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Tensor DS Drive

Quick Guide

SAFETY INSTRUCTIONS
When using electric products, basic precautions
should be followed:
❑ THIS EQUIPMENT MUST BE EARTH GROUNDED.
❑ Always disconnect the equipment from the mains,
by pulling the plug, before opening it for installation,
service etc.
❑ Do not use this product near water.
INSTALLATION HARDWARE

Figure 1 Figure 2

1. Open the lock mechanism (see figure 1)


2. Open the DS Drive by pulling it (see figure 2)
3. Connect the tool cable, power cable etc. (see figure 3)
4. Check so that the GFI is switched on
5. Close the DS Drive and lock it
6. Connect the power cable to a power supply 115/230 V
7. Turn the power on

IMPORTANT! Whenever replacing a tool, always turn the power off.

1. Tool cable connector


2. Digital inputs. Only for D312
3. Relay outputs
4. RS 232
5. I/O bus. Only activated
for D312
6. I/O bus. Only activated
for D312
7. Remote control
8. Main power connector
9. Ground fault interrupter,
GFI, 30 mA
10. Main fuse. 6.3 x 32 mm –
Figure 3 Slow Blow,15/20/25 A
2
DISPLAY/KEY PAD

1. Display
2. OK LED
1 4 3. n x OK LED
4. Lock LED
2 7
5. NOK LED
3 8 6. Alarm LED
11 7. Graph LED
5 12 8. IRDA
9. Function button
6 13 10. AutoSet button
9 14 11. Plus button (+)
15 12. Question mark
10 button
13. Enter key button
14. Minus button (-)
15. Power

OK LED – Lights up after each tightening with


correct torque.
NOK LED – Lights up af ter each tightening reaching
first target but not correct torque.

Question Mark – By pushing this button you can see:


❑ Drive program software version.
❑ Drive version (D302-Basic functionality,
D312-Advanced functionality).
❑ Drive size (DS4, DS7, DS9).
For further information check the DS Drive Manual.

3
KEY PAD FUNCTIONS

AutoSet Programming:
The AutoSet Programming
feature allows the DS Drive to
recognise a joint’s stiffness and
adjust the tool for maximum
performance for that particular
joint accordingly.

1. Press the AUTOSET button once and ASEt/F1


appears on the display.

2. Choose final torque target by pressing /


+/- buttons.

3. Press the ENTER button once to activate the


AutoSet function.
The Graph LED, lights up.

4. Resume tightening (5-8 times) until the Graph LED


disappear.

Optimum performance has been found and the system is ready


for production.

4
Fine – Tuning Final Target
This enables personnel to fine the final target.

1. Press the FUNCTION button once and Ft/F2


appears on the display.

2. Adjust final torque target by pressing


the +/- buttons. /
(The torque can be adjusted a maximum of +15%
or –5% from the original final target).

3. Press the ENTER button and the display starts


to flash.

4. When a new final target has been found within above limits,
the DS Drive is ready to run that program.
Torque Tuning
This is used when a tool is controlled against an external torque
reference. If the torque value on the DS differs from the
traceable value, a Torque Tuning should be performed.
1. Perform a number of tightenings with the external torque
transducer connected, preferably 20 tightenings or more in
order to achieve a good mean value. Calculate the mean value
from the tightenings.
2. Press the FUNCTION button twice and tunE/F3
appears on the display.
3. Press the +/- button until you have the
external mean value on the display.
/
4. Press the ENTER button and the display starts
to flash.

5. Perform another set of tightenings to control your torque.

6. If the torque is OK you are ready to run. If not, do the


complete procedure over again.

5
Motor Tuning
This function will optimize the performance of the motor and
minimize losses, i.e. after service.
1. Press the FUNCTION button three times and
tool/F4 appears on the display.
2. Press the ENTER button until the display starts
to flash.
3. Press the trigger on the tool and the tool will turn both in
forward and reversed direction (about 35-45 seconds).
The tool has now been motor tuned and is ready to use.

