Sturtevant Richmont

Sturtevant Richmont
Global Reach. Local Support.
Programmable Torque Verifier FM - Generation II
Owner's Manual
P/N: 857234A
Rev.: A
Date:May 30, 2003
Sturtevant Richmont Div. Ryeson Corporation
3203 N. Wolf Road Franklin Park, IL 60131
Phones: 847/455-8677 800/877-1347
Fax: 847/455-0347
URL: www.srtorque.com
E-mail: [email protected]
Thank you for choosing S/R for your assembly solution!
The Programmable Torque Verifier FM - Generation II is simple to operate once you
have become familiar with it. We encourage you to read this manual carefully and use it
when setting up and operating your new unit.
Should you need any additional support, please contact us via e-mail, phone, or fax, or
visit our website: www.srtorque.com.
We encourage you to use our website; the technical support it offers is expanded every
week or two, and is always available. If you have suggestions or recommendations for
additional improvements to it, we would be very happy to hear them!
Thanks Again!
Table of Contents
Chapter
Page
Chapter 1 - Introduction to the PTVFM Generation II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Chapter 2 - Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Chapter 3 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Chapter 4 - Programming the Generation II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Chapter 5 - Operating the PTV-FM Generation II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Chapter 6 - FM Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Chapter 7 - PLC Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Chapter 8 - Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Additional Information
Additional information and updated information on S/R products is made available through our
website. We urge all of our customers to check the Technical Information and FAQ sections of
our site frequently. The 24 hours a day, 7 days a week, instant availability of our site makes it
ideal for those with a question on just about any S/R product.
Our URL is: www.srtorque.com.
Page 1
Page 2
Chapter 1 - Introduction to the PTVFM Generation II
Photograph 1
Key to Photographs 1 through 4
1.
4.
7.
10.
13.
16.
19.
22.
25.
Antenna Mount
Faceplate
Run LED
LED Panel
Suspend LED
Set LED
Power Cord
Serial Port
Power Entry Module
2.
5.
8.
11.
14.
17.
20.
23.
26.
Case
Key Lock
Setup LED
Accept LED
Down Keyswitch
Mode LED
Antenna
PLC Connector
Power Setting Notice
3.
6.
9.
12.
15.
18.
21.
24.
Front Panel Screws (4)
Beeper
P-Set LED
Reject LED
Up Keyswitch
Suspend LED
Parameter Switch
On/Off Switch
Page 3
Photograph 2
Photograph 3
Page 4
1.
Antenna Mount
The antenna mount is where the antenna (20) is attached to the unit. The antenna receives the
FM radio signal from the FM Switch Wrenches.
2.
Case
The case houses all of the electronics components. It is made of steel and has a black crinkle
finish.
3.
Front Panel Screws (4)
The four (4) front panel screws attach the front panel of the case to the sides and rear. Unlike
the 1st generation of the PTV-FM, they are only removed for repair purposes. “Teaching” the
PTV-FM a new wrench is performed without front panel removal.
4.
Faceplate
The faceplate houses all programming keyswitches and all LED’s used for programming and
communications.
5.
Key Lock
The key lock provides or denies access to programming functions via the keyswitches.
Programming can only be performed when access is permitted.
6.
Beeper
The beeper provides audible signals pertinent to fastener tightening process acceptability and
batch completion during operation of the unit.
7.
Run LED
This LED is lit when the unit is in operating mode.
8.
Setup LED
This LED is lit when the unit is in the setup or programming mode.
9.
P-Set LED
The P-Set LED is lit when the unit is
10.
LED Panel
The LED panel displays the information needed during both setup/programming of the unit and
operation of it.
11.
Accept LED
The green accept LED lights when the signal from the FM Switch Wrench meets the specification
for the fastener as programmed into the PTV-FM. It indicates the torque wrench has been properly used to tighten the fastener.
Page 5
12.
Reject LED
The red reject LED lights when the FM Switch Wrench has been pulled for more than the maximum specified period of time for the programmed requirements for the fastener. This almost
always means the fastener has been overtorqued. When this LED is lit, the fastener must be
loosened, then properly torqued.
13.
Suspend
This LED lights when the unit has suspended counting signals received from the FM Switch
Wrench(es). The primary use for this function is during the wrench torque setting operation.
14.
Down Keyswitch
The down keyswitch is used to page through menu selections or lower numeric values during
programming of the PTV-FM.
15.
Up Keyswitch
The up keyswitch is used to page through menu selections or increase numeric values during
programming of the PTV-FM.
16.
Set Keyswitch
The set keyswitch is used in conjunction with other keyswitches during programming to lock in,
or “set”, certain values during programming of the unit.
17.
Mode Keyswitch
The mode keyswitch is used in conjunction with other keyswitches to display element settings
during operation.
18.
Suspend Keyswitch
The suspend keyswitch suspends counting signals received from the FM Switch Wrench(es).
This function is most commonly used during the torque setting operation on the tools.
19.
Power Cord
The power cord depicted is the one used for 120 VAC operations. Both the 120VAC and 240
VAC cords have one end that plugs into the Power Entry Module (PEM), and one end that connects into the power supply. For PTV-FM units used with 240 VAC power, the correct power
cord must be ordered with the unit.
20.
Antenna
The antenna receives the signals from the FM Switch Wrench(es). It is mounted atop the PTVFM on the antenna mount.
Page 6
21.
Parameter Select Switch
The parameter select switch allows the user to select which set of parameters the PTV-FM is to
use. A set of parameters includes: FM Switch Wrench (one only per parameter), FM channel (1
channel only per parameter) minimum pull time, maximum pull time, TBC (Time Between Clicks),
TBB (Time Between Batches), and the number of fasteners in each batch. This is a significant
addition to the Generation II PTV-FM, and is discussed more fully in the next chapter of this
manual.
