ŀ ASG-CT2500 ASG-SD2500 Series Screwdriver Controller User’s Guide Version 2.0.0 June, 2012 Page 1 Documentation Provided By HMC Electronics 33 Springdale Ave. Canton, MA 02021 http://www.hmcelectronics.
ASG Precision Fastening ASG-CT2500 User’s Guide Version 2.0.0 Major Revision: June, 2012 Firmware Revisions GUI: Firmware Version 2.1.1.0 Controller: Firmware Version C-6.11.0 To download the latest version of this manual visit: www.asgprecisionfastening.com ASG Precision Fastening (888) 486-6163 15700 S. Waterloo Rd. Cleveland, OH 44110 USA © 2012 Jergens Inc. All Rights Reserved Page 2 Documentation Provided By HMC Electronics 33 Springdale Ave. Canton, MA 02021 http://www.hmcelectronics.
Table of Contents Safety Precautions…………………………………………………………………………..………………………………………………….5 Introduction……………………………………………………………………………………………..…………………………………………6 Installation………………………………………………………………………………………………………….…..………………….……..7 Run Tool Screen………………………………………………………………………………………………………………………………….9 Tool Information Screen Setup Screen……………………………………………………………………………………………………………………………….…….
Input/Output Port Pin Guide………………………………………………………………….…………………………………………27 Graph Screens…………………………………………………………………………………..………………………………………………29 Graph Data Export Data Screen……………………………………………………………………………………………………………………………………32 Erasing Data Downloading Data System Setup Screen…………………………………………………………………………………………………………..
Safety Precautions Be sure to read all instructions and precautions contained in this manual, failure to do so may result in personal injury and/or damage to tooling and components. Do not operate or plug in the controller/system with wet hands or in wet environments. Failure to observe this may result in injury due to electric shock. Ensure the controller is properly plugged in to a grounded electrical receptacle. Do not remove the ground pin or use any adapter plugs.
Introduction Thank you for investing in a ASG-CT2500 Controller from ASG Precision Fastening! This user’s guide will assist you with setting up your controller. Please start by finding the serial number label on the bottom of the controller. Take note of the serial number and record it below with your date of purchase. This information will be necessary should any service be required in the future.
Installation Installation of the ASG-CT2500 is very straightforward. Follow these steps to connect your system for the first time: Controller Mounting: The ASG-CT2500 comes standard with a mounting plate for attaching to the wall, workbench, or tool stand. Secure the controller using the (4) provided holes in the mounting plate. These provided holes are meant for #6 screws, but can be enlarged to suit user’s needs.
Tool Installation: Connect the tool cable to the connector on the bottom of the controller by identifying the alignment tabs in the large cable connector. Align these tabs and insert the cable to the cont controller, roller, then rotate the twist-lock on the cable connector clockwise until it clicks into place.
Run Tool Screen 1 2 3 4 6 7 5 13 8 9 10 11 12 1. Task Selection: Shows the user the current task, and allows the user to select one of 12 available tasks. Selecting the button with the task name will bring up the Task Menu where another task may be selected or altered. The arrow keys will advance to the previous or next task. Settings for bolt counts, parameters, inputs, outputs, etc will switch with these actions to the settings of the selected task. 2.
7. Bolt Sequence Steps: Displays the sequence step and selected parameter. The parameter name will be highlighted red, yellow, or green at the end of its cycle to show its status. 8. Setup Button: Takes you to screens where you may set up Tasks, Parameters, Bolt Sequences, Inputs, Outputs, and System Settings. 9. Graph Button: Displays the most recent fastening cycle graphically as Torque vs. Time, Angle vs. Time, Torque vs. Angle, Speed vs. Time, and Power vs. Time. 10.
Tool Information Screen This screen displays characteristics of the tool that is attached to the ASG-CT2500 controller such as: • • • • Model Number Serial Number Number of Cycles on the Tool Max Torque • • • Max Speed Gear Ratio Calibration Value CAUTION: Tapping on the Calibration Value will take you to a screen where the value can be manually changed. This screen is for qualified calibration technicians only.
Setup Screen Entering the setup screen allows you to modify the settings of each task’s parameters, bolt counts, bolt sequences, inputs, outputs, reverse settings, and triggering. Tool Triggering: On the ‘Setup’ screen, each task can be set up to trigger the tool in the way that best fits that task. The tool can be set up for remote start, lever start (if tool is equipped with a lever), push to start, lever or push to start (together), or lever and push to start.
Bolt Retries: To enable this feature, tap the radio button on the task setup screen under the number of bolts. Set the number of retries before lockout by tapping the number and inputting the desired value. A retry is counted when the tool is put into reverse and triggered. After the designated value of retries have been achieved, the tool will not attempt another rundown without tapping the ‘reset’ button on the ‘Run Tool’ screen.
Parameter Setup: From the task setup screen, select the Parameters button. Shown will be a button for each of the 8 available parameters for that task. Some useful definitions for the Parameter Setup: Target Torque/Angle: The value at which the tool should stop the fastener rundown Torque HL/LL: The High Limit (HL) or Low Limit (LL) of acceptable torque for the fastener in the user’s process. Angle HL/LL: The High Limit (HL) or Low Limit (LL) of acceptable angle for the fastener.
