ASG ASG-SD2500 User manual

ASG-SD2500 & ASG-CT2500
ASG-SD2500 Series Screwdriver & Controller
User’s Guide
Version 3.0.4
September, 2017
Document CT2500-1 EN
Original Instructions

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ASG Precision Fastening ASG-CT2500 User’s Guide
Version 3.0.4
Major Revision: January, 2016
Minor Revision: September, 2017
To download the latest version of this manual visit:
www.asg-jergens.com
ASG Precision Fastening
[phone]
15700 S. Waterloo Rd.
Cleveland, OH 44110
USA
© 2017 Jergens Inc.
All Rights Reserved

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Table of Contents
Declaration of Conformity 5
Information on Noise Emission 6
Information on Transmitted Vibration 6
Safety Precautions 7
Introduction 10
Installation 12
Controller & Power Requirements 12
Tool 13
Pistol Grip Assembly 14
ASG-SD2500 Functions 15
ASG-SD2500 Operations 16
Run Tool Screen 17
Tool Information Screen 19
Setup Screen 20
Tool Triggering 20
Bolt Counts 20
Bolt Retries 21
Reverse Settings 21
Parameter Setup 22
Bolt Sequences 24
Prevailing Torque 25
Prevailing Torque Link 26
Task Setup 28
Renaming and Importing Tasks 28
Exporting Tasks 29

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Input Programming 30
Task Select 30
Enable Bolts 31
Remote Start 32
Reverse Select 33
Remote Reset 34
Remote Halt 35
Output Programming 36
Input/Output Port Pin Guide 38
Graph Screens 40
Graph Data Export 42
Data Screen 43
Erasing Data 43
Downloading Data 44
System Setup Screen 45
Passwords 45
Date/Time Settings 47
Tool Trigger Sensitivity 48
Tool Calibration 49
Controller Information 50
Firmware Updates 51
Touch Screen Calibration 51
LCD Brightness Adjustment 51
Service & Warranty 52

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Declaration of Conformity
Declaration of Conformity to European Union Directives
In accordance with EN ISO 17050-1:2010
We
ASG, Division of Jergens Inc.
of
15700 S. Waterloo Rd. Cleveland, Ohio, USA
in accordance with the following Directive(s):
2006/42/EC The Machinery Directive
2014/30/EU The Electromagnetic Compatibility Directive
hereby declare that:
Equipment
ASG SD2500 Electric Screwdriver System –Tool, Controller,
and Cable
Model number
ASG-CT2500, ASG-CB2500-[xx][yy], ASG-SD2500-10[zz],
ASG-SD2500-20[zz], ASG-SD2500-35[zz], ASG-SD2500-
50[zz]
[xx] = cable length in feet, [yy]=cable style (HW, RA, ESD, EX)
[zz] = tool body style (PL, PS, FX, RP, RQ)
is in conformity with the applicable requirements of the following documents
BS EN 62841-2-2:2014 - Electric motor-operated hand-held tools, transportable tools and lawn and garden
machinery. Safety. Particular requirements for hand-held screwdrivers and impact wrenches
BS EN 60745-1:2009+A11:2010 - Hand-held motor-operated electric tools. Safety. General requirements
EN ISO 12100:2010 Safety of Machinery –General Principles for design –Risk Assessment and risk
reduction
EN 61000-6-2:2005 Immunity Standards for Industrial Environments
EN 55011: 2009+A1: 2010 Group 1, Class A Industrial, scientific and medical (ISM) radio-frequency equipment –
Electromagnetic disturbance characteristics –Limits and methods of measurement.
Person Authorized to Compile the
Technical File
We hereby declare that the equipment named above has been designed to comply with the relevant sections
of the above referenced specifications. The apparatus complies with all applicable Essential Requirements of
the Directives.
Signed by:
Name:
Bryon Shafer
Position:
General Manager: ASG, Division Jergens Inc.
Done at
Cleveland, Ohio, USA
On
5/18/2016
Federico Roma Sales Manager –Europe
ASG, Division of Jergens Inc.
Via Vicolo Lombardo, 27 Villaverla, 36030, Italy

