INSTRUCTION MANUAL Date of issue: July 2007 Version: V1.09 Controller CLT-500 / RG-500 working place controller for electric screwdrivers High - System - Technik
Index 1. Priciple information... Seite 3 1.1. Rating of this manual... Seite 3 1.2. Using according to this manual... Seite 3 1.2.1. Improper use... Seite 3 1.3. Warrenty and libility... Seite 3 2. Principle safety instruction... Seite 5 2.1. Consideration of the directions of this manual... Seite 5 2.2. Operator s duty... Seite 5 2.2.1. Staff s duty... Seite 5 2.2.2. Training of staff... Seite 5 2.3. Perils in view of working with the control unit CLT-500 / RG-500... Seite 5 2.4. Perils caused by electric shock... Seite 6 2.5. Alterations of the control unit CLT-500 / RG-500... Seite 6 2.6. Cleaning an waste disposal of the control unit CLT-500 / RG-500... Seite 6 2.7. Installation... Seite 6 2.8. Power supply... Seite 6 3. Operation of the control unit CLT-500 / RG-500... Seite 7 3.1. Basic concepts... Seite 7 3.1.1. Program push button... Seite 7 3.1.2. Programs (factory setting)... Seite 7 3.1.3. LED... Seite 7 3.1.4. Function of keys in the program mode... Seite 7 3.2. Programming CLT-500 / RG-500... Seite 8 3.2.1. Lifting the menu pawl... Seite 8 3.2.2. Rotation speed clockwise Start and final value... Seite 8 3.2.3. Rotation speed counter-clockwise Start and final value... Seite 8 3.2.4. Screw time clockwise... Seite 9 3.2.5. Screw time counter-clockwise... Seite 9 3.2.6. Number of tightenings... Seite 9 3.2.7. Special functions...seite 9 3.2.8. Function of keys in the working mode... Seite 10 3.2.9. Output... Seite 10 3.3. PIN definition CLT-500 / RG-500, Port 1... Seite 11 3.3.1. Port 1 (Plug 25-pol)... Seite 12 3.3.2. Port 1 CLT-500 / RG-500 Schematic Diagram... Seite 13 4. Speed chart CLT-500 / RG-500...... Seite 14 4.1. Technical Data... Seite 16 5. Accessories...... Seite 16 5.1. Test- and Signalboxes... Seite 16 5.2. Connecting cable... Seite 16-2 -
1. Principle information 1.1. Rating of this manual This information has been written to be read, understood and to be taken into consideration from those people who are responsible for this control unit. Errors on the workplace can only be avoided and the operation without any disturbances can only be reached with knowledge of this instruction manual. Please note that we do not overtake any responsibility for damages or disturbances which result out of non-observance of the instruction manual. In the case of any difficulties in spite of consideration of the tips of the instruction manual, please contact us, we should be glad to be at your disposal for any further information you might require. 1.2. Using according to this manual! This device is exclusively meant for the control of HIOS screwdrivers CL and α-series, HST-A- and HST-CL-screwdrivers and ASA-screwdrivers from the HS-Technik-GmbH. The use for any other devices is regarded as non-directed; that means that the company HS-Technik GmbH does not overtake any responsibility for any damages resulting out of such an improper use.! The proper use of the device includes also the consideration of the directions in this manual the observance of inspection and maintenance service 1.2.1. Improper use We do not overtake any responsibility for damages caused by an improper use of this control unit or the non observance of this instruction manual. 1.3. Warranty and libility Warranty and liability claims with personal injury and material damage are impossible, in one or more of the following cases: improper use of the control unit improper mounting, operation and maintenance of the control unit operation of the device with damaged safety devices or safety devices which are not installed properly or safety devices which are out of order non observance of the directions of the instruction manual regarding transport, stocking, mounting, operation and maintenance of the control unit unauthorized conversion of the control unit improper reparations - 3 -
Copyright This manual is only meant for the operator and its staff. It contains the directions which you are not allowed to copy, distribute or inform about in any other way. This copyright remains to the company HS-Technik GmbH. Address of the manufacturer: High - System - Technik Im Martelacker 12 D-79588 Efringen-Kirchen Telefon 0 76 28-91 11-0 Telefax 0 76 28-91 11-90 E-Mail: info@hs-technik.com Internet: www.hs-technik.com - 4 -
