Skidmore Wilhelm cannot be responsible for damage or injury resulting from unsafe product use lack of maintenance or incorrect product and or system operation Contact Skidmore Wilhelm when in doub
3. the bolt should not rotate during testing The key is to maximize the friction between the bolt head and the bearing surface of the bushing The friction can be improved by keeping the bushing free of oil and grease and by removing lubricant from the underside of the bolt head Contact Skidmore Wilhelm if the bolt head is rotating and you are not obtaining required tension Copyright 2009 Skidmore Wilhelm Tungsten Capital Partners LLC All rights reserved including illustrations Revision 2 2010 Printed in USA wily 4 31 SKIDMOREWILHELM www skidmore wilhelm com Testing F959 Direct Tension Indicating DTI Washers F959 DTI washers are available in two distinct varieties squirting and non squirting Both types can be tested in the calibrator There are four different setup scenarios Each scenario is dependent on the Figure 14 placement of the DTI within the fastener DTI Washer assembly and which fastener component will be turned to tighten the assembly i e nut or bolt head Consult your project specifications and or DTI manufacturer for the proper DTI installation procedures The four typical setup scenarios are shown in the following figures SCENARIO A SCENARIO B ADAPTOR ZAKOLA L ADAPTOR PLATE PLATE CSA EO ADAPTOR BUSHING HEX BOLT HEX NUT F436 F436 WASHER WASHER F959 DTI WASHER F959 DTI WASHER Figure 15 Calibrator Cross section DTI WASHER PLACE
4. D UNDER BOLT HEAD NUT IS TURNED TO TIGHTEN Figure 16 Calibrator Cross section DTI WASHER PLACED UNDER THE NUT NUT IS TURNED TO TIGHTEN USER MANUAL MODEL MZ 100 as SKIDMOREWILHELM www skidmore wilhelm com Testing F959 Direct Tension Indicating DTI Washers Continued SCENARIO C SCENARIO D BS CEN ADAPTOR C 0 T PLATE ADAPTOR 64 HEX BUSHING i ED BOLT HEX queuing rl b BOLT 11 2 F436 zx SE uu WASHER 7 i 24 WASHER Q7 He F959 DTI t WASHER Figure 18 Calibrator Cross section Figure 17 Calibrator Cross section DTI WASHER PLACED UNDER BOLT HEAD DTI WASHER PLACED UNDER THE NUT BOLT HEAD IS TURNED TO TIGHTEN BOLT IS TURNED TO TIGHTEN spacer Bushings are recommended for long bolt DTI assemblies Turned down sockets may be required for scenarios A and D Please contact us with your application Copyright 2009 Skidmore Wilhelm Tungsten Capital Partners LLC All rights reserved including illustrations Revision 2 2010 Printed in USA 14 SKIDMOREWILHELM www skidmore wilhelm com Rotational Capacity ROCAP Testing Rotational capacity testing is a requirement on many projects Consult your project specifications and or governing body to determine your requirements The two most common rotational capacity test procedures are specified by 1 American Society for T
5. alibration Removal of the gage for a pressure calibration will not provide a true calibration of the assembly Skidmore Wilhelm recommends returning your unit to the factory for re calibration on an annual basis This will insure that the calibrator performs to original factory specifications Please consult your own quality requirements or those of the appropriate sanctioning body to determine your required re calibration cycle The following link provides detailed instructions for returning your unit for calibration htto www skidmore wilhelm com podf calibrating odf To avoid shipping damage always ship the calibrator N in its original Pelican case It is not necessary to return the adaptor plates or bushings Maintenance The calibrator requires minimal maintenance other than keeping it clean and dry None of the components are user serviceable Skidmore Wilhelm will replace the seals every five years as part of our recalibration service Please consult us if you notice oil leakage or are unsure if the calibrator is performing correctly Copyright 2009 Skidmore Wilhelm Tungsten Capital Partners LLC All rights reserved including illustrations Revision 2 2010 Printed in USA F SKIDMOREWILHELM www skidmore wilhelm com Product Specifications Max Tension Measuring Capacity 126 000 Ibf 550 kN Measurement Accuracy Within 1 of reading above 20 000 Ibf Calibration Traceable to NIST Bolt Diameter Rang
