USER MANUAL - KVL Comp Kft.
Contents
1. 4 SETUP AND OPERATION 4 1 SWITCHING ON THE CONTROLLER The device is switched on with the rocker switch located next to the power supply connec tor After switching off the device always wait at least 5 seconds before switching it on again 4 2 CONTROLS On the controllers front panel there is a white light button installed what indicates if the controller is turned on The pushbutton has a Lamptest function The error messages are indicated and the acknowledging is done with the connected devices KVL LTWO2 KVL KSWO2 12 SCREWDRIVER CONTROL BOX WITH ETHERNET NETWORK 1 POWER ON INDICATOR LIGHT If the controller is on the POWER labelled light glows The pushbutton has a Lamptest function 2 SCREW QUANTITY DISPLAY On the front panel of the device there is a 3x2 piece 7 segment display The SCREWDRIVER controller can control 3 tightening cases KVL LTWO2 GREEN YELLOW RED LIGHT TOWER WITH ACOUSTIC SIGNAL SIGNAL POST GREEN LAMP Glows if the all of the screw quantity displays are 00 SIGNAL POST YELLOW LAMP In case of server error it glows with the red 4 SIGNAL POST RED LAMP In case of error it glows SIGNAL POST AUDIBLE SIGNAL In case of control error audible signal can be heard of KVL KSWO2 KEY SWITCH MODULE WITH AS I CONTROLLER 7 ACKNOWLEDGING ERRORS Errors are acknowledged using the E7 key switch 4 3 LIGHT AND AUDIBLE SIGNS NO AUDIBLE OR VISIBLE SIGNALS Indicate2. products Outdoor use uses involving potential chemical contamination or electrical interfer ence or conditions or uses not described in this manual Installations subject to separate industry or government regulations Systems machines and equipment that could present a risk to life or property Please know and observe all prohibitions of use applicable to the products PROGRAMMABLE PRODUCTS KVL COMP shall not be responsible for the user s programming of a programmable prod uct or any consequence thereof SCREWDRIVER CONTROL BOX WITH ETHERNET NETWORK VI DISCLAIMERS CHANGE IN SPECIFICATIONS Product specifications and accessories may be changed at any time based on im provements and other reasons It is our practice to change model numbers when published ratings or features are changed or when significant construction changes are made However some specifica tions of the products may be changed without any notice When in doubt special model numbers may be assigned to fix or establish key specifications for your application on your request Please consult with your KVL COMP representative at any time to confirm actual specifications of purchased products DIMENSIONS AND WEIGHTS Dimensions and weights are nominal and are not to be used for manufacturing purposes even when tolerances are shown PERFORMANCE DATA Performance data given in this manual is provided as a guide for the user in determining suitabi
3. use 5 grey Not in use 3 3 5 TEST CONNECTOR The connectable device KVL TQ TEST Special device for switching the SCREWDRIVER controllers to 5 mode M12 4 pole male Wire colours According to Euro Norm EN 50044 The KVL TQ TEST is a special device what if it is connected the controller senses it The operation of it is depending on communication disables all functionalities of the control system The tools are usable as a normal tool SCREWDRIVER CONTROL BOX WITH ETHERNET NETWORK 3 6 SCREW QUANTITY DISPLAY On the front panel of the device there is a 3x2 piece 7 segment display The screwdriver controller can control 3 tools For distinguishing these tools we are using 3 different color codes The displays on the front panel are colored to yellow blue and brown Each one belongs to one tool KUL CAMP KUL ESTSTER VETHERHET OBEHTSCHLUSSEL ATE waa hu It is advisable to indicate these colors on the tools as well The displays show the current quantity of screw necessary for the component from 00 to 99 To one display 3 tools can be assigned From the programmed tools always only one is active at a time the other 2 are spare ones The quantity of screws necessary shown on the display always decreases with one after each tightening In case if all the displays value reaches zero the controller considers the job as done 11 KVL ATQO6EEU CHAPTER
