ZIPP Wireless torque transducer operation manual

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Fastening Technology
Torque Transducer
Wireless Rotary Torque Transducer
TTES / TTEH / TTEB / TTER / TTAS series
Operation Manual
Version 1.0

Torque Transducer
Outline
1. Transducer Selection............................................................ 3
2. Specification......................................................................... 5
3. Model................................................................................... 6
4. Attention.............................................................................. 8
5. Maintenance and Warranty ................................................. 8
6. Appearance.......................................................................... 9
7. Power ON/OFF and Charging ............................................. 10
8. Pair with Torque Controller (TCA)....................................... 11
9. LED Light Description ......................................................... 11
10. Abnormal signal.............................................................. 12
11. Prompt, Abnormal Messages and Solution..................... 12
12. Problem and Solution ..................................................... 13
13. Mechanical Specification ................................................ 16
13.1 TTES / TTAS Series........................................................ 16
13.2 TTEH Series .................................................................. 17
13.3 TTEB Series .................................................................. 17
13.4 TTER Series .................................................................. 18

Torque Transducer
1. Transducer Selection
Factors in consideration
1. The target torque vs the capacity of air impact wrench or oil pulse wrench
2. Total bolting time is expected
3. The joint condition～hardness
4. The type of torque tool to be used
5. TCA/TCB Controller
6. TTES/TTEH/TTEB～The type of fasteners
7. SB or TB～The type of bolt
8. TTER & TSSR-The Transducer with RF & NFC Reader
9. Bolting sequence control and how many stages required for tightening
the bolt
10. Traceability for job responsibility
Air torque tools-includes
Continuous drive clutch type tool such as air screwdriver or pneumatic
torque multiplier.
Discontinuous drive impact type torque tool such as air impact wrench and
oil pulse tool.
Torque Controller-includes
TCA –programmable for bolting sequence control and tightening within
several stages.
TCB - for controlling the torque of continuous or discontinuous torque tools.
Wireless Torque Transducers-includes
TTAS – equipped with GYRO for measuring the angular movement of the joint
TTES - with square drive anvil for driving various sizes of impact sockets.
TTEH - one piece design impact socket with customized hexagonal size.
TTER – Customized TTEH with RFID/NFC Reader embedded for SB and TB
TTEB - with bit holder/driver for screwdriver.

Torque Transducer
1.1 How to select an air impact wrench?
While selecting the air impact tool, it’s required to consider several factors,
such as the target torque, how many seconds required to tighten the bolt,
the system compressed air supply condition, pipe line installation and even
the joint hardness.
Be aware that a specified torque capacity of an air impact tool is measured
under 90 psi air inlet pressure within 5 or 10 seconds with its maximum air
flow rate.
For example;
If it’s required to tighten a bolt on a hard joint to a target torque of 100 NM
within 2 seconds, it’s recommended to use an air impact tool with torque
capacity of 300NM within 5 seconds。
If it’s required to tighten a bolt on a soft joint to a target torque of 100 NM
within 2 seconds, it’s recommended to use an air impact tool with torque
capacity of 600NM within 5 seconds instead。
Please refer to the chart above for your perusal to make proper selection.
1.2 How to select a wireless rotary torque transducer?
It’s recommended to use the Torque Transducer with torque capacity 1.5～2
times of the target torque, i.e. the torque capacity of the torque transducer
should be higher than the target torque. For example:
Target torque 100Nm, the torque capacity of the torque transducer should be
150Nm ～200Nm or Target torque 750NM, the torque capacity of the torque
transducer should be 1,200Nm 1,500Nm。
Torque Controller
Flow Rate
Joint Hardness
(Soft/Hard)
Target
Torque
Suggested TTE
Torque Capacity
Preferable
Tightening time
Tool Torque
Capacity @ 90Psi
TCA-Air Flow
Rate Measured
by digital Flow
Meter
automatically
TCB-With Flow
sensor
equipped
instead
Soft TT 1.5～2* TT
5 seconds T ≧ 3 * TT
3 seconds T ≧ 5 *TT
Hard TT 1.5～2* TT
5 seconds T ≧ 1.5 * TT
3 seconds T ≧ 2.5 *TT

