ASG Process Qualifier User Manual
Contents
1. cai aed nineties atin eis 29 Parameler Select iis Wn DR ERG AIRE SEARS DERE 30 Count Direction New Password Digital Inputs Current Draw View Run Time View Shutoff I LCD Contrast SOFTWARE CYBER QUALIFIER eesororerevenenenenrvrerenensnvnenseresenenensesesesenensnsesesenene 38 39 OPERATIONS GRAPHS SPECIFICATIONS teccncsssiencsscccttncsocensvsnseseescaddeteessccvectesieateatecescesnscetiessvccvedessscsvessevents 45 46 L O S PECIEICA TIONS seere 46 55250 os vene pesa evo oaa Sos Eais 47 48 INDEX C M 49 51 Introduction Thank you for purchasing ASG s TS III Qualifier The following sections describe WARNINGS and CAUTIONS for using our prod uct Make sure to read these sections before using the TS III Quali fier As with any electrical product mishandling the TS III Quali fier could cause damage to the TS III component or cause physical injury to the individual Proper care must be used at all time when operating or servicing the TS III Qualifier In addition to these sec tions carefully read the Set up Procedure and Interface Navigation Guide to ensure proper usage The Interface Navigation Guide is broken down into sections con trols that are accessible while the TS III Qualifier is Locked Advance Operations2. 13 ADVANCED OPERATIONS ERR A E a eee cet a 16 37 ARROWS OCCUR 17 19 20 BATCH CAUTIONS itea A d 5 CHANGE PARAMETER hunnene an ane 15 30 46 CHANGE PASSWORD s ee RA 32 CHECK CLUTCH CLEAR CONFIGURATION CONTRAST WESERTER RT HARE ve etes CONTROL PANED ete strek ASA Bh Te a CONNECTION PROCEDURE CYBER QUALIFIER SOFTWARE 38 39 DEFAULT PASS WORD REPRE 6 16 32 DIGITAL INPUTS i Reve Ee C RR FB ee 18 33 49 INPUTS eio tere INSTALEING THE SOFTWARE 55 er rere D EHE EH e EPOD EE LE Ee ELE e deti dedere INTERFACE NAVIGATION GUIDE INTRODUCTION 1 KEYPAD 8 KEYSWITGH ere perset 9 16 LCD CONTRAST unna 18 37 VA ES oe ttt ttti ttt 9 10 MAX CURRENT p MIN CURRENT Sun ANTEN STRUT Redet NEW PASSWORD vasene Geek virke 18 32 OPERATIONS GRAPHS xe ip YIN HP RON URB AG TIC UG ERE UR 40 44 OPTIONSSOEEWARE 5 rro Ie E PERENNE 38 39 OUTPUT SP CIFICATIONS eere eee YR YR 46 PARAMETER SECT 12 15 18 30 46 PASSWORD 16 18 32 PC INTERFACE 38 39 POWER CORD
3. Completed Batches Count Batch The third display screen shows current parameter set total com pleted batches current count and number of fasteners in a batch p Interface Navigation Guide Home Screen Display Panel The following displays will appear while the unit is in production STATUS CNT BAT View while waiting NONE 0 3 22 to A STATUS CNT VM oh aoe IN CYCLE 0 3 A EE MNT CNT BAT 2 3 ACCEPT Statuses A 2 2 3 3 Acc indicates that previous rundown was successful A successful rundown will increase the count and fire the Accept light Bat Acc indicates the previous Batch has been completed and ac cepted A complete batch will be accompanied by a double beep along with the Batch light illuminating Interface Navigation Guide Home Screen Display Panel The following displays will appear while the unit is in production and an error reject is generated A STATUS CNT BAT REJ TMin 1 3 STU te coe REJ TMax 1 3 er STATUS CNT BAT REJ TClu 1 3 Tmin The tool was unable to run long enough to satisfy the minimum time parameter Tmax The tool passed the maximum time parameter Tclu The tool s clutch did not engage A STATUS CNT BAT REJ IMin 1 3 REJ ECTS will be de scribed by their corre sponding message A STATUS CNT BAT REJ IMax 1 3 IMin tool was unable to draw enough current to satisfy the minimum curr
4. 13 9 POWER UP SEQUENGE SER b SNR WA e Fe e TEUER 11 PROGRAM MENU os SEO ICE EE C rt OEC E dea coxa pee 17 18 QUICK START GUIDE 6 7 50 Index R REAR PANEL 29 REJECT 14 RELAYS CREARI AL bE LOR ATARI GMT 18 29 REQUIREMENTS TERRE EN ERE NURSE VY TER OR ERES YN CRAP 26 RESET BATCH 8 232 mv sek ea as einar dts 9 38 46 RUNTIME Te HERREN CHER VER CUT eR Yun Ce a ds 18 35 5 SET BATCH SET UP PROCEDURE 10 SHUTOFE 18 36 SOFT START UU 9 SOFTWARE SPECIFICATIONS apene n d p OR ERE S ovata SPEED S WITCH ERE START CURRENT NIV i TOOL POWERSUPPLY CONNECTOR esee nennen TROUBLESHOOTING C re Y eO PEEL Pe REI EE 47 48 U V VIEW RUN 18 35 MEW SHUTORP GORGES AKTER 18 36 MASSA UAR 12 W 5 2 2 RE 4 XYZ 51 Copyright of ASG 1 05
5. the new value to non volatile memory and the user will be prompted to Press Any Key At this point any button may be pressed and the unit will return to the Program Menu Press Any Key During the editing process if the ESC but ton is pressed the unit will abort programming the Batch Count and return to the Program Menu 27 mi Interface Navigation Guide Globalize Often when multiple parameter sets are used only one or two variables within the parameter PROGRAM MENU sets needs to vary It s very Globalize common to have everything within multiple parameter sets be identical except for a variation in the batch count If this is the case globalizing a parameter set may help to speed up the programming process When globilization is used a parameter set is copied to all of the other parameters CYCLE BATCH REJECT In order to Globalize all parameters enter PROGRAM MENU the Program Menu and press an arrow key Globalize until the display reads PROGRAM MENU Globalize GLOBALIZE PARAM Press the ENT button in order to select Parameter Y parameter to be globalized After the ENT button is pressed the display will read GLOBALIZE PARAM Parameter Y where Y is the parameter that will be cop ied to all other parameters if selected Using the arrow keys select the parameter set to be copied Once the display shows the appropriate parameter pressing the ENT key will copy that parameter to all
6. Step 5 The unit will prompt the operator B LESS or BRUSH TOOL OFF Press ENT Key Make sure the tool is not running and press the ENT Key The unit will count down 5s thru 1s compensating for any background noise and automatically advances to the next screen Step 6 After the count down is finished the display will prompt the user to run a fastener the display should read ACAL either B LESS or BRUSH TOOL Run Fastener Run the tool on the target fastener al lowing the clutch to turn the tool off After the clutch fires the dis play should read AUTOCAL COMPLETE Press Any Key If a successful run down is not completed the user will not advance to the next screen Another target fastener should be run again allowing the tool clutch to turn the tool off After AUTOCAL COMPLETE Press Any Key is displayed pressing a key will return the operator to the Program Menu Step 7 Any of the Advanced Operations can be adjusted including Timer Bump Batch Count Count Direction etc See pages 16 37 Step 8 When finished editing parameters press the ESC button to lock the unit and return to the Display Run Screen Step 9 Run several fasteners to ensure that the unit is working properly If everything appears to be working production can begin 7 Control Panel Control Panel Most of the buttons required to operate the TS Qualifier are located on the Control Panel Each of the button s functions will be described in