4. ETWORK Read and Understand this Manual Please read and understand this manual before using the product Please consult your KVL COMP representative if you have any questions or comments I ABOUT THIS MANUAL This guide explains the installation and operation of the product Before installing and using the product read this guide carefully and be sure to understand its contents Also read and follow the safety information described in the next chapter The chapter titled Precautions contains general safety instructions of using the product and the related devices Chapter 1 Introduces the product and its structural units Chapter 2 Explains the structure of the product Chapter 3 Explains the installation of the product the wiring of the power supply and the I O lines and also the functional testing of the product Chapter 4 Explains the setup and operation of the product Il RELATED GUIDES The following guides give information on the related devices You can find the necessary information in the following documents Title of Publication KVL1210 ce CONTROL BOX WITH ETHERNET MAINTENANCE MANUAL KVL1001 POWER CABLE DATASHEET KVL1002 ETHERNET PATCH CABLE DATASHEET GREEN YELLOW RED LIGHT TOWER WITH KVL1310 ACOUSTIC SIGNAL DATASHEET KVL1163 ACKNOWLEDGEMENT MODULE DATASHEET RADIO TRANSMITTER MODULE FOR BOSCH SEC acces EXACT SCREWDRIVER sal HI PUBLICATION HISTORY The number of the publication is also indicate
5. EU CHAPTER 2 TECHNICAL DATA 2 1 DIMENSIONS The KVL ATQO6EEU controller is installed in a metal plate case Dimensions of the controller box 400 300 210 mm Colour of the controller box Grey RAL 7032 WAB 2B 6 ii 0 m 2 2 ELECTRICAL DATA Supply voltage Current drain Operating range Operating temperature Operating humidity Storage temperature Storage humidity Mains circuit connection Fuse Recommended mains connector cable SCREWDRIVER CONTROL BOX WITH ETHERNET NETWORK 230 V AC 50 Hz 10A 100 240 V 48 62 Hz 5 40 C 20 90 RH non condensing 20 70 C 10 95 RH non condensing IEC standard connector with fuse and switch 5 20 glass tube 230 V 10 A SLOW KVL POW 2 3 ETHERNET NETWORK The controller can be connected to standard 10 100 Ethernet network The industrial Ethernet socket is of type VARIOSUB RJ45 The recommended Ethernet cable is of type KVL ETN KVL ATQO6EEU CHAPTER 3 INSTALLATION AND WIRING 3 1 INSTALLING THE CONTROLLER AT THE WORKPLACE The control box will be installed on TRILOGIQ shelf system The plastic clamps what is necessary for the installation is fixed to the back cover of the control box Accessory 3 2 CONNECTING TO MAINS AND ETHERNET NETWORK The sockets are located on the side of the controller POWER SUPPLY 4 Mains 230 V AC socket Glass tube fuse 5720 glass tu
6. KVL1290 EN 01 KVL ATQO6EEU SCREWDRIVER CONTROL BOX WITH ETHERNET NETWORK USER MANUAL KVL ATQO6EEU USER MANUAL SCREWDRIVER CONTROL BOX WITH ETHERNET NETWORK Notice The following conventions are used to indicate and classify precautions in this manual Always heed the information provided with them Failure to heed precautions can result in injury to people or damage to property A DANGER Indicates an imminentiv hazardous situation which if not avoided will result in death or serious injurv Additionallv there mav be severe prop ertv damage A WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Additionally there may be severe prop erty damage A CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or property damage Trademarks Windows is a registered trademark of Microsoft Corporation in the United States and other countries The other brand and product names are trademarks or registered trademarks of their re spective owners Introduction We design and manufacture our devices with the feedback from the enterprises of the in dustry and their specific needs in mind Our pokayoke systems elaborated this way are robust and due to the sophisticated solutions applied in them they provide a long main tenance free lifecycle These devices are recommended for those
7. ance characteristics of the product are sufficient for the systems machines and equipment This manual provides information for setup and operating the product Be sure to read this manual before attempting to use the product and keep this manual close at hand for reference during operation A WARNING It is extremely important that a product be used for the specified pur purpose and under the specified conditions especially in applications that can directly or indirectly affect human life You must consult with your KVL COMP representative before applying a product to the above mentioned applications SAFETY PRECAUTIONS A CAUTION When power is ON or has just been turned OFF do not touch the power supply terminals or the surrounding areas A CAUTION Secure the AC power supply line to the terminal block with a 0 5N m of torque Loosening the screw may result in a fire or malfunction APPLICATION PRECAUTIONS N CAUTION On modifving the program alwavs ensure that switching to MONITOR or RUN mode does not lead to unexpected effects SCREWDRIVER CONTROL BOX WITH ETHERNET NETWORK CHAPTER 1 OVERVIEW This guide explains the installation wiring and setup of the KVL ATQO6EEU Ethernet net work controller and describes its operation The installation wiring and setup of the prod uct must be accomplished by experienced professionals The description of operation provides information for the workers working with the poka yoke sy