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Machinery Technical File Reference: ASG-TF-SD2500-01
EMC Technical File Reference: ASG-TF-SD2500-EMC-01
Information on Noise Emission
The ASG Division of Jergens Inc., Model SD2500 Electric Screwdriver Sound Pressure and Sound Power Levels
per EN ISO 11202 are as follows:
Model No: ASG-SD2500
Serial No: As noted on Nameplate
Year of Construction: 2015
Operating
Idle
LpAm (Operator Position)
75 dB (A)
44 dB (A)
LpAm (Bystander Position)
75 dB (A)
44 dB (A)
Peak C-weighted instantaneous SPL in the Operator’s position
69 dB (C)
53 dB (C)
Sound power emitted where the equivalent continuous A-weighted
SPL exceeds 80 dB (A).
N/A
---
The average difference between the extraneous noise level and the
sound power level at each measuring point:
LpAm Δ= 31 dB (A)
Ambient Correction Factor K3A calculated according to EN ISO 11204
Appendix A.
4 dB( A)
Measurements were made at a height of 1.5 m and 1 m from the Operator Position and all four sides of the
equipment.
The figures quoted are emission levels and are not necessarily safe working levels. While there is a correlation
between the emission and exposure levels this cannot be used reliably to determine whether or not further
precautions are required.
Factors that influence the actual level of exposure of the workforce include characteristics of the work room,
the other sources of noise, etc. such as the number of machines and other adjacent processes. Also, the
permissible level of exposure can vary from country to country.
This information, however, will enable the user of the machine to make a better evaluation of the hazard and
risk.
ASG, Division of Jergens Inc.
15700 S. Waterloo Rd.
Cleveland, Ohio 44110 USA
Information on Transmitted Vibration

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The ASG Division of Jergens Inc., Model SD2500 Electric Screwdriver transmitted vibration levels as
found according to EN ISO 60745 are as follows: Screwdriver vibration: < 2.5 m/s2
Safety Precautions
Be sure to read all instructions and precautions contained in this manual, failure to do so may result in
personal injury and/or damage to tooling and components.
DAMAGE REQUIRING SERVICE –Unplug this product from the wall outlet and request servicing by
qualified service personnel under the following conditions:
oWhen the power supply cord is damaged
oWhen the tool cable is damaged
oIf liquid has been spilled onto the enclosure of the unit.
oIf the product does not function normally by following the instructions in the User’s Guide. Adjust only
those controls that are covered by the operating instructions. Improper adjustment of the controls may
result in damage and will often require rework by a qualified technician to restore the product to its
normal operation.
oIf the product has been damaged in any way.
oWhen the unit displays a negative, distinct change in performance.
Do not operate or plug in the controller/system with wet hands or in wet environments. Failure to observe
this may result in injury due to electric shock.
Do not operate this equipment from any power source that does not match the voltage rating marked on
the equipment. Refer to the Manufacturer’s Identification Label for operational requirements.
Ensure the controller is properly plugged in to a grounded electrical receptacle. Do not remove the
ground pin or use any adapter plugs.

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CAUTION - Replace fuse with same type and rating:
0250V, 8A, Time-Lag T, 5x20mm 1kA
POWER CORD PROTECTION –The power supply cord for this product acts as the main-disconnect. It
should be routed or installed in such a matter to protect it from being walked on or pinched. The unit should be
powered down completely before connecting or disconnecting the power cable. The power cord should be removed
before moving the unit. The power cord must be placed near an easily accessible unobstructed socket outlet.
TOOL CABLE PROTECTION - Tool cable must be properly routed and festooned to avoid tangling and trip
hazards. It should not be installed in any manner that allows it to be walked on or pinched.
Do not use any part of the system (tool, cable, or controller) for anything other than its specified
application. Use of the system or its components for unintended applications could result in injury to the operator,
failure of the system, and could void the warranty.
CLEANING –If it should become necessary to clean this equipment, disconnect the unit from its power
source first. Do not use liquid cleaners, aerosols, abrasive pads, scouring powders or solvents, such as benzene or
alcohol. Use a soft cloth lightly moistened with a mild detergent solution. Ensure the surface cleaned is fully dry before
reconnecting power.
Never modify or disassemble any component of the system. Modification or disassembly of the system
could result in injury and void the warranty.
Always shut down the equipment and disconnect from all power sources prior to changing or servicing
equipment. Failure to do so could in injury or damage to the equipment.

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Always use safety glasses when using electrical assembly tools.
Do not wear loose clothing, dangling jewelry, or loose unbraided long hair when operating this tool. A
risk of entanglement is possible that may result in minor injury to the Operator.
Keep work area clear of clutter and distractions that may cause the operator to lose control of the tool
or the components.
CAUTION –Do not use this tool if you are ill, on medication that is known to cause
hand-eye coordination problems, under the influence of alcohol, illegal drugs or other impairing substances, or suffering
from depression. This includes over-the-counter medications if they cause drowsiness, impaired judgment, or
diminished physical skills. Consult with your management and advise them of your condition.
Do not operate this equipment without all guards and covers in place.
WATER AND MOISTURE –Do not place containers with liquids such as coffee, water, sodas, etc. on this unit.
Do not operate this unit in a wet environment.
Electronics Disposal - Must be recycled as required by local environmental law –do not dispose of by
adding to the Municipal waste stream.
Metal/Other Parts of the System - Must be recycled as required by local environmental law.