To set up a parameter: 1) Select one of the Parameter buttons and select either Torque Control Profile or Angle Control Profile by tapping the button on the right side of the screen to toggle between the choices. 2) 3) 4) 5) 6) Note: Torque Control Profiles Parameters will appear in BLUE on the parameter list and Angle Control Profile Parameters will appear in GREEN. Select the direction of rotation for the parameter by toggling between ‘clockwise’ and ‘counterclockwise’ at the top of the screen.
Prevailing Torque Certain applications (such as self tapping fasteners or locking helical inserts) require compensation for the prevailing torque of a fastener in the final torque of the rundown. This can be accomplished using the ‘Calc Prevail Torque’ feature in an angle control parameter. For easy identification, angle control parameters using the prevailing torque option have a purple outline on the parameter blocks.
Bolt Sequences The ‘Bolt Sequences’ button allows the user to select which parameter(s) will run for a given bolt inside each task. To assign a parameter to a bolt, select the bolt number (or multiple bolts if they will all have the same parameter(s)) then tap the button to the right to access the parameter list. Tap the parameter name you wish to choose to select that parameter for that bolt.
Task Setup From either the ‘Run Tool’ or ‘Setup’ screens, tapping the task name will bring up the ‘Task Setup’ screen shown below: All 12 tasks are displayed here and tapping any one will switch to that task. Renaming and Importing Tasks From the ‘Task Setup’ menu, pressing and holding on a task name will display the following screen: Tapping the ‘Rename’ button will allow the user to enter a customized name with the on-screen keypad.
Exporting Task Settings to USB The ASG-CT2500 controller is capable of exporting the task settings to USB for backup and transfer to other ASG-CT2500 controllers. To accomplish this, insert a USB flash drive with available memory to the port on the controller. From the ‘Run Tool’ screen, tap the task name at the top to bring up the ‘Task Setup’ menu When a USB drive is inserted, the ‘Export Task Files’ button is displayed.
Input Programming There are (8) inputs, as well as a 24V DC and ground supply available through the input connector on the screen, en, there is a row of lights at the bottom showing each bottom of the controller. On the ‘Run Tool’ scre of the 8 inputs. When an input is active, the light will illuminate blue to aid in trouble-shooting and setup. See the chart at the end of this section for pin location and other technical information.
If a task is being selected through the inputs by an external signal, the task button will not allow a user to manually select a task, the external input will have to be removed to free the logic and allow the manual selection. • ENABLE BOLTS: From the ‘Run Tool’ Screen: o Tap the ‘Setup’ Button o Make sure the task shown at the top is the one to be programmed. o Tap the ‘Inputs’ Button Assuming that there is only 1 bolt in your sequence, tap the button on the lleft eft that says ‘Bolt 1’.
want to use to start the tool by tapping the ‘Ignore’ button to the right of that input. This will toggle between ‘H’,’L’, and ‘‘Ignore’ Ignore’ with each tap. The picture to the right of this button shows what the controller is currently seeing on that input. Press the yellow [<<] button at the top and save changes if desired. Highlight Note: Ensure the driver will require the start signal to be active the entire time the driver is meant to run.
function. Only activating the reverse input will merely set the tool to reverse, it will still require the start signal to run. Highlight • REMOTE RESET: From the ‘Run Tool’ Screen: o Tap the ‘Setup’ Button o Make sure the task shown at the top is the one to be programmed. o Tap the ‘Inputs’ Button o Tap the arrow button on the bottom next to ‘Setup Bolt(s)’ so that ‘Setup Misc’ appears. Select the ‘Remote Reset’ button on the left side of the screen.
Select the ‘Remote Halt’ button on the left side of the screen. You should now see a column of buttons appear in the chart next to each input number. You may now select which input you want to use to halt the tool by tapping the ‘Ignore’ button to the right of that input. This will toggle between ‘H’,’L’, and ‘Ignore’ with each tap. The picture to the right of this button shows what the controller is currently seeing on that input. Press the yellow [<<] button at the top and save changes if desired.
Output Programming There are (8) programmable outputs, 24V DC, and ground supply available through the output connector on the bottom of the controller. See the chart at the end of this section for pin location and other technical information. All the outputs can be set up with the following instructions from the ‘Run Tool’ Screen: • • Tap the ‘Setup’ Button o Make sure the task shown at the top is the one to be programmed.
• • • BATCH REJECT: (Some portion of the task did not complete within acceptable parameters or the task was aborted) TOOL TRIGGERED: (All triggering criteria as defined in the setup screen have been satisfied. This output is only available as a solid output, not momentary or repeating) TORQUE > THRESH: (The current torque reading from the tool is greater than the programmed threshold torque in the parameter being run.
Input/Output Port Pin Guide Notes: All inputs are optoisolated Outputs are mechanical dry contacts – sealed relays. Page 27 Documentation Provided By HMC Electronics 33 Springdale Ave. Canton, MA 02021 http://www.hmcelectronics.