6. astened to a rigid beam or column flange using the supplied wing screws as shown in Figure 2 Caution Do not over tighten wing screws WING SCREWS Figure 2 Typical Column Mounting Copyright 2009 Skidmore Wilhelm Tungsten Capital Partners LLC All rights reserved including illustrations Revision 2 2010 Printed in USA SKIDMOREWILHELM www skidmore wilhelm com Installing Optional Torque Reaction Kit A torque reaction kit that mounts to the calibrator is required for all tightening tools with reaction arms See Figure 3 Torque reaction kits can be purchased from Skidmore Wilhelm Please contact us to determine the proper kit for your application Caution Reacting against an object other than the torque reaction kit can damage the calibrator and or cause personal injury Keep hands away from pinch points during tightening operations Install the torque reaction kit per the instructions supplied with the kit Make sure to also follow the wrench manufacturer s operating and safety instructions TIGHTENING TOOL TOOL REACTION ARM REACTION POST Figure 3 Typical Setup of Torque Reaction Kit USER MANUAL MODEL MZ 100 4 SKIDMOREWILHELM www skidmore wilhelm com Installing Adaptors select the appropriate size and type of adaptor plate and bushing for the fastener assembly to be tested Skidmore Wilhelm can supply a wide array of adaptors to suit your application Mount the adaptor p
7. ates and Bushing 1 1 4 adaptors which are marked with an S Minimum bolt lengths wil 21 2 pos vary with fastener 23 27 _ diameter See Figure 9 Ff 3 2 1 4 We recommend using the 1 1 8 3 1 4 2 1 2 short bolt adaptors to test 1 1 4 3 1 2 2 3 4 short bolts only Eur Fi 9 Mini Bolt Length Chart To maintain the strength of duis Mc the adaptor plates the recess diameter has been made as small as possible In some cases standard sockets may not fit Skidmore Wilhelm can supply specially machined sockets Please contact us with your application Note The above chart provides the minimum length bolt when using one F436 washer and a heavy hex structural nut If other washer and nut combinations are used such as a DTI washer the minimum lengths will change Please contact us for assistance Copyright 2009 Skidmore Wilhelm Tungsten Capital Partners LLC All rights reserved including illustrations Revision 2 2010 Printed in USA PA SKIDMOREWILHELM www skidmore wilhelm com Testing Longer Bolts Bolts that are too long to be tested with standard adaptors can be tested using Spacers and or Spacer Bushings skidmore Wilhelm can supply standard and custom made spacer Kits and Spacer Bushings Please contact us with your application Caution Do not use stacked washers as a spacer For impact wrenches Up to 7 3 4 of Spacers can be used See Figure 10 Beyond 7 3 4 it
8. e 7 thru 1 1 4 Weight Calibrator Only 21 Ibs 9 5 kg Due to continual product improvements specifications are subject to change USER MANUAL MODEL MZ 100 Joa SKIDMOREWILHELM www skidmore wilhelm com Reference Information You may find further information regarding testing procedures and best practices at the following links American Assoc of State Highway amp Transportation Officials AASHTO www transportation org American Institute of Steel Construction AISC WWW GisC Org American Society for Testing amp Materials ASTM www dastm org Canadian Institute of Steel Construction CISC WWW CISC iSSA Ca Federal Highway Administration FHWA www fhwa dot gov Industrial Fasteners Institute IFI www industrial fasteners org National Institute of Standards amp Technology NIST WWW nist gov Research Council on Structural Connections RCSC www boltcouncil org Steel Structures Technology Center Inc SSTC www steelstructures com Copyright 2009 Skidmore Wilhelm Tungsten Capital Partners LLC All rights reserved including illustrations Revision 2 2010 Printed in USA 18
