Jergens ASG HIOS BLG BC2 Installation manual

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HIOS BLG BC2
Programming Instructions
Dec 2015

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Thank you for buying an ASG BLG Series Tool. We know you have a choice in
torque tools and we appreciate that you chose ASG.
CONTENTS
Subject Page
User Interface Display and Button Functions 3-4
Screw Count and Value Setting Display Section 3
Function Display Section 3
F1 Button 4
F2 & F3 Buttons 4
Pass LED 4
Fail LED 4
Quick Start Procedure 4-6
Navigating the User Interface 6-7
Setting the Functions 7-10
Enable or Disable Error Proofing 7
Fastener Count 7
Setting the Minimum Revolutions 8
Setting the Maximum Revolutions 8
Setting the Work Reset Timer 8
Setting the Reverse Count timer 8
Setting the Buzzer 9
Setting the Min/Max Alarm Buzzer 9
Viewing the Cycle Totals 9
Adjust the Re-Hit Timer 10
Additional / Common functions 10
Reset the Count 10
Exiting the User Interface (Saving Changes) 10
General Information 10-11
Fastener Count 10
Counter On/OFF 10
Minimum/Maximum Revolutions 11
Work Reset timer and Reverse Count Timer 11
Re-Hit Timer 11
Optional Equipment 12
ESD RoHs Properties 12

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BC2 Programming Instructions
BC2 tools feature a built in Screw Counter and a Pulse System. The Pulse System is a
mechanism using an electronic signal (Pulse) that occurs during motor revolutions. By
installing several fasteners into the assembly the driver learns the number of motor
revolutions required to correctly tighten the fasteners to the desired torque. The driver
then establishes a minimum and maximum number of revolutions for an acceptable
fastener and displays the results using the RED and GREEN LEDs on the display.
The visual display and audible signals combine to alert the operator to the screw count
status and will prevent missed or improperly driven fasteners. BC2 tools also feature
an optional I/O capability which when combined with a PLC can provide full process
control.
User Interface Display and Button Functions
The BC2 interface will show numbers, letters or symbols, depending what mode the
system is in. It also contains red “FAIL” LED, a green “PASS” LED and 3 programing
buttons, F1, F2 & F3 complete the BC2 tool interface.
1. Screw Count and Value Setting Display Section
The batch count is set and the screw count is displayed when the counter
function is ON. After starting the assembly the number of fasteners remaining is
displayed. The count decreases with each fastener properly installed.
The numbers for setting the various functions appear here when that function is
being set.
2. Function Display Section
The symbols corresponding to the functions are displayed while in Set Up Mode
(See Pages 6&7)

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User Interface Display and Button Functions Cont.
3. F1 Button
Press and hold the F1 button until [ “P”] shows on the display. When the button is
released [ON]* will show on the display.
Continue to press F1 to scroll through the various set up functions.
Whenever a function is changed, press and hold F1 until the buzzer sounds twice
to save the change**
* If the counter is turned off, [OFF] will appear on the display.
** If the buzzer has been disabled it will not sound.
4. F2 and F3 Buttons
Use these buttons to change the values in the Set Up Function. Some values are
limited depending on the function being set.
Press and hold the F2 button until [ r 0] is displayed and the Pass/Fail lights blink.
This will put the tool in the joint learning mode.
5. Pass LED***
When the fastener is driven properly the Green LED is lit.
6. Fail LED***
When the fastener is not driven properly the Red LED is lit.
***The LED will remain on until the trigger is operated again.
Quick Start Procedure
Important! Before actually learning the joint, drive 1 or 2 fasteners to “exercise”the tool
and set up the starting position of the clutch.
1. Press and hold the F2 button until [r 0] is seen on the display and both the Pass &
Fail LEDs blink.