22.
Serial Port
The serial port connector is used by the factory to download the original firmware. The port is for
factory use only.
23.
PLC Connector
The PTV-FM uses a 19-pin PLC connector for communicating with PLC’s controlling operations
related to the output of the fastening operation on which the PTV-FM is used. For more on this
topic, see Chapter 6.
24.
On/Off Switch
This rocker-type power switch controls power to the PTV-FM.
25.
Power Entry Module (PEM)
The PEM is new to the Generation II PTV-FM. It serves as the connection point for the power
cord, provides the ability to select 120 VAC or 240 VAC operation, and holds the fuse that protects the circuitry and the operator. For more on this topic, see Chapter 3.
26.
Power Setting Notice
The power setting notice is a tape strip affixed to the PEM. It tells the user whether the unit was
shipped with the PEM set for 120 VAC or 240 VAC operation. Do NOT remove this strip until
you have read Chapter 3 and understand the functions of the PEM thoroughly.
Warning
Do NOT remove the Power Setting Notice strip until you have read Chapter 3 and
understand the functions of the PEM thoroughly.
There expanded capabilities of the Generation II models of the PTV-FM make it significantly different in installation, programming, and operation from the first generation. Owners of first generation units need to read this manual carefully, since the expanded capabilities resulted in new
and different procedures in these areas.
Page 7
How to Distinguish First Generation PTV-FM Units from Generation II PTV-FM Units
First Generation
Attached Power Cord
No Power Entry Module
No Parameter Select Switch
Delivered through 4/15/03.
Page 8
Generation II
Separate Power Cord
Power Entry Module on right side of unit.
Parameter Select Switch on left side of unit.
Delivery began 3/1/03.
Chapter 2 - Principles of Operation
Overview
The PTV/Switch Wrench System is designed to assist the manufacturer in closing several loops
in the quality system which have been, until now, gaps in their quality improvement efforts. The
key capabilities this system enables:
1. Ability to integrate hand torque tools into the automated line control system.
2. Process control of the actual torque wrench use process, not just the wrench calibration
process.
3. Rapid and effective training in proper torque wrench use, with reinforcement of proper use
provided with every wrench click.
This chapter will cover the system, starting with the concepts involved in the use of the
Generation II PTV-FM and FM Switch Wrench system, than move to line integration.
Concept Principles
Any and every clicker-type torque wrench can be operated in essentially three ways:
It can be clicked too quickly, or “jerked”.
This can result in either undertorquing because the torque was not transmitted to the fastener, or overtorquing if it was jerked and too much rotation was applied, even though the
time period was very brief.
It can be used properly, with force applied smoothly until the wrench clicked, then the force
immediately released.
When a preset wrench is used, this results in accurate transmission of the preset torque to
the fastener.
It can be pulled past the click.
This results in overtorquing the fastener by rotating it past the point where the correct
torque was attained.
The fact that there are two operator-induced process failure modes in clicker-type torque wrench
use has always been a weak point in their selection as assembly tools. A probability of occurrence for each failure mode exists even when the tool is used by a trained, experienced and
Page 9
quality-conscious assembler. The probability of occurrence rises with any lack of attention, training, or experience - individually and in combination.
On assemblies with multiple fasteners, the previously-listed failure modes that exist for each fastener are joined by a fourth failure mode:
Failure to torque all fasteners.
This may occur due to an interruption in the process which causes the assembler to
resume torque application starting with the wrong fastener after the interruption.
This increases the process failure mode count to three, with only one possible correct assembly
mode.
The PTV/Switch Wrench system directly addresses all three of these failure modes, reducing the
probability of occurrence and increasing the probability of detection of each. Further, the probability of detection is immediate, and immediately communicated to the operator.
The first two failure modes - jerking the wrench and pulling past the click - are directly related to
time. The PTV/Switch Wrench System uses this linkage to obtain control of the process,
Diagram 1 shows a chart with three elements. The X-axis is time, and the Y-axis is signal
strength. The principle is that the signal begins when the wrench clicks, and ends when the
operator releases pressure on it and allows it to reset. Signal transmission may be by almost
any means (hardwire, FM radio, laser, sound) as long as it begins at the click and ends when the
pressure is released. The threshold element is present to avoid any problems related to noise in
the signal, again, regardless of means of transmission.
When a clicker-type torque wrench is
used properly on a joint, there is a period
of time in which the wrench is clicked
before release; the click has a proper
duration. If a wrench is “jerked” it is
cycled in a shorter period of time than if
properly used. If the wrench is pulled
past the click, it spends a longer period of
time inside the “click”; the duration of a
proper use is exceeded.
In Diagrams 1 - 5, the vertical axis is time
0 seconds, the start of the wrench “click”.
Page 10
By determining the correct amount of
time a wrench should spend in the
“clicked” position on any given joint, we
can rule out any shorter or longer period in that position as unacceptable.
Diagram 2 depicts the addition of minimum and maximum acceptable times
for the wrench to be in the “clicked”
position. For convenience, the minimum acceptable time is called “TMIN”
and the maximum acceptable time is
labeled “TMAX”.
In Diagram 3 the wrench has been
jerked, or clicked too quickly. The
measure of time for the signal from the
wrench starts at the left and continues
until pressure on the wrench is
released and it resets, ending the click.
Since the wrench was jerked, it did not
spend sufficient time in the clicked
position to properly torque the fastener.
It never got to time “TMIN”, and therefore would not count as a properly
tightened fastener.
Diagram 4 depicts the signal from a
wrench that has been properly used.