Torque Transducer
2. Specification
Item
Tnom 50 ～ 2000Nm 5 ～ 20Nm
Power DC 3.7V / 650 mAh DC 3.7V / 650mAh
Measured Range 10% Tnom～100%Tnom 10% Tnom～100%Tnom
Torque Resolution (Nm) 0.1% Tnom 0.1% Tnom
Accuracy (CW) ±1% ±1%
Accuracy (CCW) ±2% ±2%
Static Measured Angle Range 0o - 360o 0o - 360o
Angle Resolution (Degree) 0.5o 0.5o
Maximum Torque (Nm) 100%Tnom 100%Tnom
Wireless communication RF 2.4GHz
Cable USB-Type C
Charger USB ( 5V/1A )
Operation Temperature (oC) 0 oC ~ 50 oC
Storage Temperature (oC) -10 oC~ 60 oC

Torque Transducer
3. Model
No Picture Model
Torque
Capacity
(Nm)
Input End Output End
Torque Range
(Nm)
10% 100%
1
TTES
TTES-20-FS3MS3 20 Square 3/8” Square 3/8” 2 20
2 TTES-50-FS3MS3 50 Square 3/8” Square 3/8” 5 50
7 TTES-750-FS6MS8 750 Square 3/4” Square 1” 75 750
8 TTES-1000-FS8MS8 1000 Square 1” Square 1” 100 1000
9 TTES-1500-FS8MS8 1500 Square 1” Square 1” 150 1500
10 TTES-2000-FS8MS12 2000 Square 1” Square 1-1/2” 200 2000
12
TTAS
TTAS-20-FS3MS3 20 Square 3/8” Square 3/8” 2 20
13 TTAS-50-FS3MS3 50 Square 3/8” Square 3/8” 5 50
18 TTAS-750-FS6MS8 750 Square 3/4” Square 1” 75 750
19 TTAS-1000-FS8MS8 1000 Square 1” Square 1” 100 1000
20 TTAS-1500-FS8MS8 1500 Square 1” Square 1” 150 1500
21 TTAS-2000-FS8MS12 2000 Square 1” Square 1-1/2” 200 2000
23
TTEH
TTEH-250-FS4FHM18 250 Square 1/2” Hex. 18mm 25 250
24 TTEH-250-FS4FHM24 250 Square 1/2” Hex. 24mm 25 250
25 TTEH-200-FS4FHM17L 200 Square 1/2” Hex. 17mm 20 200
26 TTEH-1000-FS4FHM30 1000 Square 1/2” Hex. 30mm 100 1000
27
TTEB
TTEB-5-MHB6FHB6 5 Hex. 6.35mm Hex. 6.35mm 0.5 5
28 TTEB-10-MHB6FHB6 10 Hex. 6.35mm Hex. 6.35mm 1 10
29 TTEB-20-MHB6FHB6 20 Hex. 6.35mm Hex. 6.35mm 2 20

Torque Transducer
30
TTER
TTER-1000-FS4FHM30 1000 Square 1/2” Hex. 30mm 100 1000

Torque Transducer
4. Attention
1. Make sure that the transducer attached to the output end of tool
securely before bolting.
 Prevent the transducer to separate from the tool during operation.
2. Do not touch transducer during rotation.
 May cause injury or damage
3. Do not put transducer into the water.
 Prevent the circuit board from shorting.
4. Use the transducer correctly according to its specification.
 Prevent the transducer from permanently deforming if over
torque.
5. Do not replace battery of the transducer by yourself.
 You may damage the battery and cause overheating, fire and
injury.
6. Recommend using the dedicated Transducer for torque inspection.
5. Maintenance and Warranty
1. 100,000 cycles or maximum-measured torque within 100% Tnom .
2. 3 months warranty for service parts.
3. Return the damaged transducer to the local dealer for reparation
4. Needs extra repair fee if damage is caused by abnormal operation (In
warranty period)

Torque Transducer
6. Appearance
No. Function Name Instruction
1 Serial Number Shows the serial number of the transducer.
2 Indicating light
Blue light for Wireless communication,
Orange light for abnormal indicator.
3 USB (Type C) Charger and upgrade the firmware.
4 Charger light
Red light for charging,
Green light for full power
5 Magnetic Switch Region Turn transducer ON and OFF, using magnet.
6 Model Shows Transducer model