7. When a time limit is programmed into Tbump the In Cycle cur rent is ignored for the duration of the Tbump time Note If the Clutch Signal current rises during Tbump indicating a clutch shut off the tightening cycle will be rejected Cycle Clutch Signal Tbump Tmin Tclutchl Tclutch2 Tmax Current 1 2 3 4 5 6 7 8 9 10 11 Time 42 Operations Graphs Not Approved Tightening Incomplete Cycle No Clutch Signal or Stripped Threads The In Cycle current curve shown in the chart below displays a typical incomplete cycle In this case the In Cycle current lasts long enough to satisfy TMin However the tool s clutch never engages and therefore the inductive current spike never occurs TClutch is violated and the fastener would be rejected In Cycle Clutch Signal Tmin Tmax Current 43 Operations Graphs Not Approved Tightening Double Hit or Cross Thread Attempting to re tighten a fastener that has already been tightened with an electric tool creates a current signature similar to the one below The In Cycle current rises very rapidly and then drops quickly when the clutch shuts the tool off Since the clutch turns the tool off almost instantly the forward current is present only briefly and does not run long enough to s
8. and Unlocked Basic Operations This operation manual is designed for both the BL and CL style TS III Qualifiers Throughout this manual all features are included in both models unless noted otherwise This operation manual is designed for the general operation of the TS III Qualifier If any additional questions or concerns should arise please contact your local ASG representative Please check parts prior to use If anything is missing or damaged contact your local ASG representative Configuration TS III Qualifier One Piece Power Cord One Piece Warning Make sure to read this section If these instructions are ignored and the product is handled inappro priately serious injury could occur Whenever disassembling the unit make sure power has been turned off and the power cord is removed from the outlet There is a high electrical voltage inside the unit that could cause an electric shock failure or fire If you have not worked on or are not familiar with electri cal components having a transformer and printed circuit boards we suggest that you return the TS III Qualifier di rectly to ASG for service modification or changeover If an abnormal odor unusual sound or smoke is observed stop using the product unplug it immediately and contact your ASG representative Do not allow any type of liquid to come in contact with any part of the unit because it could result in an electrical shock or fire Fully
9. Count Direction and return to the Program Menu 31 Interface Navigation Guide New Password In order to enter the program ming mode either the key switch was used or a password PROGRAM MENU was entered The default pass New Password word of 0104 can be overwritten and set to any four digit number In order to change the password enter PROGRAM MENU the Program Menu and press an arrow New Password key until the display reads PROGRAM MENU New Password PROGRAM PASSWORD Press the ENT button in order to edit Q password After ENT button is pressed display will read PROGRAM PASSWORD 0 CYCLE BATCH REJECT The left and right arrow keys can be used to select any of the four dig its in the password Once the desired digit is high lighted the up and down arrow keys will allow the user to change that digit Only the digit being edited will be visible The other digits will be obscured and an asterisks will appear as a place holder PROGRAM PASSWORD Once the desired password has been xx entered pressing ENT will save the Writing settings to non volatile memory and the user will be prompted to Press Any Key At this point any button may be pressed and the unit will return PROGRAM PASSWORD to the Program Menu Press Any Key During the editing process if the ESC button is pressed the unit will abort programming a New Password and return to the Program Menu 32
10. MENU EI page 31 for Count Direction more EI PROGRAM MENU See page 32 for New Password more information PROGRAM MENU See page 33 for Di gital Inputs more information PROGRAM MENU See page 34 for Current Draw more information 51 MENU See page 35 for 51 Run Time more information PROGRAM MENU SEN page 36 for View Shutoff I more SEN PROGRAM MENU FEM page 37 for LCD Contrast more SN 18 Interface Navigation Guide AutoCal Procedure The AutoCal is the first option in the Program Menu and is used to quickly set up specific parameters PROGRAM MENU including Timer Min Timer Max AutoCal and Start Current The user runs a sample fastener and allows the TS III Qualifier to review the rundown and automatically set the parameter based on that sample fastener The following steps will walk the operator through the calibration process In order to perform an AutoCal enter the PROGRAM MENU Program Menu and press an arrow key AutoCal until the display reads PROGRAM MENU AutoCal Press the ENT button to perform an AutoCal B LESS TOOL OFF When the screen reads either B LESS or Press ENT Key BRUSH TOOL OFF Press ENT Key the driver must not be running The op erator should not turn OFF the main power switch or disconnect power to the driver Pressing the ENT key is your confirmation that to tool is not running ACAL BACKGROUND After the ENT button is pressed the dis Time YsI X X play will read AC
11. PLETE Writing Once the variables are stored the display will read AUTOCAL COMPLETE Press Any Key Pressing a key at this point AUTOCAL COMPLETE will return the unit to the Programming Press Any Key Menu The ESC key can be pressed at any time during this process to abort the ACAL setup and return to the Program Menu without changing the parameter data While this data is being stored the dis hr Interface Navigation Guide Timer Min Timer Min defines the minimum amount of time a tool has to run during a fastening process in or PROGRAM MENU der to be considered a good fas Tuner Min tening If a fastening process is shorter than Timer Min a Tmin reject will be issued ROGRAM MENU In order to edit this value enter the Program Timer Min Menu and press an arrow key until the dis play reads PROGRAM MENU Timer Min CYCLE BATCH REJECT PROGRAM Tmin P Y Press the apenas in to edit the Timer XX XXX minimum run timer s value After the ENT button is pressed the display will read PROGRAM Tmin P Y Timer XX XXX where Y is the current parameter and XX XXX is the current timer s value Using the left and right arrow keys move the flashing cursor over the digit in the timer value that needs edited Once the appropriate digit is highlighted press the up and down arrows to change the digit s value Proceed in this manner until all of the desired digits are edited TIMER MIN SAVED Once the