The wrench was neither jerked nor
pulled past the click. The duration of
time the wrench spent in the clicked
position was correct; it was more than
the minimum time and less than the
maximum time. This means the
wrench was used to properly tighten
the fastener.
Page 11
Diagram 5 shows the signal from a
wrench that was pulled past the click,
most likely overtorquing the fastener.
The time the wrench spent in the
clicked position exceeds the maximum
allowable time for that joint. This fastener is rejected for overtorque.
The PTV-FM works with the FM Switch Wrench to bring systematized control to the use of manual torque wrenches. The control is applied as follows:
1. The FM Switch Wrench is a preset clicker-type torque wrench. The torque is preset using a
torque tester to assure the wrench is accurately set, then the torque setting is locked in.
2. The joint is tested with the FM Switch Wrench and an indicating torque wrench to determine
the proper duration of a click on the joint.
3. The maximum and minimum duration of a click is programmed into the PTV-FM.
4. The FM Switch Wrench is used to tighten a fastener. As soon as the wrench clicks, an FM
radio signal is sent to the PTV, and a timer starts. The signal is continuous for as long as the
wrench is in the clicked position.
5. When the pressure is released on the wrench, it resets, turning off the FM signal. This stops
the timer and the PTV compares the time to the minimum (TMIN) and maximum (TMAX)
allowable times for signal duration.
6. The PTV-FM communicates immediately to the operator the acceptability of that use of the
wrench. Front panel LED’s and a buzzer inform the operator whether or not the fastener was
accepted.
7. If the fastener was properly tightened, the PTV-FM advances the count of fasteners tightened
in the batch by one. This assists the operator in keeping track of wherever they stand in a
multi-fastener assembly.
Page 12
The PTV-FM reduces the probability of missing a fastener in a multi-fastener assembly in two
ways:
1. Displaying the count of properly-torqued fasteners (or quantity remaining to be torqued) in the
batch at all times.
2. Sending a “Batch Accept” signal to the PLC and an audible signal to the operator when the
correct number of fasteners on the assembly has been properly tightened. The PTV automatically resets to zero (or the number of fasteners to be tightened on the next assembly)
upon completion of the batch.
The operator is actually provided multiple signals at each step of the process, both for each individual fastener and for the assembly batch.
Parameters
The definition of what is interpreted by the PTV-FM as a “proper” tightening is called a “parameter”. Each parameter consists of a set of elements:
a minimum signal duration (TMIN),
a maximum signal duration (TMAX),
the FM channel the wrench will use (0-7),
which wrench will be used,
and the number of fasteners in the batch.
Time Between Clicks and Time Between Batches are additional optional elements.
The Generation II can store up to four parameters. At any given time, only one of the four may
be active. Switching among them may be performed manually via the Parameter Select Switch
on the left side of the unit, or be activated by a PLC command sent through the PLC Connector.
This provides the ability to tighten up to four different joints using only one Generation II PTVFM, a significant advance over the first generation. The four parameters can use from one to
four wrenches (for different torque levels or fastener sizes), or one to four different fastener
counts, or any combination that does not require more than four definitions of “proper” tightening
of the fasteners.
Two examples of how the Generation II works follow. The first example uses a Generation II
PTV-FM and a single FM Switch Wrench. This example assumes that the torque for all three
fasteners is the same. The second example uses six fasteners at two different torques to
demonstrate how the multiple parameter capability may be used.
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First Example
In this drawing we see the product to be assembled,
and the three fasteners to be tightened at this assembly station. The operator has been provided with an
FM Switch Wrench preset to the proper torque for the
three fasteners. The operator has been told to tighten
the fasteners with the FM Switch Wrench, and to do
so in the sequence shown.
The PTV-FM is silent, and displays the count 0.
The operator uses the FM Switch Wrench to tighten
the first fastener to specification, as shown to right.
Since the wrench was used properly, the PTV displays
the green Accept LED, and the count advances to 1
on the LED Panel.
Even if the operator were interrupted now, when work
resumes he would only need to look at the LED Panel
to know which fastener had been tightened.
The operator then resumes tightening in the established 1-2-3 pattern. He uses the wrench properly in
tightening the second fastener.
Upon completion of tightening the second fastener,
the PTV again gives him a green Accept LED, and the
count on the LED Panel advances from 1 to 2.
Page 14
The operator then tightens the third fastener in the
series, but uses the torque wrench incorrectly by
pulling past the click. This results in the red Reject
LED lighting on the PTV, and the beeper going off.
The count does not advance, since the wrench was
not used properly.
The operator next uses the wrench to loosen the fastener, and retightens it properly. Because the wrench
was used correctly, the green Accept LED lights, the
beeper sounds twice to announce the completion of
the batch, then the LED Panel resets to 0 for the next
assembly. At the same time, a Batch Accept signal is sent to the PLC port. If a connected PLC
is programmed to advance the line upon completion of the operation, the signal from the PTV
can trigger the advance. This removes the necessity for operator intervention to achieve line
advance, reducing the probability of error or delay.
Second Example
In this second example there are six fasteners to be tightened at the workstation, two on the front
of the assembly and four on the rear. The two on the front each have the same torque. The four
on the rear have the same torque as each other, but the torque is different from the fasteners on
the front. Further, the front joint is a hard joint (metal to metal), and the rear joint is a soft joint
that has a gasket, necessitating different signal durations (click times).
Page 15
This requires the use of two different FM Switch Wrenches, each set to a different torque. It also
uses the multiple parameter capability of the Generation II PTV-FM. This is not done just
because of the two wrenches required, but also because the soft joint requires a different time to
work properly. The soft joint requires more time in the clicked position to torque the joint properly. The definition of “properly” has changed from that of the front joint.