Torque Transducer
7. Power ON/OFF and Charging
 Turn transducer ON:
Step 1 Place the transducer vertical and unforced.
Step 2 Pick up the magnet from the box and take it close to the
magnetic switch region until the indicating blue LED flashes
(about 3 seconds), then move the magnet away from the
magnetic switch region.
(Transducer will turn OFF if the magnet is close to magnetic switch
region after indicating blue LED lighted)
Step 3 After turning ON the indicating blue light and it will flash, let the
transducer stand for 10 seconds.
Step 4 Transducer turns ON successfully when the indicating blue LED
is bright (*1) (*2).
(*1) The transducer is damaged when the indicating LED turns from blue to
orange with flashing, then the transducer should be returned to the
original manufacturer for repair.
(*2) The transducer is low power when the indicating LED turns to orange
without flashing.
Note: Transducer cannot turn ON during charging. Please remove the
charger and then turn ON the transducer.
 Turn transducer OFF:
1. In the power ON status, take the magnet close to the magnetic
switch region until the indicating blue light is OFF (about 2 seconds),
then move the magnet away from the magnetic switch region.
2. It will turn OFF automatically if there is no torque over five minutes.
 Charger：
The charger power is 3.5W (5V/0.7A)

Torque Transducer
8. Pair with Torque Controller (TCA)
Step 1 Go to the RF pair page of TCA.
Step 2 Turn the transducer ON and press the pair button on the screen
when the indicating blue light flashes. ( refer to the operation
manual of TCA )
Step 3 The transducer will be turned OFF automatically after pairing is
successful. (*3)
(*3) If transducer does not close automatically after pressing pair button, it
represent failure in pairing. Please pair the transducer again.
9. LED Light Description
Item State Description
Indicating
Light
Blue light with flashing Transducer is initializing.
Blue light without flashing Normal working and can connect with controller.
Orange light without flashing Low Power.
Orange light with flashing One of the parts in Transducer is damage.
Charger
Light
Red light Transducer is charging.
Green light Transducer is full power.
Red and Green light at same time Damaged battery.

Torque Transducer
10.Abnormal signal
No Problem Reason Solution
1
Bright Orange light (Not
Flashing) after initialization
Battery is low power Charge the transducer.
2
Orange light keep flashing
after initialization
1. Incorrect procedure to
turn ON transducer
2. Broken Sensor.
Check all of the procedure for
turning ON is correct. If
orange light keep flashing,
return to the manufacturer
for inspection and repair.
3
Transducer does not turn ON
when magnet is close to
switch region for over 3
seconds.
Transducer is Broken.
(The Hall sensor is broken)
Return to the manufacturer
for repair.
4
Indicating light turns to
orange and keep flashing
during working and then
turns OFF automatically
Over Torque
Turn it ON again.
Warranty is void if over
torque even once.
11.Prompt, Abnormal Messages and Solution
No Message
Error code
on
Transducer
Solution
1 Low power. 001 Charge the transducer.
2 Over torque.
002 Turn the transducer on again.
(The transducer will turn off automatically
when over torque occurs.)
3
Transducer is under abnormal
situation.
004
008
010
020
Check the transducer under zero torque
and keep it stand up when the transducer
is initializing, then turn it on again.
Or, contact with the agent.
4
Return to agent for calibration.
(The transducer has been used
over 50,000 cycles)
040
Return to the agent for calibration.

Torque Transducer
12.Problemand Solution
No Problem Solution
1 No torque signal during tightening.
1. Check if the Transducer has connected with controller.
2. Check the parameters, KS, KDI and KDP, in Transducer
are non-zero value.
3. If this situation happened after checking the above
procedure, please contact with agent for further
inspection.
2
Transducer for TTAS series reads error
in angle and angle-torque in tracing,
tacking and inspecting function in
torque wrench mode.
Contact with agent.
Note: It is highly recommended using Transducer for TTAS
series in inspecting, tracing and track mode. Do not use
Transducer for TTES, TTEH and TTEB series in tracing and
tracking and inspecting function.
3
Transducer cannot connect with
controller after turning on
successfully.
1. Pair with controller again and select the correct
transducer code.
2. Connect with calibration software and check the error
code of Transducer, then solve the problem according
to the error code.
3. If Transducer cannot connect with calibration software
or the problem still happened after following the
above step, please contact with agent for further
inspection.
4 Unstable RF signal
1. Please confirm the distance between the Controller
and Transducer is within 20 meters and there is no
Transducer in the same channel at the same time.
2. Check the other wireless communication equipment
where is in 2.4GHz does not interfere with the
communication between transducer and controller. If
there is communication interference, change another
channel for Transducer and pair again.
3. If it is still unstable, please contact with agent for
further inspection.
5
Transducer turned OFF automatically
without any prompt message during
tightening work.
Please contact with agent for further inspection.