12. insert all plugs into their proper receptacle Insuffi cient contact may generate heat that could result in a fire or electrical shock Do not fold bend or impose excessive force on the cord Excessive force on the cord may cause a short circuit which could result in a fire or electrical shock While inserting or removing the plugs don t pull on the cords This action could result in a disconnection or a broken plug Make sure to hold the plug body during insertion and removal Cautions If these instructions are ignored and product is handled inappro priately bodily injury or property damage could occur Ho di This unit accepts an AC input voltage from 100VAC to 240V AC Trying to operate this unit with a voltage outside that range may cause damage to the unit Do not place the product in an unstable location Dropping the unit could result in damage to the TS III Qualifier Do not place or store the unit in a location with moisture or dust to prevent possible fire or failure When moving the TS III Qualifier make sure to turn OFF the power and remove the power plugs Before maintenance make sure to turn OFF the power and remove the power plugs There are no user serviceable parts inside the main enclosure of the TS III Qualifier As with any printed circuit boards proper care and knowledge is critical if a customer attempts to service the TS III unit Damage occurring to the electrical components by
13. shows the appropriate 225 timer value pressing the ENT button will Writing store the new value to non volatile mem ory and user will be prompted to Press Any Key At this point any button may be pressed and the unit will TIMER BUMP SAVED I return to the Program Menu Press Any Key During the editing process if the ESC button is pressed the unit will abort programming the Timer Bump and return to the Program Menu 23 is Interface Navigation Guide Start Current Start Current defines the amount of current that needs to be drawn by a brushless tool be PROGRAM MENU fore the unit is considered to be Start Current in cycle Once the tool starts drawing this amount of current the run timers will start CYCLE BATCH REJECT Note The Start Current value is only used with brushless tools PROGRAM MENU 15 order to edit this value enter the Pro Start Current gram Menu and press an arrow key until the display reads PROGRAM MENU Start Current STRT CURRENT P Y TRIP X XX A Press the ENT button in order to edit the start current 5 value After the ENT button is pressed the display will read STRT CUR RENT P Y TRIP X XX A where Y is the current parameter and X XX is the amperage value Use the left or down arrow key to lower this value The right or up arrow keys will raise the value Proceed in this manner until the ap propriate current is displayed Once the display shows
14. the appropriate amperage value pressing the ENT button will store the new value to non volatile memory and the user will be prompted to Press Any Key At this point any button THRESHOLD SAVED be pressed and the unit will return to Press Any Key the Program Menu THRESHOLD SAVED Writing During the editing process if the ESC button is pressed the unit will abort programming the Start Current and return to the Program Menu 24 Interface Navigation Guide Min Current The Min Current defines the minimum amount of current that needs to be drawn by a brushless PROGRAM MENU tool when the tools clutch en Mee gages This threshold can be used as secondary check for the tool s clutch setting Note Min Current value is only used with brushless tools CYCLE BATCH REJECT In order to edit this value enter the Program PROGRAM MENU Menu and press an arrow key until the dis Min Current play reads PROGRAM MENU Shut Off Current MIN CRNT Press ENT button in order to edit the TRIP X XX A Min Current s value After the ENT button is pressed the display will read MIN CRNT P Y TRIP where Y is the current parameter and X XX is the amperage value Use the left or down arrow key to lower this value The right or up arrow key will raise the value Proceed in this manner until the appro priate current is displayed Once the display shows the appropriate amperag
15. under the new parameter that is selected 15 m Interface Navigation Guide Advanced Operations The features listed in the Advanced Operation section of this man ual are only accessible while the unit is unlocked The operator must unlock the unit through one of the two following methods Password Default 0104 Press the ENT key to access the Program Menu After pressing the ENT button the operator will be ENTER PASSWORD prompted to Enter a Password to 0 gain access to Program Menu and the advanced operations CYCLE BATCH REJECT Using the left and right arrow keys move the flashing cursor over the asterisk in the password that needs changed Once the cursor is over the appropriate asterisk the current number in that position will be viewed Adjust the digit to the proper password with the up and down arrows Proceed in this manner until all of the desired digits are edited The de fault password that ships with all unit is 0104 After all of the proper digits have been inserted press the ENT key to gain access to the Program Menu The unit can be locked again by pressing the ESC key Keyswitch Keyswitch Press the ENT key to access the Le Program Menu After pressing the M ENT button the operator will be prompted to Enter a Password to EH gain access to the Program Menu and the advanced operations Insert the key into the key hole located in the rear of the unit
16. volatile memory and the user will be prompted to Press Any Key At RLY BEEPER SAVED this point any button may be pressed and Press Any Key the unit will return to the Program Menu During the editing process if the ESC button is pressed the unit will abort programming the Relay amp Beeper and return to the Program Menu 29 NE Interface Navigation Guide Parameter Select This unit can be programmed to change parameter either through the keypad or remotely through PROGRAM MENU the I O Parameter Select PROGRAM MENU In order to edit this function enter the Program Menu and press an arrow ke Parameter Select 8 y until the display reads PROGRAM MENU Parameter Select PARAMETER SELECT Remote Press the ENT button order to edit Parameter Select CYCLE BATCH REJECT After the ENT button is pressed the display will read PARAMETER SELECT Keypad or Remote I O Using the arrow keys set the desired parameter select either Keypad or Remote I O The Keypad option will allow the operator to change the parameter with the left and right arrow keys from the home screen while the unit is in the locked position See page 15 for more infor mation on the Keypad The Remote I O option will allow the parame ter to be switched only through the I O See page 45 46 for more information on the Remote I O Parameter Select display shows the appropriate set Writin ting pressing ENT w
