Atlas Copco Tensor User manual

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

2
INSTALLATION HARDWARE
1. Open the lock mechanism (see figure 1)
2. Open the DS Drive by pulling it (see figure 2)
3. Connect the tool cable, power cable etc. (see figure 3)
4. Check so that the GFI is switched on
5. Close the DS Drive and lock it
6. Connect the power cable to a power supply 115/230 V
7. Turn the power on
IMPORTANT! Whenever replacing a tool, always turn the power off.
Figure 1 Figure 2
1. Tool cable connector
2. Digital inputs. Only for D312
3. Relay outputs
4. RS 232
5. I/O bus. Only activated
for D312
6. I/O bus. Only activated
for D312
7. Remote control
8. Main power connector
9. Ground fault interrupter,
GFI, 30 mA
10. Main fuse. 6.3 x 32 mm –
Slow Blow,15/20/25 A
Figure 3

15
14
13
12
11
8
7
4
1
2
3
5
6
9
10
3
DISPLAY/KEY PAD
1. Display
2. OK LED
3. n x OK LED
4. Lock LED
5. NOK LED
6. Alarm LED
7. Graph LED
8. IRDA
9. Function button
10. AutoSet button
11. Plus button (+)
12. Question mark
button
13. Enter key button
14. Minus button (-)
15. Power
OK LED Lights up after each tightening with
correct torque.
NOK LED –Lights up af ter each tightening reaching
first target but not correct torque.
Question Mark –By pushing this button you can see:
❑Drive program software version.
❑Drive version (D302-Basic functionality,
D312-Advanced functionality).
❑Drive size (DS4, DS7, DS9).
For further information check the DS Drive Manual.
–



4
1. Press the AUTOSET button once and ASEt/F1
appears on the display.
2. Choose final torque target by pressing
+/- buttons.
3. Press the ENTER button once to activate the
AutoSet function.
The Graph LED, lights up.
4. Resume tightening (5-8 times) until the Graph LED
disappear.
Optimum performance has been found and the system is ready
for production.
KEY PAD FUNCTIONS
AutoSet Programming:
The AutoSet Programming
feature allows the DS Drive to
recognise a joint’s stiffness and
adjust the tool for maximum
performance for that particular
joint accordingly.
/

5
Fine – Tuning Final Target
This enables personnel to fine the final target.
1. Press the FUNCTION button once and Ft/F2
appears on the display.
2. Adjust final torque target by pressing
the +/- buttons.
(The torque can be adjusted a maximum of +15%
or –5% from the original final target).
3. Press the ENTER button and the display starts
to flash.
4. When a new final target has been found within above limits,
the DS Drive is ready to run that program.
Torque Tuning
This is used when a tool is controlled against an external torque
reference. If the torque value on the DS differs from the
traceable value, a Torque Tuning should be performed.
1. Perform a number of tightenings with the external torque
transducer connected, preferably 20 tightenings or more in
order to achieve a good mean value. Calculate the mean value
from the tightenings.
2. Press the FUNCTION button twice and tunE/F3
appears on the display.
3. Press the +/- button until you have the
external mean value on the display.
4. Press the ENTER button and the display starts
to flash.
5. Perform another set of tightenings to control your torque.
6. If the torque is OK you are ready to run. If not, do the
complete procedure over again.
/
/

6
Motor Tuning
This function will optimize the performance of the motor and
minimize losses, i.e. after service.
1. Press the FUNCTION button three times and
tool/F4 appears on the display.
2. Press the ENTER button until the display starts
to flash.
3. Press the trigger on the tool and the tool will turn both in
forward and reversed direction (about 35-45 seconds).
The tool has now been motor tuned and is ready to use.
Copy Parameter Set
This option makes it possible to copy a parameter set.
(D312 –Advanced functionality)
1. Press the FUNCTION button four times and
COPY/F5 appears on the display.
2. Press +/- button to select the parameter set
you want to copy to another parameter set.
Confirm by pressing the ENTER button.
3. Choose the parameter set that you want to
copy the selected parameter set to by
pressing the +/- button.
Confirm by pressing ENTER button.
Change Parameter Set
When neither of the described functions are selected, the +/-
button are used to change parameter set (D312 –Advanced
functionality).
1. Press the +/- button to change parameter
set.
2. Confirm that you want to change Parameter set by
pressing the ENTER button.
/
/
/

7
FULL PROGRAMMING
Tightening strategy
You can select strategy choices as shown.
Soft Start Time
In order to facilitate screw engagement the tool starts by
turning at a very low speed during the soft start time.
Targets
At
First Target the tool will shift from Step 1 Speed to Step 2
Speed . Final Target is the level where the tool stops and the
tightening is finished.
Speeds
Step 1 Speed is the speed used during the rundown. When First
Target is reached, the tool slows down to Step 2 Speed to
tighten the second stage. To finish the tightening the tool goes
in to
Zoom Step Speed for operator comfort and minimization
of overshoot.
Step 2 Ramp
In
Step 2 Ramp you can select the acceleration of the tool in
step 2 speed between 0 and 100%.

8
RUNDOWN MONITORING
Rundown Monitoring is a function to detect bad rundowns. The
angle in both first and second step is monitored. See graph
below.
Cycle Start
Cycle Start is the
torque limit from
which the angle is
measured. The
maximum limit for
Cycle Start is First
Target.
Search Speed
The Search Speed is
the speed with which the tool will run until Cycle Start limit is
reached. The min limit is 0%. Max limit is Step 1 Speed. When
Cycle Start is reached the tool immediately accelerates to Step 1
Speed.
Step 1 Turns
The angle in the first step is measured from cycle start level until
1st target is reached. Program min (0 turns) and max (200 turns)
levels for when the angle is OK. The angle is defined in 1/10 of a
full turn.
Clamp Angle
The angle in 2nd step is measured from the point where 1st
target is reached until final target is reached. The angle in
between is called Clamp Angle. Program min (0 degrees) and
max (10000 degrees) levels for when the Clamp Angle is OK. The
angle is defined in steps of 10 degrees.