2. Principle safety instruction 2.1. Consideration of the directions of this manual Basic requirement for a safe and disturbance free operation of the device is the knowledge of the principle safety rules. Moreover, the rules and directions for the workplace have to be taken into consideration. 2.2. Operator s duty It is the duty of the operator to ensure that only people who are familiar with the principle directions of work safety and accident prevention and who are trained in the correct handling of the workplace have access to the device. The personnel will be tested regularly if they work according to the safety instructions. 2.2.1. Staff s duty All persons who are entrusted to work with the control unit have the duty to inform themselves about the principle directions of work safety and accident prevention before they start working. 2.2.2. Training of staff Only trained personnel are allowed to work at this working environment. The responsibility for mounting, operation, maintenance and repair has to be fixed clearly. The training of new staff has to be done under supervision of an experienced person. 2.3. Perils in view of working with the control unit CLT-500 / RG-500 Disturbances, which have an adverse affect on the safety, have to be eliminated promptly. The control unit CLT-500 / RG-500 has been built according to state of the art and the approved safety rules. In spite of this fact, however, there can occur situations which build perils for life and limb of the user or third or which could lead to material damage.! The work place is only meant: for a proper use in an impeccable state - 5 -
2.4. Perils caused by an electric shock Work on the electrical connection and the power supply should only be done by an electrician. The electrical equipment of the control unit has to be checked regularly. Remove loose connections and roasted cables immediately. If it is necessary to work on the control unit, the power plug has to be removed out of the socket before opening it. The control unit has to be kept close constantly. Only authorized personnel with proper tools should have access to the device. 2.5. Alterations of the control unit Do not carry out any changes, conversions or extensions on the control unit without authorization of the manufacturer. All reconstructions had to be authorized in writing through HS-Technik GmbH. Parts which are not in an impeccable state have to be changed immediately but only with original spare parts.! 2.6. Cleaning an waste disposal of the control unit Used materials have to be handled and disposed properly, especially in view of the cleaning with solvents. 2.7. Installation The control unit CLT-500 / RG-500 is only meant for the operation in dry rooms. The device should be installed far from heating and sun light, as a high temperature of the environment could lead to disturbances. 2.8. Power supply The CLT-500 / RG-500 is ready for use after you have plugged in the power connector and actuated the power switch on the back of the device. Now the display should show the type of device.! Use only original spare parts. Please consider the directions regarding voltage, frequency and current on the type plate before connecting the control unit with the power supply. - 6 -
3. Operation of the control unit CLT-500 / RG-500 3.1. Basic concepts 3.1.1. Program push button The CLT-500 / RG-500 is controlled by buttons. Some of them with twin functionality. 3.1.2. Programs (factory settings) The actual parameters will be shown ongoing at the display. 3.1.3. LED Power: NG: Ready: Torque Stop: Working content reached: Lightening green, if the device is switched on. Lightening red, if the tightening is no good. Lightening green, if the device is ready. Lightening yellow, if the tightening is OK. Lightening green, if the device is ready to use or external release is activated and in addition all screws are done. 3.1.4. Funktion of keys in program mode The CLT-500 / RG-500 provides only one single program. The access to the menu is for setting the parameters. Push the menu key = function menu (F 0)! There are different parameters. If these shall be changed, this will be made by a predefined code as following. - 7 -
3.2. Programming CLT-500 / RG-500 3.2.1. Suspend the menu interlock No signal may line up, i.e. torque stop, working content reached, NIO. Step Display 1. push menu button F 0 2. confirm with enter 100 3. one push at negative button (-) 99 input 4. enter F 0 5. enter 100 6. one push at negative button (-) 99 input 7. enter F 0 Choose function with positive (+) or negative (-) button, i.e. F 1 3.2.2. Rotation speed CW Start and final value Rotation speed CW (softstart) Recommended Range F 1 = start value 10% - 50% 10% - 100% F 2 = final value 50% - 100% 10% - 100% F 3 = time (ramp) 0,10s - 1,50s 0,00s - 5,00s 3.2.3. Rotation speed CCW Start and final value Rotation speed CCW Recommended Range Description F 4 = start value 10% - 50% 10% - 100% F 5 = final value 50% - 100% 10% - 100% F 6 = time (ramp) 0,10s - 2,50s 0,00s - 9,95s 0 = no CCW / Initial value ATTENTION! It s not allowed to use the screwdrivers ASA-6500 and ASA-6800 together with the function F 6, F 9 and F 10. (Short-cut on CCW, seriously damaging) F 6 must be 0. - 8 -