17. AL BACKGROUND Time Ys I where Y is a count down is seconds 5s 4s 3s 2s 1s and is the background noise that is being compensated After all background noise is eliminated the operator will be automati cally advanced to the next screen Continued on the next page 19 Interface Navigation Guide Auto Calibration Continued Following the unit elimination of background noise the TS III Qualifier will automatically ACAL B LESS TOOL advance to the next screen and Run Fastener should display ACAL either BRUSH or B LESS TOOL Run Fastener Be sure that the right type of tool is being used with the unit before proceeding CYCLE BATCH REJECT The operator will need to rundown the target fastener The target fastener must match all of the required specifications because all of the parameter will be based off of the most recent rundown i e the target fasteners Once the unit witnesses the clutch stopping all of the timers and threshold will automatically be calculated and stored to non volatile memory for the parameter set that the unit was in at the beginning of the process Automatically following a successful rundown the profile from the previous sample rundown is loaded The profile from this sample fastener creates the Timer Min Timer Max Start Current and inserts the default into all of the other remaining parameters play will read AUTOCAL COM AUTOCAL COMPLETE Writing
18. C The tool s speed is directly propor tional to output voltage Refer to the ASG catalog for tool speeds Rear Panel Keyswitch Beeper RS 232 Connect AC Input and Main Power Switch The main power switch for the unit and the power entry module are found on the rear panel This unit is capable of running on an AC input voltage of 100V AC to 240VAC The keyswitch allows a user to reach the programmable functions without entering a password The unit s beeper provides audible feedback when rejects occur and can provide a double when a batch accept occurs See page 29 The RS 232 port can be used as a secondary means of programming the unit or getting information from the unit See page 45 48 The 12 Pin I O Connector contains several input and output func tions See page 46 for more details 9 Connection Procedure Connection Procedure The following are general guidelines for connecting the TS III Qualifier Specific programming instructions are described in the Interface Navigation Guide See pages 11 37 1 Plug tools power cord into the rear of the electric screwdriver and then the front of the TS III Qualifier 2 Plugthe AC cord into the rear of the TS III Qualifier and then into the wall Verify that all connections are secure Flip the Qualifier s main power switch to the ON position The unit should begin th
19. ES Interface Navigation Guide Digital Inputs The Digital Inputs menu option is a trouble shooting mode If this item is selected the signals PROGRAM MENU that the tool is sending the TS Digital Inputs can be monitored In order to view these signals enter the PROGRAM MENU Program Menu and press an arrow key until Digital Inputs the display reads PROGRAM MENU Digi tal Inputs DIGITAL INPUTS Press the ENT button in order to monitor the RUN OFF BRK OFF tool s digital signals Once in this mode the left side of the display will show the state of the tool s In Cycle run That side of the display will either read RUN ON or RUN OFF In a brush tool this signal should be off until the run switch is activated either though a lever or push to start In a brushless tool the left side of the display will always read RUN ON because most brushless tools constantly issue a run request even if the tool s run switch is off The right side of the display show s the state of the tool s clutch sig nal This message will read BRK OFF most of the time When a tool clutch engages either brush or brushless this message will briefly read BRK ON If the ESC button is pressed the unit will return to the Program Menu 33 NE Interface Navigation Guide Current Draw The Current Draw menu option is a trouble shooting mode PROGRAM MENU This mode can be particularly Current Draw handy when deciding how to program the Start C
20. II s timer will not start until load is applied this re sults in a more consistent timer reducing the potential of free run errors Timer Min Timer Min defines the minimum amount of time a tool has to run during a fastening cycle to be considered a good fastening See page 21 for more information Timer Max Timer Max defines the maximum amount of time a tool can run during a fastening cycle to be considered a good fastening See page 22 for more information Accept Range The peak current must occur within this Accept Range between the Min and Max Current for a successful fastening cycle Min Current The Min Current defines the minimum amount of current that needs to be drawn by a brushless tool when the tool clutches out See page 25 for more information Max Current The Max Current defines the maximum amount of current that can be drawn by a brushless tool when the tool clutches out See page 26 for more information 41 Operations Graphs Approved Tightening Using Timer Bump In graph below represents the use of Timer Bump The Tbump is essential when a screw presenter is combined with the TS III Qualifier The graph shows how using the Tbump function during an assembly process will not affect a properly assembled screw However when a screw is picked up from the presenter typically the driver is quickly run to locate the screw on the bit If the Tbump function is not turned on then a reject will be generated
21. IN SAVED Once the display shows the appropriate Writing timer value pressing the ENT button will store the new value to non volatile memory and the user will be prompted to Press Any TIMER MIN SAVED Key At this point any button may be Press Any Key pressed and the unit will return to the Pro gram Menu During the editing process if the ESC button is pressed the unit will abort programming the Timer Max and return to the Program Menu 22 pi Interface Navigation Guide Timer Bump Timer Bump defines an amount of time that tool can run and that run will be ignored if the PROGRAM MENU clutch does not fire i e torque is Timer Bump not achieved This timer may be used to eliminate nuisance rejects PROGRAM MENU order to edit this value enter the Pro gram Menu and press an arrow key until the display reads PROGRAM MENU Timer Bump PROGRAM Tbmp P Y Press the ENT button in order to edit the Timer XX XXX bump timer s value After the ENT button is pressed the display will read PROGRAM Tbmp P Y Timer 2 XX XXX where Y is the current parameter and XX XXX 15 the current timer s value Using the left and right arrow keys move the flashing cursor over the digit in the timer value that needs edited Once the appropriate digit is highlighted press the up and down arrows to change the digit s value Proceed in this manner until all of the desired digits are edited TIMER BUMP SAVED Once the display