The first FM Switch Wrench will be preset for the torque for Nuts #1 & #2, and the times and
other components of the parameter will be programmed into the Generation II as Parameter 1.
The second FM Switch Wrench will be preset to the torque for Nuts #3 - #6, and the times and
other components of the parameter will be programmed into the Generation II as Parameter 2.
Again, all the operator needs to do is follow the correct sequence using the correct tools. A color
coding can be applied to the wrenches (colored tape or a daub of paint) as additional visual cues
for the operator during assembly.
In operation, the steps and feedback for each would be as follows:
1. The assembly moves into the assembly station. The operator picks up Switch Wrench #1,
and torques the first nut properly. The operator receives a green Accept LED and the count
on the LED Panel advances from 0 to 1.
2. The operator then uses the same torque wrench to tighten the second fastener in the
sequence, and performs the second tightening properly. The operator again receives a green
Accept LED on the PTV, a double beep is sounded to signal the completion of the batch, a
batch accept signal is sent to the PLC Connector, and the count is reset to 0 for this parameter.
3. The operator returns Switch Wrench #1 to the workbench, and obtains Switch Wrench #2.
He then rotates the Parameter Selector from A to B. Since no fasteners have been tightened
for this parameter, the count displayed on the LED Panel is 0.
4. The operator uses Switch Wrench #2 to tighten Nut #3. Since he performs the operation
properly, a green Accept LED is lit and the count advances from 0 to 1.
5. The Supervisor comes up and asks the operator a question. A three-minute discussion
ensues before the operator returns to the task. He need only look at the PTV-FM to see the
number of fasteners correctly tightened, and knows to work on Nut #4. He performs this task
properly, and again receives a green Accept LED, and the count advances from 1 to 2.
Page 16
6. On Nut #5 the operator inadvertently jerks the wrench. Since there is no green Accept LED
lit and the count did not advance, he knows he must retorque the fastener. He loosens the
fastener, then properly retorques it. The green Accept LED lights and the count advances
from 2 to 3 on the LED Panel.
7. The operator then moves to the last fastener on the assembly. The FM Switch Wrench is
used properly, applying the proper torque and earning the operator a green Accept LED, a
double-beep from the beeper to indicate the batch of fasteners is completed, and a reset to 0
on the LED Panel in preparation for the next assembly. A Batch Accept signal is sent to the
PLC Connector to signal completion of the assembly to the PLC.
In this second example, the operator changed the parameter in use by rotating the Parameter
Select Switch. The PLC had been programmed to count the batch accept signals coming from
the PTV, and advance the line only on the even numbered signals.
The change in active parameter from A to B could have been accomplished via PLC command
instead. The batch accept from Parameter A could have triggered the command to switch to
Parameter B.
The means by which the signals to the PLC are used to control the line are limited only by the
PLC hardware and the desire of the PLC programmer.
Please note that S/R does not perform PLC programming. Our expertise is in torque application
and measurement. We provide the signals at the connector, and leave their application to the
ingenuity of our customers.
Page 17
Page 18
Chapter 3 - Installation
Installation Considerations
The PTV-FM and FM Switch Wrenches use FM radio to communicate with each other. The
PTV-FM uses PLC cables to communicate with the rest of the facilitys' IT structure. The PTVFM communicates with the operator via visual and audio devices, and requires electric power.
The above, and the constraints they impose,must be taken into consideration when determining
where and how to install the PTV-FM. To insure proper functioning, we strongly recommend
that:
A. The PTV-FM be installed within 50 feet/15 meters or less of the station where the FM Switch
Wrench(es) will be used.
B. The installation location be in direct line-of-sight of the FM Switch Wrench use location. FM
signals are rapidly degraded by walls and other structures.
C. The installation be within 4 feet/1.2 meters of an appropriate electric power outlet.
D. The installation be within 20 feet /6 meters of any PLC controller to be used with the PTV-FM.
E. The PTV-FM be installed at no more than shoulder height. Access to the exterior of the unit
is often required.
F. For optimum productivity, the front of the unit should face the location where the operator will
use the FM Switch Wrenches.
Installation Procedure
This installation procedure is written for those units that will use a 110 VAC power source, and
which are set for 110 VAC power. If the unit purchased is to be used with 220 VAC power, and
was not purchased preset to 220 VAC power, see the section on changing voltage in the Power
Entry Module (PEM) before proceeding.
1. Three items from the box will be needed for the installation: the PTV-FM Generation II, the
Antenna, and the Power Cord.
2. Check the Power Setting Notice on the right side of the Generation II and insure it states the
Power Entry Module is set for 110 VAC power.
3. Check the power source to be used to power the Generation II and insure it is indeed 110
VAC.
Page 19
4. Remove the Power Setting Notice from the case.
5. Check the voltage window on the Power Entry Module. It should display "110V".
A. If the window does not display "110V", there are two options available.
1. Use a different power source that is 220 VAC.
2. Change the PEM to work with 110 VAC power. See the section on the PEM towards
the end of this chapter.
B. If the window does display "110V", proceed to the next step.
6. Remove the Antenna from the poly bag and the individual bag inside. Set the PTV-FM
upright. The antenna attachment point is in the center of the top of the unit. Carefully install
the antenna by aligning the threaded connector and antenna, then screwing the antenna onto
the connector. The antenna should be snug, not tight.
7. If the unit is to be wall- or rack-mounted, position the unit in the installation location and
mount it via the four mounting holes at the extreme left and right of the case flange on the
rear of the unit.
8. Check the On/Off Switch and insure it is in the Off position.
9. Connect the Power Cable to the PEM, then insert the grounded plug into the 110 VAC power
supply.