3.2.4. Cycle time CW Cycle time CW Recommended Range Description F 7 = min. work time 0,20s - 1,50s 0,02s - 5,00s Within this time no torque signal may appear. F 8 = max. work time 0,25s - 3,00s 0,10s - 9,95s After this time the screwdriver stops working. Minimum time must be shortly. With setting max. 9,97s OFF will be shown on the display and the screwdriver is working till the lever is released. 3.2.5. Cycle time CCW Cycle time CCW Recommended Range Description F 9 = min. work time 0,02s - 0,50s 0,02s - 5,00s Within this time every torque signal will be ignored. F 10 = max. work time 0,10s - 3,00s 0,10s - 9,95s After this time the screwdriver stops working. Minimum time must be shortly. With setting max. 9,97s OFF will be shown on the display and the screwdriver is working till the lever is released. 3.2.6. Number of screws (counter) Schraubenanzahl Recommended Range F 11 = Amount of screws 1-25 1-100 3.2.7. Special functions Special functions Description F 12 = OK / NG judgement on / off F 13 = External release on / off F 14 = Sound (Peeper) on / off F 15 = Automatic / manual mode on / off on = Automatic / off = Manual F 16 = Current limitation 1A - 5A Safety cut-off F 17 = All or ASA all/asa except ASA-4500 / only ASA-4500 F 18 = Testmode (Setting reset with on / off Working time is displayed. Master Reset or switch the If it s more than 10sec. the display unit On/Off ) shows - - -. F 19 = Version 1.09-9 -
3.2.7. Special functions (continuation) Please use the menu key to exit the parameter settings. Now you have finished the programming.! Using ASA-4500 F 17 must be on ASA. Please consider BEFORE working. 3.2.8. Function of keys in the working mode External release With key Minus (-) you can reset the External release. NIO Quit With key Plus (+) you can reset NIO signal. 3.2.9. Output The output socket is meant for the connection with the screwdriver cable. A description of the pins can be found below. Seizure of output 3 Negative pole 4 Status 2 Switch off 5 Ground 1 + Positive pole - 10 -
3.3. PIN definition CLT-500 / RG-500, Port 1 PIN Pin1 Pin14 Pin2 Pin15 Pin3 Pin16 Pin4 Pin17 Pin5 Pin18 Pin6 Pin19 Pin7 Pin20 Pin8 Pin21 Pin9 Pin22 Pin10 Pin23 Pin11 Pin24 Pin12 Pin25 Pin13 Manual mode Start Stop NG Quit External release Master Reset Gnd Gnd Opto Gnd Opto Gnd Output Gnd Output Gnd Output 24V Output 24V 24V 24V Output NG Output work content reached Output Output motor running Automatic Mode Start Stop NG Quit CCW Master Reset Gnd Gnd Opto Gnd Opto Gnd Output Gnd Output Gnd Output 24V Output 24V 24V 24V Output NG Reserve Torque reached signal Output motor running - 11 -
3.3.1. Port 1 (Plug 25-pol) All In-/Out-ports are galvanic isolated. The maximal current of Port 1 is 400mA. The output voltage (active high) is min. 22V with a current load of max. 200mA. The output voltage (active low) is min. 2V with a current load of min. 200μA. U max H I max U max L U min H 24V 11mA 3V 18 V PIN Pin20 + Pin8 Pin7 + Pin19 Function 24V-Output If there is no further external power supply for the I/O-interface this output is able to provide up to 400mA of current. Input-, Output voltage 24V (may connected with PIN 20 or PIN 8) Pin9 Output working content reached (not with automatical mode) Pin10 Pin21 Pin22 Output motor running Output NG Output Torque reached Pin1 Pin2 Pin3 Input Start Input NG Quit Input Master Reset Pin14 Input Stop (static) Pin15 Input External release (comfirmation) Pin5 + Pin17 Pin6 + Pin18 Input Opto Ground Input Ground Pin16 + Pin4 Ground potential for PIN 5 + PIN 17 + PIN 6 + PIN 18 If there is no external power (24V). - 12 -
3.3.2. Port 1 CLT-500 / RG-500 Schematic Diagram - 13 -