9. esting amp Materials ASTM See www astm org for further information 2 American Assoc of State Highway amp Transportation Officials AASHTO The test procedure can be downloaded at the following link http www fhwa dot gov bridge rotational htm Rotational capacity testing can be performed in the calibrator by following the relevant setup procedures described in this manual However Rotational capacity testing in the field can be a challenging procedure This test especially on plain bolts requires quite a bit of torque It can take as much as twice the torque and bolt tensions can reach 50 above what is required for normal installation Check with your wrench supplier to make sure you have a tool capable of running the test Safety should always be your highest priority The extra rotation and higher loads unique to ROCAP testing can result in broken bolts Make sure to always follow your standard safety practices USER MANUAL MODEL MZ 100 Joa SKIDMOREWILHELM www skidmore wilhelm com Calibration All calibrators sold by Skidmore Wilhelm are factory calibrated using precision compression presses dead weights and or proving rings that are traceable to NIST standards A written Calibration Certificate is included with each unit The calibrator should only be re calibrated by a AN qualified technician using NIST traceable equipment The calibrator is calibrated as an assembly and N disassembly will void the c
10. ional Capacity Testing verification of TC Bolts amp DTI washers etc We have enclosed a copy of the latest edition of the Structural Bolting Handbook for your reference Be sure to check with the Steel structures Technology Center at www steelstructures com for updates If the calibrator has not been used recently exercise it by tightening and loosening a bolt several times before recording test results Once the calibrator has been properly setup and exercised testing can begin Some important points to consider Please refer to your project specifications to determine the testing procedures required for your application If in doubt contact the Engineer of Record or relevant governing body DO NOT exceed the maximum range on the gage dial This can cause pre mature failure of the pressure gage DO NOT leave a bolt under tension in the calibrator for an extended period of time This can cause pre mature failure of the sealing system Keep the calibrator clean and free of excess oil grease and dirt such as zinc dust from galvanized bolts Only use cleaning solutions that are compatible with Nitrile rubber USER MANUAL MODEL MZ 100 Joa SKIDMOREWILHELM www skidmore wilhelm com Special Testing Applications Testing Short Bolts Bolts that are too short to MODEL MZ 100 be tested with standard MINIMUM BOLT LENGTH adaptors can be tested Regular Short Bolt using special Short Bolt Diameter Adaptors Adaptors Pl
11. is recommended that a combination of Spacers and a spacer Bushing be used See Figure 11 For manual wrenches and tightening tools with reaction arms We recommend using spacer bushings in combination with a maximum of 1 5 of spacers The goal is to keep the tightening tool as close as possible to the front of the calibrator See Figure 11 SPACERS Figure 10 Typical Use of Spacers when Using an Impact Gun SPACER BUSHING Figure 11 Typical Use of Spacer Bushings USER MANUAL MODEL MZ 100 SKIDMOREWILHELM www skidmore wilhelm com Testing Tension Control TC Twist Off Bolts TC bolts have a spline at the end of the thread and may have a round or E 1 hex head and or flange A E E a TC bolts are sold by the manufacturer as a pre lubricated assembly which Figure 12 Typical TC Bolt includes the nut and washer See Figure 12 Proper lubrication of the nut and thread is important to the performance of this type of fastener system Consult the fastener manufacturer distributor if in doubt about proper lubrication Conditions TC bolts require special installation tools but can tested in the calibrator using an appropriately sized Adaptor Plate and special counter bored TC Adaptor Bushing as shown in Figure 13 Standard and special bushings are available from Skidmore Wilhelm Please contact us with your application Figure 13 Counter bored TC Adaptor Bushing The head of