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Quick Start Procedure Continued
2. Start learning the joint by driving 3 or more of the same fastener into the same joint.
Make sure to use the same fasteners, parts and method of pick up to be used in
production. As you drive each fastener you will see the actual number of motor
revolutions displayed.
3. Press the F3 button to select an acceptable range for the Pass/Fail criteria.
This will be displayed in the following order; ±0%,±5%,±10%,±15%,±20%.
4. Press the F1 button to confirm the reference values for Pass/Fail and the acceptable
range. The display will alternate between showing the Maximum and Minimum
numbers of motor revolutions for the joint learned. Pressing F3 while these numbers
are flashing allows you to change the ±% for Pass/Fail and will display the new
numbers for the Maximum and Minimum values as changed by the selected %.
Example, Say the reference values for an acceptable fastener are Min 90 and
Max 120 and the range selected is 0%. Any fastener driven where the motor turns
between 91 and 119 revolutions, and the clutch shuts off, will result in a Pass, or
Green LED. Fewer than 90 or more than 120 revolutions will result in a Fail, or Red
LED. If the motor is run for 90 revolutions or more and the trigger is released,
with no clutch shut off (ABORT), the result is a Fail or Red LED.
5. Press and hold the F2 button until the buzzer sounds twice, the Minimum and
Maximum values and the word HIOS scroll across the display to complete learning
the joint.
6. Press and hold the F1 button to see [P ] on the display, then release to see [ON ]
show on the display. Press the F1 button once to see [n05 ] with the “5” flashing.
This would indicate that the count is set to 5 fasteners.
7. To change the count, press the F3 button. Each press of the button will increase the
flashing number by one count, up to 9, after 9 the count will start over at 0.

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Quick Start Procedure Continued
The count, or batch, can be set between 1and 99, press the F2 button to move from
the ones place to the tens place, press the F3 button again to increase the tens place
between 0 and 9.
When finished setting the count, save and exit by pressing and holding the F1 button
until you hear the buzzer* sound twice and the word HIOS scrolls across the display.
* If the buzzer has been disabled it will not sound!
The Quick Start Procedure may set a wider range between the Minimum number of rotations and
the Maximum number of rotations than you would want. By using the set up mode functions you
can customize the set up to where you could detect a missing washer or an improper length
fastener.
Navigating the User Interface
The following shows the different displays as seen in the order they appear as you scroll through
the different functions by pressing and releasing the F1 button. The numbers shown in the
display drawings below are the factory default settings and will change to reflect the values you
choose for your application
Instructions on how to set each different function can be found starting on page XX
1. Press and hold F1 for 2+ seconds until [P ] appears to enter the setup mode.
Release the F1 button to see [On ] show on the display.
2. With [On ] showing, press and release F1 to see [n05] on the display.
With [n05] showing, press and release F1 to see [u60 ] on the display.
3. With [u60] showing, press and release F1 to see [n20] on the display.
With [n20] showing, press and release F1 to see [├1.0] on the display.
Navigating the User Interface Continued

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Navigating the User Interface Continued
4. With [├1.0] showing, press and release F1 to see [ r 0.4] on the display.
With [ r 0.4] showing, press and release F1 to see [ d03] on the display.
5. With [ d03] showing, press and release F1 to see [U 3] on the display.
With [U 3] showing, press and release F1 to see [L00] on the display.
6. With [L00] showing, press and release F1 to see [≡0.5] on the display.
Continue to press and release F1 to return to the beginning or press and hold F1 for
2 seconds to exit the User Interface
Note! The numbers shown in the above illustrations and mentioned in the text below are the
factory default settings. These numbers will change to reflect the values you select for your
application. Setting the Functions
1. Enable or Disable Error Proofing. (see screens 1&2 on page 6) To enable or
disable error proofing, press and hold F1 for more than 2 seconds. The letter “P will
show on the display until the button is released. When the button is released, either the
word [On ] or [OFF] will show on the display. Press and release F3 to toggle between
[On ] and [OFF]. Press and hold F1 for more than 2 seconds to save and exit. When
[OFF] is selected the tool will operate like a regular driver.
2. Fastener count. (see screen #3 on page 6) The fastener count shows on the
display when the driver is in use. Each time a fastener is driven properly the number on
the display will decrease by 1. When the last fastener is driven 0 will show on the
display for a period of time before the count is reset. To change the count get to screen
#3 [n05] with the 5 flashing on the display, by following the instructions for navigating
on page 6. To change the count, press and release F3 to increase the ones digit
between 0 and 9. Press F2 to select the tens digit and press F1 to increase between1
and 9. Press and hold F1 for more than 2 seconds to save and exit.