10. If the Generation II is to be used with a PLC, see the Chapter on PLC Communications and
follow the instructions there to establish communications. When the PLC wiring is completed,
insert the male 19-pin PLC plug into the PLC Connector.
11. Move the Power On/Off Switch to the ON position.
Power Entry Module Procedures
The Power Entry Module (PEM) serves two functions. The first function is to allow the user to
work from either 110 VAC or 220 VAC power for the unit. The second function is to protect the
units' electrical circuitry with a fuse.
WARNING
Before performing any work on the Power Entry Module, electric power to the unit
must be disconnected. Failure to disconnect electric power before working on the
Power Entry Module may result in serious injury or death.
Page 20
Changing the Power Setting
A. Obtain a flat tip screwdriver.
B. Locate the Power Entry Module on the lower half
of the right side of the PTV.
C. Insert the tip of the screwdriver under the Tab of
the Fuse/Voltage Selector Holder.
D. Gently pry the holder out to release it.
E. Once the holder is released, slide the holder completely out of the PEM.
F. The Voltage Selector & Indicator Card is a card
that can be removed by sliding it sideways out of
the holder. Remove the card from the holder by
sliding it gently out of its’ channel in the holder.
G. Turn the Voltage Selector & Indicator over so the
240V is upright and the 110V is upside down.
H. Reinsert the Voltage Selector and Indicator into
the holder in the new orientation. If the correct
voltage now shows in the window in the holder,
the operation has been properly performed. To
reinstall the holder into the Power Entry Module,
reverse the steps taken to remove it. When this is
complete, the module should appear as it did at
the start of the process, but with the corrected voltage showing through the window.
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Replacing the Fuse
A. Obtain a flat tip screwdriver.
B. Locate the Power Entry Module on the lower half of the right side of the PTV.
C. Insert the tip of the screwdriver under the Tab of the Fuse/Voltage Selector Holder.
D. Gently pry the holder out to release it.
E. Once the holder is released, slide the holder completely out of the PEM.
F. The 1 Ampere, 250 Volt fuse is in the Fuse Holder directly above the Voltage Selector &
Indicator card.
G. Lift the fuse out of the fuse holder, and replace with a fuse of the same size and capacity.
H. Align the Fuse/Voltage Selector Holder with the slots on the PEM and reinsert the Holder.
Page 22
Chapter 4 - Programming the PTV-FM Generation II
Programming the PTV-FM is performed via the keyswitches on the faceplate of the unit. The
keyswitches work individually and in conjunction with each other to set the various components
of each parameter.
There are noticeable changes in programming the Generation II over the first generation of the
PTV-FM. The additional capabilities of this generation necessitated some, and suggestions from
the user community generated others. Please carefully read and follow the instructions in this
chapter until you are thoroughly familiar with programming under this regime.
Programming the Generation II follows some basic rules. They are:
1. The active parameter on the Parameter Selection Switch is the one programmed.
2. The first menu level consists of the elements of the selected parameter.
3. The UP keyswitch is the most efficient means of moving through the elements for each
parameter.
4. When the element of the parameter is displayed, the SET keyswitch is used to enter and exit
the submenu that programs the element (except for those that exit automatically upon completion).
5. The UP and DOWN keyswitches are used to move among the available options in the submenu value selections, and the SET keyswitch is used to lock them in and either move to the
next value or return to the elements upon completion.
Elements of Each Parameter - Definitions
TBB . . . . . . . . . . . . . .Time Between Batches
TBC . . . . . . . . . . . . . .Time Between Clicks (in a batch)
TMAX . . . . . . . . . . . . .Time Maximum (maximum cycle/click duration for an acceptable click)
TMIN . . . . . . . . . . . . .Time Minimum (minimum cycle/click duration for an acceptable click)
BEEP . . . . . . . . . . . . .Beep (when the unit beeps to the operator)
RELAYS . . . . . . . . . . .Relay function (PLC)
CLEAR TOTAL . . . . . .Clears batch count
BATCH . . . . . . . . . . . .Batch count (number of fasteners for batch)
CLEAR WRENCHES .Clears memory of wrenches learned
CHANNEL SELECT . .Manual programming of the channel to be used.
MANUAL LEARN . . . .Learning the wrench on the manually-selected channel.
AUTO LEARN . . . . . . .Automatic detection of the channel and wrench for learning.
Prior to programming the unit for assembly line use it is necessary to have several pieces of
information at hand.
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1.
2.
3.
4.
5.
6.
7.
The number of fasteners on the assembly
The minimum acceptable time (duration) of signal for the joint.
The maximum acceptable time (duration) of signal for the joint.
The minimum time required between wrench cycles (clicks).
The minimum time required between batches (groups of fasteners).
The channel on which the FM Switch Wrench for each parameter to be programmed is set.
Each FM Switch Wrench to be programmed into the unit must be readily available.
The maximum and minimum signal duration (click time) numbers are usually determined by
experimentation prior to programming for production. The steps contained in this section are
readily modified for experimenting prior to entering the production program.
Programming Steps
1. Assure PTV-FM is plugged into the appropriate power source.
2. Move the Power Switch to the On position.
The LED Display will show the following in sequence:
PTV
V 2.NN
Count
A. 0
Note that "A" is the selected parameter and "0" is the number of completed fasteners on the
assembly for that parameter.
3. Determine which of the four Parameters will be used, and rotate the Parameter Selection
Switch to that Parameter (A, B, C, or D).
4. Insert the Key into the Key Lock.
5. Turn the key to the PROG position. The following items will scroll across the LED Display in
sequence:
MENU OPTIONS - AUTO LEARN (Repeats)
6. Press the SET keyswitch. The unit will then display:
CLICK WRENCH
7. Click the wrench to be used for this parameter at this station, holding the wrench in the
clicked position until a “chirp” is emitted by the Gen II. Separate the clicks by several seconds.