22. TS III Qualifier Operation Manual TM Products for Assembly ASG Division of Jergens Inc Jergens Way 15700 S Waterloo Road Cleveland OH 44110 3898 Tel 216 486 6163 Toll Free 888 486 6163 Fax 216 481 4519 E mail asginfo asg jergens com WWW asg jergens com Table of Contents INTRODUCTION CONFIGURATION rre CHEAP ERRx A A ERE ORR X X ERO x ALL ERA PER Ren 3 WARNINGS amp 00 4 5 QUICK START 6 7 CONTROL PANEL 8 9 CONNECTION PROCEDURE rreseresevevsvnensnsnsrenesesssnensnenenenenvensnensnsnensnenvnvsvensnenensnsneneee 10 INTERFACE NAVIGATION GUIDE POWER UP SEQUENCE 11 HOME SCREEN 12 14 BASIC OPERATIONS 2 15 Reset Batch 15 ADVANCED OPERATIONS 16 37 Password KEYS WU oi essetis bao cd pU ON CHR de e ARR REP US Apres Eden Ae 16 Program Menu 17 18 5555 0 08191 56 061696060660 156 60966 8665 680646600586 19 20 Timer METH ep M ND HE UD MU ND RU UNA EMO Mq 21 WU ISDN PII 22 Timer M 23 Start Current 24 LIBRE dU 25 Mere oeste p RE pd MEME DUM es 26 Batch COUN 27 Globalize
23. ailable The computer will also need to have the display set to at least an 800 x 600 resolution A high color set ting is recommended 16 bits or better A free comm port is necessary in order to communicate with a Qualifier Complications can arise if another program is attempting to use the comm port while the Cyber Qualifier software is running In order to use the Cyber Qualifier software a modular phone cable RJ11 wired straight through and an RJ11 to DB9 converter must be used Installing the Software To install the software on a computer with a Windows operating system run the SETUP EXE program on the Cyber Qualifier CD The setup program will lead the installer through the installation Depending on which version of Windows is being used the machine may need to be restarted once during the installation and the installa tion process re initiated Make sure that no other software is run ning on the target machine during the installation process Running the Software After the program is installed a new entry will be found under the Window s Start Menu To start the program Cyber press the Window s Start Button On the menu that ap pears choose Programs and then click on CyberQ Alternately the user can find and then double click on the CyberQ icon This will also start the application 38 E PC Interface Editing Parameter Sets From the main form selecting Edit Parameter on the mode changin
24. and turn it to the horizontal position If the keyswitch remains in the horizontal position the Program Menu can be accessed even if the key is removed The unit can be locked again by turning the key to the vertical position and pressing the ESC key 16 ls Interface Navigation Guide Advanced Operations The following features are available only while the unit is unlocked Program Menu The following is a listing of all options located in the ENT Programming Menu While in the Program Menu Arrows ALL advances operator to the next or previ ous option in the menu ENT select the displayed option ESC exit the menu PROGRAM MENU See page 19 20 for AutoCal more information PROGRAM MENU See page 21 for Timer Min more information PROGRAM MENU See page 22 for Timer Max more information PROGRAM MENU See page 23 for Bump more information PROGRAM MENU See page 24 for Start Current more information PROGRAM MENU See page 25 for Min Current more information PROGRAM MENU See page 26 for Max Current more information Continued on the next page 17 Interface Navigation Guide ogram Select Continued From Previous Page PROGRAM MENU See page 27 for Batch Count information PROGRAM MENU See page 28 for Globalize information PROGRAM MENU mcum page 29 for Relay amp Be ep more Ke gt PROGRAM MENU page 30 for Parameter Select PROGRAM
25. atisfy TMin h Cycle Clutch Signal 1 Tclutch2 Tmin Current Time 44 Specifications Input Specifications Input Voltage Range Input Current Frequency Power Factor Output Specifications Output Voltage Low Output Voltage High Output Power Minimum Load Output Tolerance Ripple Noise Overload Protection Setup Rise Holdup 230V AC General Specifications Input Output Isolation Efficiency Switching Frequency MTBF 85 264 VAC 2 2A 115VAC 1 1A 230VAC 47 440 7 gt 0 96 230V gt 0 98 115V 20VDC 30VDC 150 Watts 290 150mVp p typical 105415096 Constant Current Limit Auto Recovery 600ms 30ms 20ms I P O P 3000V AC I P G 1500VAC O P 0 5KVAC 8096 typical 135Khz fixed typical 191 800 Hrs 21 9 years 45 Specifications Schematic Input Specifications Inputs Optically Isolated Remote Start Short Pin 1 to Pin 2 to use Reset Ground Pin 3 amp Apply 24VDC to Pin 4 Momentary Parameter Inputs Ground Pin 3 amp Apply 24VDC to Pins 5 and or 6 and or 7 Maintained Binary Parameter Selection Parameter Parameter 2 IN Parameter 1 IN Parameter 0 IN A OVDC OVDC OVDC B OVDC OVDC 24VDC C OVDC 24VDC OVDC D OVDC 24VDC 24VDC E 24VDC OVDC OVDC F 24VDC OVDC 24VDC G 24VDC 24VDC 24VDC H 24VDC 24VDC 24VDC Specifications Relay S
26. button Writing will store the new value to non volatile memory and the user will be prompted to Press Any Key At this point any button may be pressed and the THRESHOLD SAVED unit will return to the Program Menu Press Any Key During the editing process if the ESC button is pressed the unit will abort programming the Max Current and return to the Program Menu 26 Interface Navigation Guide Batch Count The Batch Count is typically programmed to be the number of fasteners in a given assembly A PROGRAM MENU Cycle Accept signal will be gen Batch Count erated each time a proper fasten ing occurs A Batch Accept however will occur when the CYCLE BATCH REJECT count reaches the batch value In order to edit this value enter the Program PROGRAM MENU Menu and press an arrow key until the dis Batch Count play reads PROGRAM MENU Batch Batch Count P Y Press the ENT button in order to edit the Batch 2 XXX batch count s value After the ENT button is pressed the display will read BATCH COUNT Batch XXX where Y is the current parameter and XXX 1s the number of fasteners in a batch Use the up or down arrow key to raise or lower the batch value by 1 The left and right arrow keys will raise or lower the value by 10 Pro ceed in this manner until the appropriate batch value is displayed BATCH SAVED Once the display shows the appropriate due batch pressing the ENT button will store Writing