4. Speed chart CLT-500 / RG-500 Speed chart CLT-500 together with 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 95% 100% CL-2000NL CL-3000NLX CL-4000NLX CL-6500NLX CL-7000NLX CLS-4000NLX rpm rpm rpm rpm rpm rpm 70 100 100 90 75 170 100 150 150 135 115 225 135 200 200 180 150 340 170 250 250 225 190 425 205 300 300 270 225 510 240 350 350 315 265 595 270 400 400 360 300 680 305 450 450 405 340 765 340 500 500 450 375 850 375 550 550 495 415 935 410 600 600 540 450 1020 440 650 650 585 490 1105 475 700 700 630 525 1190 510 750 750 675 565 1275 545 800 800 720 600 1360 580 850 850 765 640 1445 610 900 900 810 675 1530 645 950 950 855 715 1615 680 1000 1000 900 750 1700 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 95% 100% 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 95% 100% CLS-6500NLX CLS-7000NLX a-4500nlx a-5000nlx a-6500nlx a-6500nlx-ht rpm rpm rpm rpm rpm rpm 140 130 170 100 170 70 210 195 255 150 255 105 280 260 340 200 340 140 350 325 425 250 425 175 420 390 510 300 510 210 490 455 595 350 595 245 560 520 680 400 680 280 630 585 765 450 765 315 700 650 850 500 850 350 770 715 935 550 935 385 840 780 1020 600 1020 420 910 745 1105 650 1105 455 980 910 1190 700 1190 490 1050 975 1275 750 1275 525 1120 1040 1360 800 1360 560 1190 1105 1445 850 1445 595 1260 1170 1530 900 1530 630 1330 1235 1615 950 1615 665 1400 1300 1700 1000 1700 700 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 95% 100% All speed details have a tolerance of approximately ± 5%. After programming the speeds should bechecked allways. - 14 -
10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 95% 100% a-7000nlx-k rpm 120 180 240 300 360 420 480 540 600 660 720 780 840 900 960 1020 1080 1140 1200 Speed chart RG-500 together with HST-A-6500M HST-A-6500S HST-A-6500H HST-A-HT rpm rpm rpm rpm 50 60 70 70 75 100 105 105 100 135 140 140 125 170 175 175 150 205 210 210 175 235 245 245 200 270 280 280 225 305 315 315 250 340 350 350 275 375 385 385 300 410 420 420 325 440 455 455 350 475 490 490 375 510 525 525 400 545 560 560 425 580 595 595 450 615 630 630 475 650 665 665 500 680 700 700 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 95% 100% ASA-4500 ASA-6500 ASA-6800 ASA-8000 ASA-8500 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 95% 100% rpm 70 105 140 175 210 245 280 315 350 385 420 455 490 525 560 595 630 665 700 rpm rpm rpm 85 65 55 130 100 85 170 130 110 215 165 140 255 200 165 300 230 195 340 265 220 385 300 250 425 330 275 470 365 300 510 400 330 555 430 360 595 465 385 640 495 410 680 530 440 725 560 470 765 595 495 810 630 520 850 660 550 rpm 70 105 140 175 210 245 280 315 350 385 420 455 490 525 560 595 630 665 700 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 95% 100% All speed details have a tolerance of approximately ± 5%. After programming the speeds should bechecked allways. ATTENTION! It s not allowed to use the screwdrivers ASA-6500 and ASA-6800 together with the function F 6, F 9 and F 10. (Short-cut on CCW, seriously damaging) F 6 must be 0! - 15 -
4.1. Technical Data CLT-500 / RG-500 Input: 85-260 V AC, 50 / 60 Hz Current consuption: max. 1,4 A, 230 V AC max. 2,8 A,115 V AC Performance giving: max. 200 W Efficiency: > 80% Output: 32 V DC, max. 5 A Fuse: 5 AT Interface: I/0-Port Safety class: I Weight: ca. 2,6 kg Measure (W x H x D): 165 x 115 x 265mm Checked: CE, EN 60204-1 / EN 61000-6-2, EN 60555-2, UL 1950, CSA 234 5. Accessories 5.1. Test- and Signalboxes Testbox for CLT-500 and RG-500 for the examination and testing of the settings Part-Nr. CLT-500-PR Signalbox for CLT-500 and RG-500 completely wired for line operation Part-Nr. CLT-500-SB Signals showing: Start Stop Start CCW Startup delay time Failed acknowledgement Stop CCW External release Master reset 5.2. Connecting cable Signals showing: Master reset ( RED) NG QUIT switch + horn ( RED) Torque reached ( GREEN) External release ( GREEN) Part-Nr. CL65-0660 5-pol. connecting cable for CL-, α-, HST-A-, HST-CL-types 2,0m CL65-0660-45 5-pol. connecting cable for CL-, α-, HST-A-, HST-CL-types 4,5m 2W2022 Connecting cable for ASA-types 2,4m 2W2024 Connecting cable for ASA-types 5,0m - 16 -
Declaration of Conformity We declare under our sole responsibility, that this product is in compliance with the relevant guidelines listed below in accordance with design and construction. If the equipment should be modified without our consent, this explanation gets invalid. The equipment listed below complies with currentls valid EGB / EMV norms. Manufacturer: Company: HS-Technik GmbH Village: Im Martelacker 12 D-79588 Efringen-Kirchen Phone: +49 (0)7628-9111-0 Fax: +49 (0)7628-9111-90 E-Mail: info@hs-technik.com Equipment description: Control unit for all CL-, α-, HST-A-, HST-CL-screwdriver and ASA-screwdriver with Ramp and variable speed setting. Type name: CLT-500 / RG-500 Used EG guidelines: 89/336 EWG changed through 92/31 EWG and Art. 5, 93 / 68 EWG 89/392 EWG changed through 91/368 / EWG, 93 / 44 EWG and Art. 6, 93 / 68 / EWG 73/ 23 EWG HS-Technik GmbH Im Martelacker 12, D-79588 Efringen-Kirchen H.-Martin Hanke Senior Managing Director Date: 25.05.2006-17 -