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8. When the PTV receives a signal from the wrench, it will display first the channel on which it
received the signal, then the strength of the signal ("GOOD").
9. Press the UP keyswitch to get to the Time Between Batches. The LED Display will show:
TBB
10. Press the SET Key to enter the programming of the TBB. The LED Display will show "0000",
with the leftmost zero blinking. The four digits are the time in seconds that is the minimum
time required between batches of fasteners. To change the blinking number, use the DOWN
or UP arrow until the desired number is displayed and blinking. To accept the number that
you have selected, press the SET Keyswitch. This will lock in the number accepted, and
cause the next number to the right to become the active number.
11. Continue programming the TBB using the UP, DOWN, and SET keyswitches until the number
of seconds required between batches is displayed. Press the SET keyswitch again to lock in
the time. The unit will return to displaying "TBB".
12. Press the UP keyswitch to advance to the next element of the parameter. The LED Display
will then show "TBC", for Time Between Clicks. This is the minimum required time between
each wrench cycle (click) that the unit will require before accepting another signal.
13. Press the SET keyswitch to begin programming the TBC. Again the LED Display will display
"0000", with the leftmost zero the active one (the active digit is always the blinking one). The
time increment is seconds; the programming is to set the number of seconds required
between clicks. Use the UP, DOWN, and SET keyswitches to select then set each digit,
working from the 1000's column on the left to the single digit column on the right.
14. When the last digit of the TBC has been set, the LED panel will again display "TBC". Press
the UP keyswitch to advance to the next element of the parameter.
15. The next element is the TMAX or Time Maximum. This is the specification for the maximum
duration of a signal; the most time the wrench may be in the "clicked" position. To begin setting this time, press the SET keyswitch.
16. The LED Display will show the current maximum time setting in a "seconds.tenths" format,
with a default setting of "0.5", or ½ second. The whole seconds digit (0) will be flashing as
the active digit. To change the value of the whole seconds part of the time, use the UP or
DOWN keyswitch. When the value desired is displayed, press the SET keyswitch to set the
value and move to the tenths part of the TMAX element. Use the UP and DOWN keyswitches to display this portion of the element, then press the SET keyswitch to lock it in. Press the
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UP keyswitch to move to the next element of the parameter.
17. The next element is the Time Minimum for the minimum time the wrench should be in the
cycled or clicked position for each acceptable use of the wrench. This element of the parameter is shown as TMIN on the LED Display. Press the SET keyswitch to enter programming
of the element. The display will again be in the "seconds:tenths" mode, with "0.0" as the
default value. The whole seconds value will be blinking. To accept this value, simply press
the SET keyswitch. To change the value, use the UP or DOWN keyswitches. When the
desired value is displayed, press the SET keyswitch. This will lock in the displayed value for
the whole seconds and make the tenths of a second digit active. Use the UP or DOWN
keyswitch to obtain the desired value on the display, then use the SET keyswitch to lock in
the value. The display will return to TMIN. Press the UP keyswitch to go to the next element
of the parameter.
18. BEEP will appear on the LED keyswitch. Press the SET keyswitch to enter programming of
this element. The LED Display will change to "ON". Pressing the UP keyswitch will cause
the display to read "REJECT ONLY", a second press of the UP keyswitch will cause the display to read "OFF". These are the three options for BEEP. Use the UP keyswitch to page
through them until the one desired is displayed, then press the SET keyswitch to lock in the
selection. Press the Up keyswitch to move to the next element of the parameter.
19. The LED Display will change to read "RELAYS". Press the SET keyswitch to access the
relay setting options. The current selection (MOMENTARY or LATCHING) will scroll across
the LED Display. To switch from one to the other, use the UP keyswitch. When the desired
relay setting scrolls, press the SET keyswitch to lock in the selection. Press the UP
keyswitch to advance to the next element of the parameter. See Chapter 7 for pin identification and output.
20. The next element is "CLEAR TOTAL", and will be displayed scrolling across the LED Display.
To clear the total number of assemblies in the internal counter, press the SET keyswitch.
Press the SET keyswitch again to return to the element selection process. Press the UP
keyswitch to advance to the next element.
21. The next element is "BATCH" which will scroll across the LED Display. This is the number of
fasteners in the assembly or subassembly batch. Press the SET keyswitch to access the
batch count setting. The LED Display will show "/001" and the leftmost zero will be the active
selection. Up to 299 fasteners may be in a batch. Use the UP keyswitch to page through the
selections (0, 1, 2) then the SET keyswitch to lock in the selection when it is blinking. This
will cause the tens column to become the active selection. Use the UP and DOWN
keyswitches to display the desired number, then the SET keyswitch to lock in the selection.
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The ones column digit will begin flashing. Use the UP and DOWN keyswitches to display the
desired selection, then press the SET keyswitch to lock in the last digit and return to the
BATCH element. Press the UP keyswitch to go to the next element.
22. The LED Display will then scroll "CLEAR WRENCHES" from right to left. Press the SET
keyswitch to clear the wrenches from memory. Press the SET keyswitch a second time to finish clearing the memory. The LED Display will show a set of four rotating lines while the
memory is cleared. When this is completed, "DONE" will be briefly displayed, then the
"CLEAR WRENCHES" selection message will resume scrolling across the screen. To
advance to the next element, press the UP keyswitch.
23. "CHANNEL SELECT" will start scrolling across the screen. Press the SET keyswitch to
access channel selection. The LED Display will then show "CH-N", with "N" being the number of the current setting. To change the channel, use the UP or DOWN arrow keyswitch until
the desired channel is displayed. When the desired channel for communicating with the FM
Switch Wrench is shown on the LED Display, press the SET keyswitch, then press the UP
keyswitch to move to the next element.