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Introduction
Thank you for investing in the ASG-SD2500 Precision Screwdriver System from ASG Precision Fastening! This user’s
guide will assist you with setting up your system.
Please start by finding the serial number labels on each component of your system.
Take note of the serial numbers and record it below with your date of purchase. This information will be necessary
should any service be required in the future.
ASG-CT2500 Serial Number: :

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ASG-CB2500-xxxx Serial Number: :
ASG-SD2500-xxxx Serial Number: :
Date of Purchase: :
Tool Model Number Key
ASG-SD2500-20PL
Cable Model Number Key
ASG-CB2500-10HW
Maximum Torque
(inlb)
FX –Fixture Mount
PL –Push/Lever Start Combo
PS –Push-to-Start
RP –Right Angle (1/4” square)
RQ –Right Angle (1/4” hex)
Cable Length
(feet)
HW –Heavy Weight Strain Relief
RA –Right Angle (at Tool End)
ESD –Electro-Static Discharge Covering
EX –Extension Cable

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Installation
Controller Installation & Power Requirements:
The ASG-CT2500 comes standard with a mounting plate for attaching to the wall, workbench, or tool stand. Secure the
controller using the (4) provided holes in the mounting plate. These provided holes are meant for #6 screws.
For other ASG-CT2500 mounting options, please visit the website at: http:\\www.asg-jergens.com
All dimensions are in inches.
Controller Power Requirements:
100-240VAC / 1-Phase / 50-60Hz

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Ensure the controller power cord can reach a properly grounded receptacle without creating a trip hazard in the work
area. The controller should also be mounted within view of the operator, and should be accessible and within reach for
programming and modification. Provide adequate clearance on all sides for access of technicians and 6” of clearance
below for cables to attach to the ports.
Tool Installation:
Connect the tool cable to the connector on the bottom of the controller by identifying the alignment tabs in the large
cable connector. Align these tabs and insert the cable to the controller, then rotate the twist-lock on the cable
connector clockwise until it clicks into place.
Note: To remove the cable from the controller, rotate the twist-lock on the cable connector counter-clockwise
until it pops free, and then remove the cable from the controller.
Obtain the ASG-SD2500 tool and identify the key slot on the screwdriver connector into which the screwdriver cable
connects. Find the red dot on the small end of the cable, and align it to the slot in the screwdriver connector. Insert the
cable to the tool firmly until it clicks into place.
Note: To remove the cable from the tool, slide the grip of the cable connector away from the tool, then pull the
cable out of the tool.
Connect the controller to the power source and power-up the controller.
Twist-lock
Alignment
Tabs
Grip
Dot

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Do not depress either the push to start spindle or the throttle lever during controller power-up, doing so may
result in a ToolEE Error which will require a reboot of the controller.
Pistol Grip Assembly
Should the application require it, ASG Precision Fastening offers an optional Pistol Grip Assembly (P/N ASG-AC2500-PG)
for sale.
To Install:
•Ensure the screwdriver cable is removed from the tool
•Use a 5/32” punch to drive out the throttle lever pin that attaches the throttle lever to the screwdriver
•Remove the throttle lever and spring from the tool (save these pieces to use at a later time to convert the tool
back to the In-Line configuration)
•Slide the screwdriver into the pistol grip assembly with the forward/reverse buttons facing directly opposite the
handle
•Position the heel of the pistol grip to the tool where the throttle lever was just removed and align the holes
•Re-insert the throttle lever pin to the tool through the pistol grip heel, carefully drive it into place so that the pin
is below the surface of the tool
•Use a 5/32” Allen wrench to tighten the fastener by the trigger until it is secure
5/32” Allen
Fastener
Throttle Lever Pin

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ASG-SD2500 Functions
All ASG-SD2500 Screwdrivers are of light-weight aluminum construction and come standard in the inline configuration,
with optional pistol grip and lever triggers.
Standard Features:
•Forward/Reverse Button
•LED Status Ring –indicates torque/angle high, low, or pass
•High Intensity LED Headlights (not present on fixture mount or angle models)
•Push-to-Start triggering (inline models only)
•¼” Hex Quick-Change Chuck (inline models only)
•Suspension Bail
Optional Features:
•Throttle Lever
•Fixture Mount Body
Forward/Reverse Button
Quick Change Chuck
LED Headlights
LED Status Ring
Throttle Lever
Foam Grip
(Optional P/N ASG-AC2500-FG)