12. late into the counter bore on the front of the calibrator using four supplied 74 20 hex bolts Snug tighten the mounting bolts Figure 4 Typical Figure 5 Typical Hex Adapior Plate Adaptor Bushing Align the flats of the bushing to the flats of the piston pocket and insert the adaptor bushing See Figure 6 Make sure that the bushing Is fully seated in the pocket FRONT VIEW OF CALIBRATOR BACK VIEW OF CALIBRATOR ADAPTOR PLATE ADAPTOR 1 4 20 HEX HEAD BOLT BUSHING Figure 6 Installation of Adaptor Plate and Bushing Copyright 2009 Skidmore Wilhelm Tungsten Capital Partners LLC All rights reserved including illustrations Revision 2 2010 Printed in USA Fs SKIDMOREWILHELM www skidmore wilhelm com Installing the Fastener Assembly to be Tested Install fastener assembly to be tested as follows e Insert the threaded end of the bolt thru the adaptor bushing from the back side of the calibrator e Install the washer and nut on plate side See Figure 7 e onug tighten and you are ready for testing FRONT VIEW BACK VIEW OF CALIBRATOR OF CALIBRATOR NUT amp BOLT WASHER HEAD Figure 7 Installation of Fastener Assembly to be Tested USER MANUAL MODEL MZ 100 as SKIDMOREWILHELM www skidmore wilhelm com How to Read the Gage The calibrator gage measures bolt tension in units of pounds force lbf Dials with metric force units are also available Many engineeri
13. ng specifications use units of kips Converting kips to pounds force is simple 1 kip 1000 Ibf Gage Dial Scale Resolution The large marks are in increments of 10 000 Ibf and the small marks are in increments of 2000 Ibf as shown in Figure 8 Red amp Green Lines These lines represent the minimum installed bolt tension for the most common ASTM A325 amp A490 structural bolts They are for reference purposes only Please refer to the Structural Bolting Handbook or your project specifications to determine the proper bolt tension requirements NEEDLE INDICATING 60 000 Ibf or 60 kip TENSION LOAD 100000 100000 TENSION NDS FORCE 120000 z 12 EN LINES A490 126000 BOLT SION POUNGEBMORCE 120000 RED LINES A325 GREEN LINES A490 126000 2000 Ibf INCREMENT SKIDMOREWILHELM www skidmore wilhelm com E 7 T SKIDMOREWILHELM www skidmore wilhelm con SK 732 10 000 Ibf INCREMENT NEEDLE INDICATING NO LOAD ON THE CALIBRATOR Figure 8 Example of How to Read Gage Dial Copyright 2009 Skidmore Wilhelm Tungsten Capital Partners LLC All rights reserved including illustrations Revision 2 2010 Printed in USA PR SKIDMOREWILHELM www skidmore wilhelm com Testing Procedures The calibrator can be used for a wide variety of test procedures such as Pre Installation Verification by Turn of Nut Method or Calibrated Wrench Method Rotat
14. t as to the proper safety precautions and operations Failure to follow the proper safety procedures can cause equipment damage and or personal injury Copyright 2009 Skidmore Wilhelm Tungsten Capital Partners LLC All rights reserved including illustrations Revision 2 2010 Printed in USA wily 4 31 SKIDMOREWILHELM www skidmore wilhelm com Principle of Operation The calibrator is an oil filled hydraulic load cell with a hole through the center of the piston amp body A sample bolt nut and washer as shown in Figure 1 are installed thru the piston hole using the appropriately sized adaptors As the nut is tightened the bolt stretches and the piston applies a compressive force to the hydraulic oil contained between the piston and calibrator body This force causes a pressure increase in the hydraulic oil that is proportional to the increase in bolt tension A specially calibrated gage measures the pressure and provides a reading of equivalent tensile force developed in the bolt ADAPTOR BUSHING PISTON PRESSURE GAGE PORT ARAS c Wa SSS KOS J i dun Cost iF A a K WW ay CALIBRATOR ADAPTOR PLATE Figure 1 Typical Calibrator Cross Section USER MANUAL MODEL MZ 100 O SKIDMOREWILHELM www skidmore wilhelm com Calibrator Setup amp Operation Mounting the Calibrator The calibrator should be securely f
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