24. "MANUAL LEARN" will scroll across the LED Display. This is used to "teach" a new wrench
to the unit. To have the Generation II "learn" a new wrench, the wrench must be immediately
available and ready to be clicked. Press the SET keyswitch to begin the process. The LED
Display will then scroll the channel on which it is set, followed by the instruction "CLICK
WRENCH". The red SETUP LED will light. Click the wrench to be learned by the unit and
hold it in the “clicked” position until the Gen II emits a “chirp”. This must be done in five (5)
seconds or less. Then repeat the “click and hold” until a second “chirp” is heard. When the
wrench has been learned, "GOOD" will be displayed, then the red SETUP LED will go out
and "MANUAL LEARN" will resume scrolling across the LED Display. If no click is received
on the selected channel in five seconds or less, the unit will exit the learning mode, the red
SETUP LED will go out, and "MANUAL LEARN" will resume scrolling across the LED Display.
Teaching a wrench to the unit may be re-entered by pressing the SET keyswitch, or you can
advance to the next element by pressing the UP keyswitch.
25. The next element is "AUTO LEARN" which will scroll across the LED Display. To enter the
AUTO LEARN function, press the SET keyswitch. The instruction to "CLICK WRENCH" will
appear, and the red SETUP LED will light. Click the wrench to be learned twice, holding it in
the “clicked” position each time until a beep is obtained and the channel number followed by
"GOOD" appear scrolling across the LED Display. This function is somewhat different from
the MANUAL LEARN function, in that it checks channels as well as for the wrench. When
completed, the display will resume scrolling "AUTO LEARN".
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26. All elements of the selected parameter have been programmed. Turn the Key to the LOCK
position to leave the Programming Mode and re-enter the Operating Mode. The display will
then show the parameter and the number of fasteners tightened in the batch so far (0), in the
format "A. 0".
27. To set the elements for another parameter, rotate the Parameter Selection Switch to the
desired parameter, and return to Step 2 of this procedure.
NOTES:
It is not necessary to program every element to change one element of a parameter after
the first setup. Simply enter the PROG (programming), then use the UP keyswitch to move to
the element to be changed. Use the SET keyswitch to enter the programming of that element,
and the UP/DOWN/SET keyswitches as necessary to set the element to the desired value.
Press the SET keyswitch at the end to lock it in. If more elements are to be changed, use the
UP keyswitch to advance to the element in the menu, and program it. When the necessary elements have been changed, advance the elements until TBB is again displayed, then turn the
KEY to LOCK to resume operation.
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Chapter 5 - Operating the PTV-FM Generation II
The Generation II is much simpler to operate than the first generation of PTV-FM once programming and communications have been established.
When the unit is first turned on it is in Operating Mode. The active parameter and the number of
fasteners correctly tightened are displayed on the LED Display, and the green Accept LED is lit.
Four rapid beeps are issued, and the current Parameter is displayed followed by a 0.
To begin using the unit, the operator need only pick up the FM Switch Wrench and begin using it
on the assembly.
An improperly torqued fastener will result in the reason for the rejection being displayed on the
LED Display, as well as the red Reject LED being lit.
FM Switch Wrench cycled too quickly (jerked) results in:
Red Reject LED lit
One long beep
TMIN on the LED Display
FM Switch Wrench cycled too long (pulled past the click) results in:
Red Reject LED lit
One long beep
TMAX on the LED Display
The display of either of the above will remain until the next acceptable click.
A properly torqued fastener will result in:
A green Accept LED
An advance of the count of acceptable fasteners.
A properly torqued fastener that is the last in the batch will result in:
A green Accept LED
A double beep.
A reset of the count to 0.
In between individual fasteners and at the end of a batch of fasteners, the Suspend LED will be
flashing for the period of time the unit was programmed to ignore signals from the FM Switch
Wrench.
If the operator moves too quickly from one fastener to the next, the wrench is clicked before the
Suspend function expires. This results in one of three conditions occurring:
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1. If the second click occurs so rapidly after the first click that signal processing is still occurring, the result may be a TMAX rejection. The signal has been treated as one click that is
longer than the allowed maximum time. Example:
TMAX
2. If the signal arrives after signal processing but before the TBC timer starts, the result may
be that nothing occurs.
3. If the signal arrives after the TBC timer starts but during the specified waiting period, the
result will be a TBC display and a reject sound.
TBC
If a batch is completed and the first fastener of the next batch is tightened before the expiration
of the specified Time Between Batches, the error will be signaled with the display of the TBB
notice and a reject sound. Example:
TBB
Press the MODE keyswitch once and the batch size will be scrolled across the LED Display.
Example:
BATCH LIMIT / 3
Press the MODE keyswitch again and the total number of batches for that parameter will be
scrolled across the LED Display. Example:
BATCH TOTAL A.
6
Press the MODE keyswitch a third time and the current signal strength will be appear on the LED
Display. The scale is 00 to 99, with 00 meaning there is effectively no signal, and 99 equaling
the strongest possible signal. The display changes very quickly as the signal starts, the information processed, and the signal ends. If you cannot determine the strength because of the rapidity of the number change, click the wrench and hold it in the “clicked” position. This feature can
be helpful in determing the placement of the unit for best reception. Example:
SIGNAL 84
Press the MODE keyswitch a fourth time and the current fastener count will be scrolled across
the LED Display and the unit returned to operating mode. Example:
COUNT
A.
0
If it is necessary to check the torque setting on the FM Switch Wrench, simply push the SUSPEND keyswitch. The red Suspend LED will light continuously and signals from the wrench will
be ignored. To resume operation, simply press the SUSPEND keyswitch again.