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All ASG-SD2500 Series Screwdrivers have programmable internal memory that contains configuration information from
the factory. It will identify itself to the controller and provide the following information:
•Tool Model Number
•Tool Serial Number
•Cycles Completed
•Maximum Torque
•Maximum Speed
•Gear Ratio
•Calibration Value

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ASG-SD2500 Operation
First-time users should take some time to become familiar with the ASG-SD2500 prior to use. With the power to the
controller off, cycle the lever and push-to-start spindle to become accustomed to the feel and resistance. Repeat this
step with the controller power on, to feel the operation of the tool.
Motor Specifications
Motor Voltage: 32 VDC
Motor Power: 50 Watt
Forward/Reverse
Depress and release the forward/reverse button on the tool to switch between forward (RH rotation) and reverse (LH
rotation). A straightforward way to know which mode the tool is in is that if the colored LED lights are flashing on/off,
the tool is in reverse.
Changing Bits
Bits can be changed easily through the use of the Quick-Change Chuck that comes standard with the inline versions of
the ASG-SD2500 Screwdriver. Inline drivers (PL, PS, & FX models) are intended to use ¼” hex power bits. Right angle
models utilize either ¼” square sockets for the RP model, or ¼” insert bits for the RQ models. Power drive bits are not
recommended for the RQ models.
To insert a bit: Align the bit’s hex end into the spindle opening. Grasp the black collar on the quick change chuck and
push it away from the tool towards the bit. Apply pressure to the bit until it clicks into place. Release the black collar
and gently pull on the bit to ensure it is seated and locked into place.

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Run Tool Screen
1. Task Selection: Shows the user the current task, and allows the user to select one of 32 available tasks.
Selecting the button with the task name will bring up the Task Menu where another task
may be selected or altered. The arrow keys will advance to the previous or next task.
Settings for bolt counts, parameters, inputs, outputs, etc will switch with these actions
to the settings of the selected task.
2. Tool Button: Displays the Tool Information screen that shows tool characteristics.
3. Final Target: Displays the target value of the active Parameter, either torque or angle.
4. Torque Reading: Displays the torque seen by the tool during or at the end of the fastening cycle. This
field will color code at the end of a fastening cycle to denote Pass (green), Fail –High
(red), or Fail –Low (yellow) as defined by high and low limits of the selected Parameter.
5. Angle Reading: Displays the angle seen by the tool during or at the end of the fastening cycle. This field
will color code at the end of a fastening cycle to denote Pass (green), Fail –High (red), or
Fail –Low (yellow) as defined by high and low limits of the selected Parameter. The
field remains un-highlighted when Angle Monitoring is disabled within the Parameter.
6. Inputs: Displays (1) radio button for each of the (8) available inputs. The appropriate radio
button will illuminate blue when the input is active.
7. Bolt Sequence Steps: Displays the sequence step and selected parameter. The parameter name will be
highlighted red, yellow, or green at the end of its cycle to show its status. This sequence
shown is for the current bolt only.
8. Setup Button: Takes you to screens where you may set up Tasks, Parameters, Bolt Sequences, Inputs,
Outputs, and System Settings.
9. Graph Button: Displays the most recent fastening cycle graphically as Torque vs. Time,
Angle vs. Time, Torque vs. Angle, Speed vs. Time, and Power vs. Time.
1
2
3
4
5
13
7
8
9
10
11
12
6

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10. Data Button: Displays a table that contains rundown characteristics for the last 100 fastening cycles.
Additional data is available in the internal memory and can also be downloaded to a USB
flash drive from this screen.
11. Repeat Button: Depressing this button keeps the controller on the current bolt in a batch. The bolt
sequence will not advance to the next bolt until the button is released.
12. Reset Button: Depressing this button resets the fastening bolt count in the event of a failure, retry
lockout, or user request. The reset button also resets any currently active outputs. This
button may be disabled when the controller is locked with a password.
13. Outputs: Displays (1) radio button for each of the (8) available outputs. The appropriate radio
button will illuminate blue when the corresponding output relay is closed.

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Tool Information Screen
This screen displays characteristics of the tool that is currently attached to the ASG-CT2500 controller such as:
•Model Number
•Serial Number
•Number of Cycles on the Tool
•Max Torque
•Maximum Speed
•Gear Ratio
•Calibration Value
All the information shown on the screen above is stored on the internal memory of the SD250 screwdriver itself, and
therefore travels with the tool when taken from one controller to another.
CAUTION: Tapping on the Calibration Value will take you to a screen where the value can be manually changed.
This screen is for qualified calibration technicians only. Improperly changing the calibration value of the tool could lead
to inaccurate torque readings and potential tool damage.