Torque Transducer
6
Follow the pair step and controller
does not respond and Transducer
does not turns OFF automatically after
clicking the pair button
1. Connect the transducer with the calibration software
and check the error code of Transducer, then solve the
problem according to the error code.
2. If Transducer cannot connect with the calibration
software, please contact with agent for further
inspection.
7
Follow the pair step and controller
does not respond and Transducer
turns OFF automatically after clicking
the pair button
8
After upgrading the software of
transducer or controller, Transducer
cannot pair and connect with
controller.
Confirm the software version of Transducer is
corresponding to the Controller.
9
The vibration level is abnormal with
the same tool.
The component of vibration detection is broken.
(Not guaranteed if the vibration level had been over 15)
Transducer can still work in other mode except in the
tracing, tracking and inspecting function for the torque
wrench mode.
10
The using time, from full power to low
power, may be shorter and shorter in
use. (after 50,000 cycles)
It is a normal phenomenon, because of the battery’s
characteristic.
11
Charger light show two color, red and
green.
12
It is still lower power after charging
over 3 hours.
13
Transducer cannot turn on by
magnetic
14
Actual torque is unstable with the
same tool
15
Indicated color of vibration level turns
to yellow with red background.
It is the prompt for over vibration.
If occurred the warranty is void.
16
Backlash between the shaft and the
shells.
The cushion is broken.
Please return to agent for inspection and repair.
17 The shaft is broken. This problem is not in warranty.
18 The shells are broken. Please return to agent for repair.
19
Produce Powder between shells and
shaft
It is normal phenomenon
20 The USB cannot be plug in.
Confirm there is no foreign particle inside the connector.
If found something, kindly clean it by air gun but without

Torque Transducer
moisture and dust, Or return to agent for cleaning.
21
Charger light does not turn ON when
Transducer is charging
1. Check power supply is stable on DC 5V / 0.7A.
2. Change the workable charger cable.
3. Avoid that use the USB Hub to charge Transducer over
2 pieces at the same time.
The problem still happened after following the above step,
please contact with agent for further inspection.
22
Charging light flash when Transducer
is charging
1. Check power supply is stable on DC 5V / 0.7A.
2. Change the workable charger cable.
3. Avoid that use the USB Hub to charge Transducer over
2 pieces at the same time.
The problem still happened after following the above step,
please contact with agent for further inspection.
23
The burned-software cannot upgrade
the software.
1. Check the USB cable is workable.
2. Check the USB port on PC and PC can detect the USB
port.
3. Check the com-port number is correct and make sure
transducer is connected.
4. Try reversing USB type C
5. If Still cannot update successfully, kindly return to the
agent for inspection and repair.
24
Considerable error margin between
Transducer and torque master in
torque wrench mode.
1. Check the accuracy of torque master or torque
wrench.
2. Transducer can be re-calibrated by following method:
(1) Calibrate Transducer with calibration software by
yourself.
(2) Return to agent for calibration.
Note: Torque may be unstable if over-torque occur even
once due to incorrect operation.
25
Incorrect torque after self-calibration
by user.
1. Please calibrate Transducer again
2. Or contact with agent and return Transducer to agent
for calibration.