Listed 24VDC pins are supply pins, do not hook up external 24V 24VDC DC to the controller, internal damage can occur. Listed Ground pins are tied to the earth ground of the controller’s input power supply, do not hook up to external equipment grounds to avoid ground conflicts. Do not use CT2500 outputs to switch high inductive loads – damage to relays can occur. Page 28 Documentation Provided By HMC Electronics 33 Springdale Ave. Canton, MA 02021 http://www.hmcelectronics.
Graph Screens In order to assist the user with setting up and trouble-shooting problem joints, the latest rundown is stored in the controller in graph form. From the ‘Run Tool’ screen, tap the ‘Graph’ button at the bottom of the screen. Along the bottom of the screen can be found the available graphs, tap the appropriate button to view: • Torque vs. Time: Graphs the last rundown with Torque on the Y axis in whatever units are specified in the parameter, and Time on the X axis in milliseconds (ms).
• Speed vs. Time: Graphs the last rundown with Speed on the Y axis in rotations per minute (rpm), and Time on the X axis in milliseconds (ms). • Power vs. Time: Graphs the last rundown with Power on the Y axis in Watts (W), and Time on the X axis in milliseconds (ms). In each graph there is a ‘Legend’ button on the top of the screen.
Graph Data Export to USB (GUI Firmware v2.2.0.0 and later) In order to enable the graph data export function, a key file must be saved to a USB flash drive and inserted to the controller. This file can be obtained from ASG and saved to the USB main directory inside a folder named ‘Keys’. Once inserted, an icon will appear on the ‘Run Tool’ screen next to the ‘Tool’ button indicating the feature is enabled. Upon the completion of each rundown, the controller will export the graph data to the USB drive.
Data Screen For data traceability, rundown information is stored in table form for view and download from the controller. To access this data, tap the ‘Data’ button on the bot bottom tom of the ‘Run Tool’ screen. The last 100 rundowns since the last controller reboot is available to view on screen.
Erasing Data To erase the data shown on the screen, tap the ‘Erase’ button at the bottom of the chart. A screen will ask you to confirm your intentions to erase the data before the data is cleared. NOTE: Erasing the data with this button will not clear the data from the internal memory of the controller; it will merely remove it from view in the table. Any erased data is still available for download to USB as described in the next section.
Data available in these downloaded files includes the following: • • • • • • • • • • • • • Date Time Tool Model Number Tool Serial Number Tool Cycle Number Task Name Bolt Number Torque Units Parameter Target Prevailing Torque Value Applied Torque Final Torque Reading Final Angle Reading • • • • • • • • • • • • • Cycle Time Result Note Parameter Name Parameter Type Parameter Threshold Torque Parameter Torque HL Parameter Torque LL Parameter Angle HL Parameter Angle LL Downshift Torque Rundown Speed Downsh
System Setup Screen The ‘System Setup’ screen allows the user to set system controls and tool settings. See the following sections for further information. Passwords From the ‘System Setup’ screen, tap the ‘Passwords’ button. The controller allows (3) individual passwords, each password allows access to the controller when locked. Each password allows full access to unlock the controller. When a controller is locked, the controller will still navigate to most screens and settings will be viewable.
Modifying features in a locked controller controller:: Navigate to the setting or feature that needs to be modified and tap the appropriate button or number. The controller will then prompt the user for a password to unlock the controller. Once a password is accepted, settings can be changed on any screen. To re-lock the controller again after modifications have been made, tap the ‘Lock’ button at the bottom right-hand corner of the ‘Run Tool’ screen.
Date/Time Settings To set the controller’s date and time, tap the ‘Date/Time’ button on the ‘System Setup’ screen. Adjust the date and time with the up and down arrow keys above and below each number. Note: the time is formatted in a 24 hour format, and the date is in MM/DD/YY format. Tap the [<<] button to return to the previous screen and save changes.
To adjust the threshold, use the up and down arrow keys to move the green bar up or down the slider. To test, push the lever or pull chuck to move the white bar up to the green threshold bar and verify the tool begins to run when desired. Tool Calibration To view the calibration value of the tool connected to the controller, tap the ‘Tool Cal’ button on the ‘System’ screen. The calibration value will be displayed, and can be modified if required.
Controller Information To view basic information about the controller and to give the controller a name, tap the ‘Controller Info’ button on the ‘System’ screen. This screen displays the following: • • • • Controller Name Controller Serial Number GUI Board Firmware Version Controller Board Firmware Version Changing the Controller Name: To change the controller name, tap the button on the ‘Controller Information’ screen that shows the current name, and then enter the new name on the screen.
Touch Screen Calibration Should the user feel the need to recalibrate the touch screen, this option is available under the ‘System’ screen. Tap the ‘Touch Screen Cal’ button and follow the on-screen directions to complete this process. LCD Brightness Should the controller be used in extremely dark or light environments, the LCD touch screen brightness can be adjusted under the ‘System’ screen. Use the up and down arrow buttons to adjust the brightness. The controller comes factory set at 60%.