27. detail later in this operation manual The CYCLE The BATCH illuminates after The REJECT illuminates the final fastener is properly illuminates after a single inserted in the group after a single fastener is fastener is properly improperly inserted inserted CYCLE BATCH REJECT A Lo Le D Hed The four arrow buttons UP DOWN LEFT and RIGHT are used during programming The arrow keys are used to navigate through menus raise and lower values during program ming and move the cursor to select items that need to be edited The ENT button has a wide variety of functions including saving parameters selecting an items changing screens and continuing through different operations The ESC button also has an assortment of functions includ ing exiting screens without saving and canceling operations E G Wald Control Panel Front Panel Soft Start Speed The five pin circular connector is used Q Q I to supply power to a tool and also to tool 10 read signals back from tool un The Soft Start switch turns the Soft eese e Start feature ON and OFF If the Soft Output 30 20 VDC Start feature is enabled the tool will spin slowly for a revolution or two before increasing to full speed Note Can only be enabled with brush tools Tool speed is governed by the Speed switch When this switch is in the HI setting the VDC out will 30VDC On the LO setting the power supply provides 20VD
28. display shows the appropriate timer value pressing the ENT button will store the new value to non volatile memory and the user will be prompted to Press Any Key Atthis point any button may be TIMER MIN SAVED pressed and the unit will return to the Pro Press Any Key gram Menu During the editing process if the ESC button is pressed the unit will abort programming the Timer Min and return to the Program Menu Writing 21 hr Interface Navigation Guide Timer Max Timer Max defines the maxi mum amount of time a tool can run during a fastening process PROGRAM MENU and still be considered a good Timer Max fastening If a fastening takes longer than Timer Max a Tmax reject will be issued PROGRAM MENU In order to edit this value enter the Program Timer Max Menu and press an arrow key until the dis play reads PROGRAM MENU Timer Max PROGRAM Tmax P Y Press the ENT button in order to edit the Timer XX XXX maximum run timer s value After the ENT button is pressed the display will read PROGRAM Tmax P Y Timer XX XXX where Y is the current parameter and XX XXX is the current timer s value CYCLE BATCH REJECT Using the left and right arrow keys move the flashing cursor over the digit in the timer value that needs edited Once the appropriate digit is highlighted press the up and down arrows to change digit s value Proceed in this manner until all of the desired digits are edited TIMER M
29. e Power Up Sequence See page 11 OX onc NG When the TS III Qualifier brings up the Home Screen See page 12 14 it is ready for programming Interface Navigation Guide Power Up Sequence amp Home Screen When the unit is powered up the LCD will display the following screens and then proceed to the Home Screen Monitored Power Supply Tool Type s BRUSHLESS Redon S e Screen so you know how your OR Tool Type qualifier is con BRUSH figured The firmware 2 version installed Firmware Version in your TS III 1 5 Qualifier is dis played at this point in the Power Up Se quence ASG Copyright 2004 This is your A STATUS CNT BAT virke cispiayea NONE 2 3 during normal operation Interface Navigation Guide Home Screen Display Panel There are three screens associated with the home screen display panel Pressing either the UP or DOWN arrow keys will allow the user to change the view on the LCD screen Current Parameter Set STATUS CNT BAT CYCLE OK 1 3 Status Count Batch The first of these screens shows the current parameter set status of the last fastening current count and the number of fasteners in the batch Current Parameter Set A STATUS TOTAL CYCLE OK 30212 Status Completed Batches The second display screen shows current parameter set status of last fastener and total completed batches Current Parameter Set A TOTAL CNT BAT 30212 1 3
30. e value pressing the ENT button will store the new value to non volatile memory and the user will be prompted to Press Any Key At this point any button may be pressed and the unit will return to the Program Menu THRESHOLD SAVED Writing THRESHOLD SAVED Press Any Key button is pressed the unit will abort programming the Min Current and return to the Program Menu During the editing process if the ESC 25 ER Interface Navigation Guide Max Current The Max Current defines the maximum amount of current that can be drawn by a brushless tool PROGRAM MENU when the tool clutches out This Max Current threshold can be used as a secon dary check for the tool s clutch setting Note The Max Current value is only used with brushless tools PROGRAM MENU In order to edit this value enter the Program Max t Menu and press an arrow key until the dis ME play reads PROGRAM MENU Max Cur rent MAX CURRENT P Y Press the ENT button in order to edit the TRIP XX XX max 5 value After the ENT button is pressed the display will read MAX CUR RENT P Y TRIP XX XX A where Y is the current parameter and XX XX is the amperage value Use the left or down arrow key to lower this value The right or up arrow key will raise the value Proceed in this manner until the appro priate current is displayed Once the display shows the appropriate THRESHOLD SAVED amperage value pressing the ENT
31. ed in the Program ming Menu See Page 34 for more information 47 Troubleshooting Troubleshooting Q I changed from HI Speed to LO Speed and now I keep getting rejects A The TS III Qualifier monitors current over a period of time to verify a good cycle When the speed of the tool is changed the re sult is that the insertion of the fastener will take more or less time The fastener characteristics associated with the new speed setting will not match up with the characteristics used to establish the pa rameters with the previous speed setting Whenever the speed set ting is adjusted another AutoCal should be performed with the new speed setting selected This will ensure the proper times are estab lished for a good cycle Q I turned ON my Slow Start and now I keep getting rejects A The TS III Qualifier monitors current over a period of time to verify a good cycle When the Slow Start is enable the start of the tool is changed and the result is that the insertion of the fastener will take more time The fastener characteristics associated with the Slow Start setting will not match up with the characteristics used to establish the parameters with the previous setting Whenever the Slow Start setting is enabled another AutoCal should be performed with the new Slow Start turned ON This will ensure the proper times are established for a good cycle 48 p Index A AC INPUTA kst 9