Torque Transducer
13.Mechanical Specification
13.1 TTES / TTAS Series
*TTES series are designed for dynamic operation while TTAS series are for static torque
control and verification.
Model
Specifications
(Tnom)
Designation Net Weight
A
mm
B
mm
C
mm
D E
mm
F G
mm
Kg Lb
TTES-20-FS3MS3 20 Nm 82.2 45.0 24.0 3/8” 12.5 3/8” 12.0 0.18 0.40
TTES-50-FS3MS3 50 Nm 82.2 45.0 24.0 3/8” 12.5 3/8” 12.0 0.20 0.44
TTES-100-FS3MS3 100 Nm 82.2 45.0 24.0 3/8” 12.5 3/8” 12.0 0.21 0.46
TTES-180-FS4MS4 180 Nm 96.7 45.0 29.6 1/2” 18.0 1/2” 17.0 0.3 0.66
TTES-250-FS4MS6 250 Nm 105.2 60.0 29.6 1/2” 18.0 3/4” 21.5 0.50 1.1
TTES-500-FS4MS6 500 Nm 105.2 60.0 40.0 1/2” 18.0 3/4” 21.5 0.60 1.3
TTES-750-FS6MS8 750Nm 110.7 60.0 40.0 3/4” 25.0 1” 25.5 0.75 1.65
TTES-1000-FS8MS8 1000 Nm 126.7 60.0 54.0 1” 29 1” 27.3 1.1 2.42
TTES-1500-FS8MS8 1500 Nm 127.4 60.0 54.0 1” 29 1” 31.1 1.5 3.3
TTES-2000-FS8MS12 2000 Nm 143.4 60.0 54.0 1” 31 1-1/2” 37.5 1.8 4.0
TTAS-20-FS3MS3 20 Nm 82.2 45.0 24.0 3/8” 12.5 3/8” 12.0 0.18 0.40
TTAS-50-FS3MS3 50 Nm 82.2 45.0 24.0 3/8” 12.5 3/8” 12.0 0.20 0.44
TTAS-100-FS3MS3 100 Nm 82.2 45.0 24.0 3/8” 12.5 3/8” 12.0 0.21 0.46
TTAS-180-FS4MS4 180 Nm 96.7 45.0 29.6 1/2” 18.0 1/2” 17.0 0.3 0.66
TTAS-250-FS4MS6 250 Nm 105.2 60.0 29.6 1/2” 18.0 3/4” 21.5 0.50 1.1
TTAS-500-FS4MS6 500 Nm 105.2 60.0 40.0 1/2” 18.0 3/4” 21.5 0.60 1.3
TTAS-750-FS6MS8 750Nm 110.7 60.0 40.0 3/4” 25.0 1” 25.5 0.75 1.65
TTAS-1000-FS8MS8 1000 Nm 126.7 60.0 54.0 1” 29 1” 27.3 1.1 2.42
TTAS-1500-FS8MS8 1500 Nm 127.4 60.0 54.0 1” 29 1” 31.1 1.5 3.3
TTAS-2000-FS8MS12 2000 Nm 143.4 60.0 54.0 1” 31 1-1/2” 37.5 1.8 4.0

Torque Transducer
13.2 TTEH Series
*This series of Transducer can be custom-made with hexagonal opening to fit different
sizes of bolt or nut.
13.3 TTEB Series
*TTEB series are designed for screwdriver.
Model
Specifications
(Tnom)
A
mm
B
mm
C
mm
D
mm
E
mm
F G
mm
H
mm
I
mm
Kg Lb
TTEH-250-FS4FHM18 250 Nm 93.7 45 26.0 27.0 20.0 1/2” 18.0 18.0 13.0 0.5 1.0
TTEH-250-FS4FHM24 250 Nm 96.7 45 30.0 34.0 23.0 1/2” 18.0 24.0 15.0 0.5 1.0
TTEH-200-FS4FHM17L 200 Nm 97.7 45 24.0 24.0 25.0 1/2” 18.0 17.0 17.0 0.45 0.77
TTEH-1000-FS4FHM30 1000Nm 119 60 35.0 42.0 47.5 1/2” 18.0 30.0 17.0 1.3 2.87
Model
Specifications
(Tnom)
A
mm
B
mm
C
mm
D
mm
E
mm
F
mm
G
mm
Kg Lb
TTEB- 5-MHM6FHM6 5Nm 121 45 10 6.35 23.5 6.65 23.5 0.15 0.33
TTEB-10-MHM6FHM6 10Nm 121 45 10 6.35 23.5 6.65 23.5 0.15 0.33
TTEB-20-MHM6FHM6 20Nm 121 45 10 6.35 23.5 6.65 23.5 0.15 0.33

Torque Transducer
13.4 TTER Series
*TTER type Transducer can be custom-made upon request while ordering.
Model
Specificatio
ns
(Tnom)
A
mm
B
mm
C
mm
D
mm
E
mm
F G
mm
H
mm
I
mm
Kg Lb
TTER-1000-FS4FHM30 1000Nm 118.7 60 35.0 42.0 47.5 1/2” 18.0 30.0 17.0 1.3 2.87

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ZIPP Wireless torque transducer operation manual