9
HIGH SPEED RUNDOWN
High Speed Rundown allows the tool to make the rundown at a
higher speed than Step 1 Speed. The function is used when a
fastener has a long rundown angle and there is a risk for
overshooting when the joint is hard.
SELF TAP
The Self Tap function is used for thread forming screws and
other fasteners with a torque pulse in the beginning of the
rundown higher than the desired 1st target or final target, see
graph below.

10
CONFIGURATION
The Configuration window has three different subgroups:
System Administration, I/O Configuration (containing I/O Setup
and RE-Alarm Setup) and Tool Service Setup.
1. In System Administration you define the operator interface.
2. In I/O Configuration – I/O you define how to use the
different input and output connections on the DS Drive. For
cable connection, see page 11.
3. In I/O Configuration – RE-Alarm Setup you set the
characteristics for the external alarm. The RE-Alarm only
works for DS when its hex switch is set to position 3.
4. Tool Service Setup gives you information about the service
status of the tool and also a possibility to program your own
service interval, see page 12.
5. Selector Source decides what input is used to select
between p-sets. You can choose between:
❑None
❑I/O Digital
❑I/O Bus (Selector 4 and Selector 8, see page 11)
The I/O Bus only works for DS when its hex switch is set to
position 5 for Selector 4 and position 6 for Selector 8.

11
INPUTS AND RELAYS
Figure 1 shows how to connect in order to obtain a signal on one of
the digital inputs. The power source can either be built in 24 VDC or
an external power source. Figure 2 shows how to connect to obtain
OK and NOK signals using relay outputs RE1 & RE2.
By programming the inputs with Selector bit 0-3, see figure 3, it
is possible to have up to eight different p-sets. The inputs are
interpreted binary according to the table below.
Figure 1 Figure 2
Figure 3
Parameter
set
Selector bit 012345678
0 010101010
1 001100110
2 000011110
3 000000001

12
TOOL SERVICE SETUP
In the
Tool Service Setup window you can see information about
last service date and number of tightenings after service. It is
also the start window to set the service date in the tool and the
service interval. You activate the service indicator by changing
the pull down menu to ON.
When clicking the "T ool Service
Reset" but ton, a new window is
shown where you set the
service interval and service
date. The default value is
250,000 tightenings, which is
also our max recommended
interval for a normal joint. When
pressing OK and STORE the
counter will be reset to 0.

13
ERROR CODES
Error codes are displayed with four characters, beginning with an E.
All error codes are found in the DS Drive Manual.
Group 0 Rundown failures, E000-E031
Group 1 Event related errors, E100-E131
Group 2 User input error, E200-E231
Group 4 Communication errors, E400-E431
Group 5 Hardware errors TOOL, E500-E531
Group 6 Hardware errors DC3000/MC3000, E600-E631
Error
code Description
Ack-
now-
ledge What to do? Help text
E001 Torque LO No Start button was probably released to early. Let
the tool ”finish” the tightening. ”Torque value”
E002 Torque HI No
The programming is bad. Please check the
programming and make sure that you have
some movement on the socket in the second
stage.
”Torque
value”
E004 Angle1 LO No Check programming or the joint. LO°1
E005 Angle1 HI No Check programming or the joint. HI°1
E006 Angle2 LO No Check programming or the joint. LO°2
E007 Angle2 HI No Check programming or the joint. HI°2
E101 Pset invalid
(Check sum
error) Yes Change Final target by the F2 function on the
Drive Key Pad and store it. Afterwards change
it back to its original value.
E108
Rundown
prohibited
due to key-
pad usage
No Press on the SET or ENTER button on the key pad until you see four dashes or dots on the
display.
E112 Rehit No
You tried to tighten the fastener when it was
already tightened and Alarm On Rehit was
marked inTTDS/Configuration. Please unmark
Alarm On Rehit or retighten the fastener.
E115 Direction
uncertain Yes
You have probably pressed the start button too
quick since last time. Please allow more time
between releasing the start button and trying
to start the tool again.
E120 Motortuning
failure Yes Redo the Motortuning. If this does not work,
service the tool.
E131 Tool Discon-
nected Yes Shut the drive off and connect the tool. Start
the drive.
E206 Pset nr
invalid No Two or more sockets are lifted at the same time
or pset 9 or higher is chosen.

www.atlascopco.com
Error
code Description
Ack-
now-
ledge What to do? Help text
E403 IO device not
responding No Check cables and restart drive.
E408 Multiple devices of same type on
IO bus Yes You are only allowed to use one.
E409 Multiple selectors
on IO bus Yes
E410 No selector found and pset
source is IO bus Yes
Connect the Selector and restart
the drive or choose None
on Selector Source inTTDS/
Configuration.
E412 IO expander has
ID <> 2 Yes
E413 RE Alarm has ID
<> 3 Yes
E415 4 socket selector
has ID <> 5 Yes
E416 8 socket selector
has ID <> 6 Yes
E501 Tool overheated No Let the tool cool down and restart.
E502 Service Indicator Yes Service the tool.
E517 Tool maxtorque or Gear Ratio out
of range Yes Check tool memory.
E601 Dcbus LO Yes Restart drive. If problem still
remains check line voltage.
E602 Dcbus HI Yes Restart drive. If problem still
remains check line voltage.
ERROR CODES
9833 1424 01Åtta.45 Tryckeri AB 2008:1