8. be 230 V 2A SLOW On off switch Ethernet socket Light column connector KVL LTWO2 Key switch connector KVL KSWO1 TEST connector gt A a SCREWDRIVER CONTROL BOX WITH ETHERNET NETWORK For connecting to the mains circuit we recommend the type KVL POW cable Ensure that the controller is switched off when you connect the cable A WARNING Risk of electric shock when using wrong or damaged mains connector cable A WARNING Risk of fire and human injury when using damaged repaired fuses or fuses not of the appropriate type For connecting to the Ethernet network we recommend the type KVL ETN cable The AS i network plug is standard M12 sensor plug 3 3 EXTERNAL LIGHT COLUMN CONNECTOR The device that can be connected KVL LTWO2 Light column green yellow red light and audible signal Wire colours According to Euro Norm EN 50044 We deliver the KVL LTWO2 module with a 2m long cable M12 5 pole socket e Wire color 1 Brown Horn 1 2 White Red a 3 Blue Green 2 4 4 Black Yellow 5 Grey Common 3 KVL ATQO6EEU 10 3 4 EXTERNAL KEY SWITCH CONNECTOR The connectable device KVL KSWO2 Error acknowledging module with SIEMENS E7 key switch for the con trollers delivered to the VW group M12 4 pole socket Wire colors according to Euro Norm EN 50044 l We deliver the KVL KSWO2 module with a 2m long cable Wire color 1 Brown Switch 2 White Switch 3 Blue Not in use 4 Black Not in
9. d on the cover of the publication NUMBER OF PUBLICATION KVL1209 EN 01 Date of Publication No of Publication Chapter Revised content 12 2010 Kvi1209 EN 01_ tstedition KVL ATQO6EEU IV WARRANTY AND LIMITATIONS OF LIABILITY WARRANTY KVL COMP s exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year or other period if specified from date of sale by KVL COMP LIMITATIONS OF LIABILITY KVL COMP shall not be responsible for special indirect or consequential damages loss of profits or commercial loss in any way connected with the products whether such claim is based contract warranty negligence or strict liability In no event shall the responsibility of KVL COMP for any act exceed the individual price of the product on which liability is asserted In no event shall KVL COMP be responsible for warranty repair or other claims regarding the products unless KVL 5 analysis confirms that the products were properly han dled stored installed and maintained and not subject to contamination abuse misuse or inappropriate modification or repair V APPLICATION CONSIDERATIONS SUITABILITY FOR USE The following are some examples of applications for which particular attention must be given This is not intended to be an exhaustive list of all possible uses of the products nor is it intended to imply that the uses listed may be suitable for the
10. ending on the programming mode counts back one or goes back to the original numerical value If a tools displayed value reaches OO the corresponding screwdriver will be disabled After tightening the last screw the display will show zero the light columns green light will glows continuously indicating that the work is done At this time the device sends a work OK message to the server and all the torque wrenches are disabled Waiting for the next tools data The controllers operation is illustrated with the following example SCREWDRIVER CONTROL BOX WITH ETHERNET NETWORK SERVER SERVER PLC SPS PLC SPS In the system for the three tools three torque wrenches are connected one wrench to each case According to the example with the yellow code colored wrench 2 with the blue 1 and with the brown bolts has to be tighten 1 Starting to work The server or controller PLC at starting gives the tightening pa rameters to the controller With the yellow code colored wrench 2 screws on its display 2 with the blue wrench 1 screw on its display 1 has to be tighten With the brown code coloured wrench there is no work to be done on this work piece On its display is OO and the rotation is disabled 2 With the yellow code colored wrench 1 screw was tighten Under the yellow code colored display we will see 1 the rest of the necessary tightening 3 With the blue code colored wrench 1 screw was t