32. ent parameter when the clutch engaged IMax The tool passed the maximum current parameter when the clutch engaged Note Brushless tools only m Interface Navigation Guide Basic Operations The following features are only active while the TS III Qualifier is in the locked position Reset Batch The Reset Batch will clear the value in the count resetting it to zero A STATUS CNT BAT In order to reset the batch the opera NONE tor must be On the Home Screen Press the ESC button in order to reset RESET BATCH the batch count ENDS EN After the ESC button is pressed the display will read RESET BATCH ENT YES ESC NO Use the ENT button to confirm the batch clear and the ESC button to cancel this operation After either button is pressed the operator will automatically return to the Home Screen Change Parameter The Parameter can be changed through the Keypad or Remotely through the I O This section only describes changing the parameter with the Keypad Note This function must be enabled in the Pro gram Menu see page 30 for changing the Parameter Select Keypad or Remote I O A STATUS CNT In order to change the parameter the operator must be on the Home Screen NONE 0 3 Pressing either the left or right arrow STATUS CNT BAT key the operator will scroll through the NONE 0 3 eight different parameter options After changing the parameter the operator will be immediately ready to run
33. g drop down and then pressing the Change Mode button will take the software to the Edit Parameter form Using this form parameters can be downloaded from the TS III Qualifier edited and then uploaded to the unit In order to download the current parameter settings from the TS III Qualifier select the appropriate comm port and then press the Re trieve Settings button The software will initiate communications with the Qualifier retrieving the current parameter settings once communications are established and then update the form with the parameter settings Once the settings are retrieved the user can choose to edit any of these settings by selecting the desired cell and then chang ing the value in the cell After all of the desired settings are altered the user can then choose to upload those new settings to the TS III Qualifier Once again the user should be certain that the appropriate comm port is selected Then pressing Program New Settings will initiate a trans fer from the Cyber Qualifier software to the TS III Qualifier The TS III Qualifier will accept the new settings into its parameter sets A button with the picture of a printer also appears on this form Pressing that button will send a copy of the current parameter sets to the Window s system printer Pressing the Return To Monitor Mode button will send the software back to the Monitor Mode form Pressing the X button in the upper right hand corner of this fo
34. ill save the settings to non volatile memory and user will be prompted to Press Any Key At this point DIRECTION any button may be pressed and unit will Press Any Key return to the Program Menu During the editing process if the ESC button is pressed the unit will abort programming the Parameter Select and return to the Program Menu 30 Interface Navigation Guide Count Direction This unit can be programmed to count up from zero until the batch is reached or count down PROGRAM MENU to zero Count Direction CYCLE BATCH REJECT In order to edit this function enter the Pro PROGRAM MENU gram Menu and press an arrow key until the Count Direction display reads PROGRAM MENU Count Direction COUNT DIRECTION Press the ENT button in order to edit the Count XXX Count Direction After the ENT button is pressed the display will read COUNT DI RECTION Count XXX where XXX is either UP or DOWN Using the arrow keys set the desired count direction either up or down COUNT DIRECTION Once the display shows the appropriate set Writing ting pressing ENT will save the settings to non volatile memory and the user will be prompted to Press Any Key At this point DIRECTION SAVEDI 9 button may be pressed and the unit will return to the Program Menu Press Any Key During the editing process if the ESC button is pressed the unit will abort programming the
35. ing what values should be used for the minimum and maximum run times If the ESC button is pressed the unit will return to the Program Menu 35 i Interface Navigation Guide View Shutoff I Another trouble shooting mode programming aid is the View Shutoff I mode PROGRAM MENU View Shutoff I This mode can be particularly handy when deciding how to program the Min Current and Current for a brushless tool CYCLE BATCH REJECT If this item is selected the TS will act like a current meter showing the user the current level when the tool shuts off or the clutch en gaged Note The View Shutoff I Current value is only used with brushless tools PROGRAM MENU In order to view this value enter the Pro View Shutoff I gram Menu and press an arrow key until the display reads PROGRAM MENU View Shutoff I SHUT OFF CURRENT Press the ENT button in order to monitor the tool s current use Once in this mode the bottom line of the LCD will display the current level in amperage when the tools clutch engaged This value will be updated automatically each time the tool runs This information can be very useful in determining what values should be used for the Min Current and Max Current If the ESC button is pressed the unit will return to the Program Menu 36 in Interface Navigation Guide LCD Contrast The LCD display can be adjusted so that the text 1s darker or lighter by acce
36. of the other pa rameters and the user will be prompted to Press Any Key At this point any button may be pressed and the GLOBALIZE SAVED ynit will return to the Program Menu Press Any Key GLOBALIZE PARAM Writing During the editing process if the ESC button is pressed the unit will abort programming the Globilization and return to the Program Menu 28 p Interface Navigation Guide Relay amp Beep The output relays in this system can be programmed to be either momentary or latching If the PROGRAM MENU relays are momentary they will close briefly 200ms when and event occurs When set to latch ing the relay closes and remains that way until the tool starts running again CYCLE BATCH REJECT The beeper in this system can be programmed to double beep when a batch accept occurs PROGRAM MENU 15 order to edit these items enter Pro Relay amp Beep gram Menu and press an arrow key until the display reads PROGRAM MENU Relay amp Beep RELAY BEEPER Press the ENT button in order to edit relay RLY XXX BEEP YYY or beeper settings After the ENT button is pressed the display will read PGM RELAY BEEPER RLY XXX BEEP YYY where XXX is either MOM for momentary or LAT for latching and YYY is either ON or OFF Using the arrow keys set the desired relay and beeper setting RLY BEEPER SAVED Once the display shows the appropriate settings pressing ENT will save the set tings to non