Copy Parameter Set


This option makes it possible to copy a parameter set.
(D312 – Advanced functionality)
1. Press the FUNCTION button four times and
COPY/F5 appears on the display.
2. Press +/- button to select the parameter set
you want to copy to another parameter set. /
Confirm by pressing the ENTER button.
3. Choose the parameter set that you want to
copy the selected parameter set to by /
pressing the +/- button.
Confirm by pressing ENTER button.

Change Parameter Set


When neither of the described functions are selected, the +/-
button are used to change parameter set (D312 – Advanced
functionality).
1. Press the +/- button to change parameter
set. /

2. Confirm that you want to change Parameter set by


pressing the ENTER button.

6
FULL PROGRAMMING

Tightening strategy
You can select strategy choices as shown.
Soft Start Time
In order to facilitate screw engagement the tool starts by
turning at a very low speed during the soft start time.
Targets
At First Target the tool will shift from Step 1 Speed to Step 2
Speed. Final Target is the level where the tool stops and the
tightening is finished.
Speeds
Step 1 Speed is the speed used during the rundown. When First
Target is reached, the tool slows down to Step 2 Speed to
tighten the second stage. To finish the tightening the tool goes
in to Zoom Step Speed for operator comfort and minimization
of overshoot.
Step 2 Ramp
In Step 2 Ramp you can select the acceleration of the tool in
step 2 speed between 0 and 100%.

7
RUNDOWN MONITORING
Rundown Monitoring is a function to detect bad rundowns. The
angle in both first and second step is monitored. See graph
below.

Cycle Start
Cycle Start is the
torque limit from
which the angle is
measured. The
maximum limit for
Cycle Start is First
Target.
Search Speed
The Search Speed is
the speed with which the tool will run until Cycle Start limit is
reached. The min limit is 0%. Max limit is Step 1 Speed. When
Cycle Start is reached the tool immediately accelerates to Step 1
Speed.
Step 1 Turns
The angle in the first step is measured from cycle start level until
1st target is reached. Program min (0 turns) and max (200 turns)
levels for when the angle is OK. The angle is defined in 1/10 of a
full turn.
Clamp Angle
The angle in 2nd step is measured from the point where 1st
target is reached until final target is reached. The angle in
between is called Clamp Angle. Program min (0 degrees) and
max (10000 degrees) levels for when the Clamp Angle is OK. The
angle is defined in steps of 10 degrees.

8
HIGH SPEED RUNDOWN
High Speed Rundown allows the tool to make the rundown at a
higher speed than Step 1 Speed. The function is used when a
fastener has a long rundown angle and there is a risk for
overshooting when the joint is hard.

SELF TAP
The Self Tap function is used for thread forming screws and
other fasteners with a torque pulse in the beginning of the
rundown higher than the desired 1st target or final target, see
graph below.

9
CONFIGURATION
The Configuration window has three different subgroups:
System Administration, I/O Configuration (containing I/O Setup
and RE-Alarm Setup) and Tool Service Setup.

1. In System Administration you define the operator interface.


2. In I/O Configuration – I/O you define how to use the
different input and output connections on the DS Drive. For
cable connection, see page 11.
3. In I/O Configuration – RE-Alarm Setup you set the
characteristics for the external alarm. The RE-Alarm only
works for DS when its hex switch is set to position 3.
4. Tool Service Setup gives you information about the service
status of the tool and also a possibility to program your own
service interval, see page 12.
5. Selector Source decides what input is used to select
between p-sets. You can choose between:
❑ None
❑ I/O Digital
❑ I/O Bus (Selector 4 and Selector 8, see page 11)
The I/O Bus only works for DS when its hex switch is set to
position 5 for Selector 4 and position 6 for Selector 8.

10
INPUTS AND RELAYS
Figure 1 shows how to connect in order to obtain a signal on one of
the digital inputs. The power source can either be built in 24 VDC or
an external power source. Figure 2 shows how to connect to obtain
OK and NOK signals using relay outputs RE1 & RE2.