11. firms where one of the following problems has emerged and would like to develop a solution Frequently occurring errors in production processes Products must be called back due to installing parts of wrong type High scrap costs caused by selecting wrong part Workers often forget to tighten the screws fixing the part Workers forget to install or more parts and this mistake is noticed too late The pokayoke systems of KVL COMP aid the effective troubleshooting of these errors KVL COMP 2010 All rights reserved It is forbidden to reproduce or store this document or part of it in any data retrieval system or transfer it in any form in any way mechanically electronically photocopying recording or with any other technique without prior written permis sion from KVL COMP We do no take patent responsibility for the information disclosed here Also as KVL COMP is constantly striving to improve its high quality products the information included in this guide can change without notice During the creation of this guide we try to be as accurate as possible but KVL COMP does not take responsibility for the possible errors or omissions Also KVL COMP does not take any responsibility for the possible damages resulting from using this guide SCREWDRIVER CONTROL BOX WITH ETHERNET NETWORK CONTENTS About this Manual 1 Related SS ee 1 PUBIC GUON ee ee 1 IV Warranty and Limitations of Liabilit
12. lity and does not constitute a warranty It may represent the result of KVL 5 test conditions and the users must correlate it to actual application requirements ERRORS AND OMISSIONS The information in this manual has been carefully checked and is believed to be accurate however no responsibility is assumed for clerical typographical or proofreading errors or omissions Vil PRECAUTIONS This section provides general precautions for using the related devices The information contained in this section is important for the safe and reliable applica tion of product You must read this section and understand the information contained before attempting to set up or operate a product INTENDED AUDIENCE This manual is intended for the following personnel workers trained to the specific task working on the assembly stations and on the assembly line operating the device work group leaders professionals responsible for the installation setup and maintenance of the device KVL ATQO6EEU GENERAL PRECAUTIONS The user must operate the product according to the performance specifications described in the operation manuals Before using the product under conditions which are not described in the manual or ap plying the product to other systems machines and equipment that may have a serious in fluence on lives and property if used improperly consult your KVL COMP representative Make sure that the ratings and perform
13. nance service A WARNING In the following cases switch off the control box disconnect network cable and call a service technician immediately The network cable or its connector is damaged or worn Liquids penetrated the control box The control box was exposed to rain or other forms of water The control box fell or its case is damaged The operation of the control box is unstable or the control box is malfunc tioning The control box emits unusual noise smoke or unpleasant smell 16 KVL COMP s r o Komensk ho 35 94301 Sturovo SLOVAKIA Tel 00 36 33 501 616 Fax 00 36 33 501 615 www kvicomp eu info kvlcomp eu KVL COMP Vez rl stechnikai H 2500 Esztergom Nagy Sandor Jozsef utca 3 HUNGARY Tel 00 36 33 501 616 Fax 00 36 33 501 615 www kvicomp eu info kvlcomp eu
14. orque With this wrench the work is done Under the blue code colored display we will see 00 The control ler disables the rotation of the wrench 4 At the second process with the yellow code colored wrench the tighten screw is not the correct screw the screw is longer than it should be the screw is oblique the operator loosens the bolt The controller counts back one under the yellow code colored display we will see 2 the rest of the necessary tightening 5 With the yellow code colored wrench 1 screw was tighten Under the yellow code colored display we will see 1 the rest of the necessary tightening 6 With the yellow code colored wrench 1 screw was tighten With this wrench the work