37. pecification 2A Max Current 220VDC Max Switching Voltage 60W Max Switching Power Remote Start Remote Start Opto Input Common Reset Input Parameter 2 Input Parameter 1 Input Parameter 0 Input 2A Relay Reject Relay Out Batch Relay Out OUTPUTS 4 Cycle Relay Out Run Relay Out Relay Common 2A Relay 2A Relay 2A Relay Troubleshooting Troubleshooting Q When trying to AutoCal I see the following screen what does this mean CYCLE BATCH REJECT AUTOCAL Check Clutch A If Check Clutch appear while performing an AutoCal there are two possible symptoms One a Brush type tool could be connected to the TS III Qualifier which is designed for a Brushless tool or the Brushless tool has not been modified for use with the TS III Quali fier If the Brushless Driver has not been modified for the Qualifier please call ASG Customer Service 888 486 6163 to send your tool in for the modification to be performed Q When the tools runs in free air the unit continuous signals reject and the alarm sounds A The Start Current might be set at the same amperage level that the tool draws while running under no load free in the air The Start Current should be adjusted either slightly above the no load free speed of the tool or slightly below To establish the no load free speed use the Current Draw option locat
38. rm will end the program 39 Operations Graphs Note of the Operations Graphs are for Brush Style Electric Tools except where it is noted Brushless tools chart would be similar but not the same as Brush tools Please call ASG Customer Service if there are any questions 888 486 6163 Approved Tightening The following graph demonstrates a tightening cycle that would be accepted by the TS III Qualifier The In Cycle current level rises and runs for a time greater than the minimum timer Tmin and less then the maximum timer Tmax When the clutch shuts off the In Cycle current rapidly drops off and the Clutch Signal current increases The Clutch Signal represents the inductive cur rent spike that rises when the clutch shuts off the tool the clutch shut off must occur after Tclutch 1 and before Tclutch 2 h Cycle Clutch Signal Tclutch1 Tclutch2 Tmax Current 40 Operations Graphs Brushless Approved Tightening Overview 06 o oo 9 In Cycle Clutch Signal Start Current This is the Start Timer when the running current cross this threshold the TS III s timer starts See page 24 for more information Timer Bump This is the Timer Bump designed to ignore the first X amount of time in a fastening cycle See page 23 for more information Start Point The TS I
39. ssing the LCD PROGRAM MENU Contrast feature LCD Contrast In this mode the display will show a value that represents a contrast setting for the display As that value is altered the user can see what effect it has on the view ability of the display In order to view this value enter the Pro PROGRAM MENU gram Menu and press an arrow key until the LCD Contrast display reads PROGRAM MENU LCD Contrast LCD CONTRAST Press the ENT button in order to adjust the Contrast 2 XX display s contrast Once in this mode the bottom line of the LCD will display the Con trast XX where XX is a number that represents the current setting Using an arrow key the contrast value can be adjusted CONTRAST SAVED Once the display s contrast suits the user Writing that new contrast can be saved to non volatile memory by pressing the ENT key CONTRAST SAVED During the editing process if the ESC but Press Ane Ke ton is pressed the unit will abort program y ming the Timer Min and return to the Pro gram Menu CYCLE BATCH REJECT 37 PC Interface Introduction The Cyber Qualifier software is not included with your purchase however it can be used to adjust your Parameter Sets Requirements The Cyber Qualifier software needs to run on a computer that is running Windows 9X Windows NT Windows ME Windows 2000 or Windows XP The computer should have at least 32 MB of RAM memory and have 5MB of hard disk space av
40. the cus tomer attempting to service the unit voids all warranties and all work performed is the sole responsibility of the customer Quick Start Guide Warning Make sure to review the WARNINGS and CAUTIONS sections located on pages 4 and 5 before using the TS III Qualifier CYCLE BATCH REJECT TOOL TYPE BRUSHLESS Step 1 Power up the unit waiting for the Home Screen See pages 11 14 to appear During power up the device will identify the tool type for which the unit is configured either BRUSH or BRUSHLESS Be sure that the tool to be used with this device matches the tool type TS III BL Qualifier Part Number 66517 TS III CL Qualifier Part Number 66515 Step 2 Attach one end the cord to the tool and the other end to the TS III Qualifier tightening the knurled knob Select the desired tool speed HI or LO Turn the Soft Start either ON or OFF Note The Soft Start only work with brush style tools CYCLE BATCH REJECT ENTER PASSWORD Step 3 Press the enter ENT button and enter the Programming Menu Either use the Arrow keys to insert password 0104 default or bypass the password by turning the key to the programming position Horizontal Continued on the next page 6 Quick Start Guide Step 4 Use the arrow keys to navigate to the AutoCal option in the Pro gram Menu Once at the Auto Cal option press the enter ENT button to select it CYCLE BATCH REJECT
41. urrent Min Current and Max Current for a Brushless tool If this item is selected the TS III will act like a current meter showing the user how much current is being drawn by the tool either brush or brushless PROGRAM MENU In order to view this value enter the Pro gram Menu and press an arrow key until the Current Draw display reads PROGRAM MENU Current URRENT DRAW Press the ENT button in order to monitor the 0 00A tool s current use Once in this mode the bottom line of the LCD will display the current draw in amps This value will be constantly updated while in this mode If the ESC button is pressed the unit will return to the Program Menu 34 i Interface Navigation Guide View Run Time Another trouble shooting mode programming aid is the View Run Time mode PROGRAM MENU View Run Time In this mode the display will show how long the tool ran dur ing the previous fastening cycle PROGRAM MENU In order to view this value enter the Pro View Run Time gram Menu and press an arrow key until the display reads PROGRAM MENU View CYCLE BATCH REJECT Run Time VIEW RUN TIME Press the ENT button in order to monitor the Time X XXXs tool s current use Once in this mode the bottom line of the LCD will display the amount of time that elapsed during the last fastening cycle This value will be updated automatically each time the tool runs This information can be very useful in determin
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