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Setting the Functions Continued
3. Setting the Minimum Revolutions. (see screen #4 on page 6) Note! the BC2 counts
the motor revolutions, not the actual revolutions of the fastener! Get to screen #4 with [u60]
showing with the 0 flashing on the display by following the instructions for navigating on
page 6. The Minimum and Maximum revolution numbers are actually expressed by 3
digits while only 2 will show on the display during setting. To change the count, press
and release F3 to increase the ones digit between 0 and 9. Press F2 to select the tens
digit and press F3 to increase between1 and 9. Press F2 again to select the hundreds
digit and press F3 to increase between1 and 9. Press and hold F1 for more than 2
seconds to save and exit.
4. Setting the Maximum Revolutions. (see screen #5 on page 6).Get to screen #5
with [n20] showing with the 0 flashing on the display by following the instructions for
navigating on page 6. The Minimum and Maximum revolutions number is actually
expressed by 3 digits while only 2 will show on the display during setting. To change
the count, press and release F3 to increase the ones digit between 0 and 9. Press F2
to select the tens digit and press F3 to increase between1 and 9. Press F2 again to
select the hundreds digit and press F3 to increase between1 and 9. Press and hold F1
for more than 2 seconds to save and exit. Note!, while driving a fastener you will see the
motor revolutions on the display while the fastener is being driven, then the total number of
actual motor revolutions will stay visible for a moment before the display defaults to the
remaining fastener count.
5. Setting the Work Reset Timer. (see screen #6 on page 6) Get to screen #6 with
[├1.0] showing with the 0 flashing on the display by following the instructions for
navigating on page 6. The Work Reset Timer controls the time a buzzer will sound and
[ 0] will show on the display between driving the last fastener in the batch and the
display resets with a new starting count. The Work Reset time can be set between 0.0
and 3.9 seconds. To set the Work Reset Time press and release F3 to increase the
ones digit between 0 and 9, Press F2 to select the tens digit. Press and release F3 to
increase the 10s digit between 0 and 3. Press and hold F1 for more than 2 seconds to
save and exit. Note, when setting the reverse count time, the Work Reset Time must be set
higher than the Reverse Count Time.
6. Setting the Reverse Count Timer. (see screen #7 on page 7) Get to screen #7
with [r 0.4] showing with the 0 flashing on the display by following the instructions on
pages 6&7. The Reverse Count Timer sets a time to decrease the Count by 1 when a
screw is removed. The Reverse Count can be set between 0.1 and 1.0 seconds. To set
the Reverse Count Timer press and release F3 to increase the ones digit between 1
and 9. Press and release F2 to select the tens digit. Press and release F3 to increase
the tens digit between 0 and 1. Press and hold F1 for more than 2 seconds to save and
exit. Note! Reverse Count Time cannot be set higher than 1.0

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Setting the Functions Continued
7. Setting the Buzzer. (see screen #8 on page 7) Get to screen #8 with [d03]
showing with the 3 flashing on the display by following the instructions on pages 6&7.
The buzzer can be set as an indicator, an alarm or to enable or disable various
functions. The chart below shows what each digit controls;
2nd digit (tens place)
0=Buzzers Enabled / Reverse Count Enabled
1=Buzzers Enabled / Reverse Count Disabled
2=Buzzers Disabled / Reverse Count Enabled
3=Buzzers Disabled / Reverse Count Disabled
1st digit (ones place)
2=Clutch Signal Buzzer Disabled
3=Clutch Signal Buzzer Enabled
To set the Buzzers, press and release F3 to increase the ones digit between 2 and 3.
Press and release F2 to select the tens digit. Press and release F3 to increase the tens
digit between 0 and 3. Press and hold F1 for more than 2 seconds to save and exit.
8. Setting the Min/Max Alarm Buzzer. (see screen #9 on page 7) Get to screen #9
with [U 3] showing with the 3 flashing on the display by following the instructions on
pages 6&7. The Min/Max Alarm Buzzer can be set as an alarm to alert when the
Trigger is released or the clutch activates and the motor revolutions are below the
Minimum number set or above the Maximum number set. The chart below shows what
each digit controls;
1st digit (ones place)
0=Neither the Minimum or the Maximum Alarms will sound
1=Only the Minimum Alarm will sound
2=Only the Maximum Alarm will sound
3=Both the Minimum and the Maximum Alarms will sound
To set the Buzzers, press and release F3 to increase the ones digit between 0 and 3.
Press and hold F1 for more than 2 seconds to save and exit.
9. Viewing the Cycle Totals. (see screen #10 on page 7) Get to screen #10 with
[L00} showing on the display. These numbers indicate the total number of cycles where
the clutch activates whether the Count is On or OFF. Running the tool and releasing
the trigger before the clutch activates will not count as a cycle. These numbers can be
used to determine when to perform maintenance or to rotate the tool out of service.
The picture below shows how to read the numbers. Note! These numbers can’t be
adjusted. Nothing will appear until after 99,999 Cycles and the maximum will be 9,999,999 Cycles.