is done Under the blue code colored display we will see OO The controller disables the rotation of the wrench The operator finished all the work to be done all three displays show 00 The controller sends a work OK message to the server 15 KVL ATQO6EEU 4 5 DAILY CHECKS BEFORE WORK Daily routine check of control cabinet Cabinet door is closed Proper ventilation and protection of the inner parts are only provided with closed cabinet door Touching the inner parts can cause electric shock Via the open door dust can penetrate the cabinet The accumulating dust de creases cooling efficiency and leads to a higher probability of failure If any device failed the above checks immediately call mainte
15. s normal operation THE GREEN LIGHT IS ON NO AUDIBLE SIGNALS The device completed the production cycle and sends an IO signal THE RED LIGHT IS ON An error occurred during the cycle THE YELLOW AND THE RED LIGHTS ARE ON Communication error occurred THE DEVICE GIVES AN AUDIBLE SIGNAL In case of control error audible signal can be hearing 13 KVL ATQO6EEU 4 4 WORK PROCESS 14 The controller controls up to 3 different tools In every case only one screwdriver is ac tive By default every screwdriver is disabled The screwdriver controller receives the necessary data from the server This data con tains the quantity of screws necessary for all 3 tools to the work piece at the work sta tion On the 7 segment display on the front panel of the device the necessary quantity of SCreWS appear The controller enables the screwdriver what we have to work with the belonging dis play is not showing 00 If a work piece arrives to the station where is no tightening necessary on the display 00 00 00 will appear the device will switch to work OK mode and all 3 displays will be erased The screwdriver stays disabled if there is no work needs to be done by it At this time we can start the tightening of the appropriate screw The amount of tight ening necessary with the tool is shown on the 7 segment display always decreases with one after each tightening In case we loosen a screw the display dep
16. stem 1 1 SHORT INTRODUCTION OF POKAYOKE SYSTEMS The meaning of the Japanese words Poka Yoke in free translation Poka random unintentional error mistake fault Yoke elimination prevention Meaning mistake free error free work workstation technology process development in order to avoid human errors The aim of poka yoke is the full scale prevention of product defects waste avoidance minimization of quality control costs to provide error free working conditions and work To sum up poka yoke is a system that assists manufacturing and assembling that helps and simultaneously controls the workers Using poka yoke effectively improves waste avoidance The KVL ATQO6EEU is part of the Ethernet network based poka yoke system developed by KVL COMP 1 2 THE LOCATION OF THE SCREWDRIVER CONTROLLER IN THE POKAYOKE SYSTEM The torque wrench Poka yoke s aim is to help the operator s job and reduce the error possibilities During producing any kind of device often happens that the components are connected together with bolting The bolting is strongly influencing the final products usability durability and reliability In many cases the operators during a day torque hundreds of screws Unavoidably it occurs that they miss a screw or the tightening is not done properly The KVL ATQO6EEU screwdriver controller with Ethernet network what was developed by the KVL Comp helps to eliminate these occurring errors KVL ATQO6E
17. y 2 V PADDING ji ea CONS 2414 ION ee ea een ee 2 VL Die Amer sao A A 3 Mill Preca ii to AS oir rere ree rene 3 CHAPTER Lada 5 OVERVIE E E er ee 5 1 1 Short introduction of pokavoke systems cccccccesseccccessccccaesececeeeceeeeeecceseueceeeeneceeeeeeeeetas 5 1 2 The location of the SCREWDRIVER controller in the pokayoke 5 CHAPTER 6 TECHNICAL DA TA 6 2 DIET IO Sd 6 BIC CANO 7 2 A die eo y OA US Er e Un Eee 7 CHAPTER ica 8 INSTALLATION AND WIRING totes docente ee era 8 3 1 Installing the controller at the 8 3 2 Connecting to mains and Ethernet 8 External light column COMME CTO Rasa 9 3 4 external key switch connector 10 ci COICO ti canto 10 3 6 Screw quantity display siii 11 CTIA TER 12 SETUP ANO OPERATION ceras 12 lS WICC ANE OR the controller en 12 42 ONT O E i ea a EA 12 4 3 Lightand audible 13 AO PCR A A d 14 4 5 Daily checks before etika ia ira gal 16 KVL ATQO6EEU SCREWDRIVER CONTROL BOX WITH ETHERNET N
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