Figure 1 Figure 2

By programming the inputs with Selector bit 0-3, see figure 3, it


is possible to have up to eight different p-sets. The inputs are
interpreted binary according to the table below.
Figure 3

Parameter
set

Selector bit 0 1 2 3 4 5 6 7 8
0 0 1 0 1 0 1 0 1 0
1 0 0 1 1 0 0 1 1 0
2 0 0 0 0 1 1 1 1 0
3 0 0 0 0 0 0 0 0 1

11
TOOL SERVICE SETUP
In the Tool Service Setup window you can see information about
last service date and number of tightenings after service. It is
also the start window to set the service date in the tool and the
service interval. You activate the service indicator by changing
the pull down menu to ON.

When clicking the "T ool Service


Reset" but ton, a new window is
shown where you set the
service interval and service
date. The default value is
250,000 tightenings, which is
also our max recommended
interval for a normal joint. When
pressing OK and STORE the
counter will be reset to 0.

12
ERROR CODES
Error codes are displayed with four characters, beginning with an E.
All error codes are found in the DS Drive Manual.
Group 0 Rundown failures, E000-E031
Group 1 Event related errors, E100-E131
Group 2 User input error, E200-E231
Group 4 Communication errors, E400-E431
Group 5 Hardware errors TOOL, E500-E531
Group 6 Hardware errors DC3000/MC3000, E600-E631

Ack-
Error now- Help
code Description ledge What to do? text
Start button was probably released to early. Let ”Torque
E001 Torque LO No
the tool ”finish” the tightening. value”
The programming is bad. Please check the
programming and make sure that you have ”Torque
E002 Torque HI No
some movement on the socket in the second value”
stage.
E004 Angle1 LO No Check programming or the joint. LO°1
E005 Angle1 HI No Check programming or the joint. HI°1
E006 Angle2 LO No Check programming or the joint. LO°2
E007 Angle2 HI No Check programming or the joint. HI°2
Pset invalid Change Final target by the F2 function on the
E101 (Check sum Yes Drive Key Pad and store it. Afterwards change
error) it back to its original value.
Rundown
prohibited Press on the SET or ENTER button on the key
E108 due to key- No pad until you see four dashes or dots on the
pad usage display.

You tried to tighten the fastener when it was


already tightened and Alarm On Rehit was
E112 Rehit No
marked in TTDS/Configuration. Please unmark
Alarm On Rehit or retighten the fastener.
You have probably pressed the start button too
Direction quick since last time. Please allow more time
E115 uncertain Yes
between releasing the start button and trying
to start the tool again.
Motortuning Redo the Motortuning. If this does not work,
E120 failure Yes
service the tool.
Tool Discon- Shut the drive off and connect the tool. Start
E131 nected Yes
the drive.
Pset nr Two or more sockets are lifted at the same time
E206 invalid No
or pset 9 or higher is chosen.

13
ERROR CODES

Ack-
Error now- Help
code Description ledge What to do? text
IO device not
E403 No Check cables and restart drive.
responding
Multiple devices
E408 of same type on Yes You are only allowed to use one.
IO bus
Multiple selectors
E409 Yes
on IO bus
Connect the Selector and restart
No selector
the drive or choose None
E410 found and pset Yes
on Selector Source in TTDS/
source is IO bus
Configuration.
IO expander has
E412 Yes
ID <> 2
RE Alarm has ID
E413 Yes
<> 3
4 socket selector
E415 Yes
has ID <> 5
8 socket selector
E416 Yes
has ID <> 6
E501 Tool overheated No Let the tool cool down and restart.

Åtta.45 Tryckeri AB 2008:1


E502 Service Indicator Yes Service the tool.

Tool maxtorque
E517 or Gear Ratio out Yes Check tool memory.
of range
Restart drive. If problem still
E601 Dcbus LO Yes
remains check line voltage.
Restart drive. If problem still
E602 Dcbus HI Yes
remains check line voltage.
9833 1424 01

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