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Setting the Functions Continued
10. Adjust Re-Hit Timer. (see screen #11 on page 7) Get to screen #11 with [≡0.5]
showing with the 5 flashing on the display by following the instructions on pages 6&7.
The Re-Hit Timer sets a time period between the clutch shut off and a second or third
trigger-pull-clutch-shut-off sequence before an Error / Fail is registered. The Re-Hit
timer can be set between 0.0 and 9.9 seconds. To set the Re-Hit Timer, press and
release F3 to increase the ones digit between 0 and 9. Press and release F2 to select
the tens digit. Press and release F3 to increase the tens digit between 0 and 9. Press
and hold F1 for more than 2 seconds to save and exit. Note! the Re-Hit Timer functions
only when the green Pass LED is lit upon a fastener rundown.
Additional / Common Functions
1. Reset the Count. If it becomes necessary to terminate the assembly process before
all fasteners have been installed, the count can be reset to the starting number at any
time. To reset the count, press and hold F3 for more than 2 seconds. The word HIOS
will scroll across the display and the display will reset to the starting count.
2. Exiting the User Interface. (exiting also saves any changes made to the values)
The User Interface can be exited at any particular point without scrolling through the
remaining screens. Example; You are at the Count screen and you confirmed that the
count is set at 5. To exit (and save any changes) press and hold F1 for more than 2
seconds. The next screen will appear briefly, the buzzer will beep twice (if enabled)
and the word HIOS will scroll across the display. The current count will then show and
the tool is ready to operate.
General Information
Fastener Count. The fastener count number seen on the display always registers the
number of fasteners remaining to complete the assembly.
Counter On/OFF. Remember that when the counter is turned off the driver operates
like a normal driver with no error proofing or counting functions.

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General Information Continued
Minimum/Maximum Revolutions. Remember that the Minimum and Maximum
revolutions are the motor revolutions, not the number of revolutions of the bit, or
fastener. You may notice a difference in the Maximum revolution numbers when driving
fasteners of the same length. This is due to the fact that the clutch has some “slack”
caused by its construction. This is the reason you need to drive several fasteners
before learning a joint. This may also be the reason for an error on a fastener driven
after running the tool in reverse when loosening or removing a fastener.
Because the number of motor revolutions will be greater than the actual rotation of the
fastener it is possible to “fine tune” the fastener to be able to detect the presence or
absence of a washer or an improper length fastener in the joint
If you are using a screw presenter to pick up the fasteners you should set the Minimum
Revolutions high enough so that when the trigger is pulled to rotate the bit into the
head of the fastener to pick it out of the presenter, you don’t generate an error.
Work Reset Timer and Reverse Count Timer When the last fastener in the batch has
been driven properly, the green (Pass) LED is lit, the Buzzer beeps (if enabled), the
Maximum Revolutions show on the display briefly, then a 0 is seen before the count is
reset to the starting count. The Work Reset Timer controls how long the green LED
stays lit, the buzzer beeps, and 0 remains on the display before the counter resets to
the starting count.
The Reverse Count Timer sets a time period where removing a fastener will increase
the count shown on the display by one. After this time period, removing a fastener will
not affect the count.
It is not necessary to set the Reverse Count Timer to use the Work Reset Timer but it
is necessary to set the Work Reset Timer to use the Reverse Count Timer. In order
properly identify the removal of any screw in the batch, the Work Reset Timer must be
set Higher than the Reverse Count Timer. Otherwise removing the final screw in the
assembly will not be recognized and the count will not be increased, but will be reset.
Example; There are 5 screws in the batch, when the two timers are set properly and 4
fasteners are driven correctly with the count showing 1, driving and removing the final
fastener will reset the count to 1. When the two timers are set improperly and 4
fasteners are driven correctly with the count showing 1, driving and removing the final
fastener resets the count to 5
Re-Hit Timer. In some applications it may be desirable to pull the trigger a second or
third time after the initial clutch shut off to properly clamp a gasket or lock washer.
Setting the Re-Hit timer will allow this practice without registering an error, lighting the
Red (Fail) LED or sounding the buzzer.

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Optional Equipment
The BLG BC2 tools perform the counting and Error Proofing functions as standalone
units. With the options below it is possible to add I/O capability, data capturing
capability and the ability for process control by interfacing with a PLC or other controls.
#65665 BLG BC2 I/O Cable with sample software.
#65664 BLG-IO-Pro 1I/O Box.
ESD Properties. BLG tool Housings are constructed with Anti-Electrostatic Resin.
The surface resistance is less than 3x1012 Ω
RoHs BLG Tools are RoHs Compliant