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Chapter 6 - FM Communications
Principles
The PTV-FM and FM Switch Wrench work together as a system using FM radio signals in the
900 MHz band as the medium of communication. There are several ramifications to this:
1.
2.
3.
4.
5.
6.
7.
8.
The FM Switch Wrench must have a useable battery in it.
The antenna on the PTV-FM must be installed.
Both the PTV-FM and the FM Switch Wrench must be set to the same channel.
The PTV-FM Generation II must have the power on.
The PTV-FM must not be in “Suspend” status, where it ignores wrench signals.
The “seed code” transmitted by the wrench must have been “learned” by the PTV-FM.
The FM Switch Wrench must be located within 50 feet (15m) of the PTV-FM.
FM radio signals are “line-of-sight”; intervening structures can disrupt communications.
The vast majority of the problems encountered with the system result from one of these basic
requirements being unmet.
“Learning” the code transmitted by each wrench was covered in Step 24 of the procedure for
programming the Generation II. This must be performed every time a wrench transmitter is
added to the system or replaced on a current wrench.
The Generation II can hold in memory the codes for up to four wrench transmitters. The method
by which they are held is “rolling”; addition of a fifth transmitter wipes out of the memory the first
transmitter learned. The sixth transmitter learned eliminates the memory of the second transmitter learned, and so forth.
If changing wrenches or replacing transmitter boards, always make sure that all wrenches to be
used with the unit are communicating properly.
Channel Selection
Channel selection is made based upon reliability of communication between the FM Switch
Wrench and the PTV-FM Generation II unit. In some facilities any channel will work well, in others there may be only one or two that provide the necessary reliability. If the initial factory settings do not achieve the goal of reliability in the facility where the system will be used, experimentation will be needed to determine the optimum settings.
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Selecting the channel on the Generation II is covered in Step 23 of the programming procedure
in Chapter 3 of this manual (Page 27). As an element of each parameter, it is readily accessible
in the Program mode and can be changed in less than one minute.
All FM Switch Wrenches are shipped from the factory with all three jumpers installed. This
means they are set for Channel 7. Setting the Generation II to Channel 7 allows rapid startup.
The Generation II identifies each transmitter (wrench) by a code transmitted at the start of each
“click” of the wrench. This reduces the probability of crosstalk. To further reduce the probability,
we suggest that when multiple tools are used with the unit, different channels be used by each
tool. A separation of 2 channels between wrenches on the same Generation II PTV-FM is optimum for reducing the potential for crosstalk.
Channel selection on the FM Switch Wrench is performed via jumpers. The Jumpers are plastic
and metal devices that fit over electronic pin pairs attached to the transmitter board at the end of
the battery holder inside the Electronics Module
Channel
Jumper 1
Jumper 2
Jumper 3
of the FM Switch Wrench. Pin pair # 1 is next to
0
OFF
OFF
OFF
the edge of the circuit board, pair #3 is the clos1
OFF
OFF
ON
2
OFF
ON
OFF
est to the center of the board. When FM Switch
3
OFF
ON
ON
Wrenches are shipped from the factory, all three
4
ON
OFF
OFF
Jumpers are installed, setting the transmitter for
5
ON
OFF
ON
6
ON
ON
OFF
Channel 7. To change the channel, remove the
7
ON
ON
ON
required Jumper(s) per the chart to the right.
Gently grasp the plastic jumper and slide it straight up to remove it. Jumper installation is performed by aligning the two holes in the bottom with the pins of the selected pair, then pushing
straight down to slide it fully onto the pins.
INSTRUCTION TO THE USER
This product has been tested and found to comply with the limits of Part 15.249 paragraphs
A-E with regards to output power, transmission content, harmonics, and occupied bandwidth
of a class B device. Operation is subject to the following two conditions:
(1)
this device may not cause harmful interference, and
(2)
this device must accept any interference received, including interference that may
cause undesired operation.
This equipment generates, uses, and can radiate radio frequency energy. It is unlawful to
remove or modify any part of this device including the antennas, cables, or enclosures.
Doing so may void the user's authority to operate this equipment.
Page 32
Chapter 7 - PLC Communications
The PTV-FM Generation II has a 19-pin female Amphenol Connector to facilitate communication
with PLC’s used for line control and other functions in assembly operations. The location of the
connector is shown on Page 4 of this manual.
The schematic diagram below shows the proper use of each pin and the code for it. . Each of
the pin receptacles in the connector is marked with a raised letter to facilitate proper wiring.
Notes:
1.
All Relay signals provide +24VDC on their output pin by default.
2.
All NPN outputs connect to ground.
3.
All other signals are 24VDC inputs.
Computer Communications
The Generation II has a 9-pin RS-232C serial port for factory use in manufacturing of the unit.
There is no end-user use of this port.
Page 33
Page 34
Chapter 8 - Frequently Asked Questions
Can multiple PTV-FM units be used in close proximity to each other without crosstalk?
Yes. There are several built-in safeguards to preclude the problem of crosstalk. The first of
these is the use of eight FM channels. Simply using different channels on units in close proximity effectively eliminates the problem. Further the use of the “seed code” at the start of each
transmission identifies the unique tool. The PTV-FM will not accept signals from transmitters the
seed code of which has not been “learned”.
The transmitter board has been replaced in the FM Switch Wrench. Will the PTV-FM work
with this wrench now?
Yes, as soon as the PTV-FM has “learned” the new transmitter. See Step 24 on the Manual
Learn element of the parameter in the programming procedure to find out how to do this.
Can the PLC output be used to control other processes?
The PLC itself, not the output receptacle, will control other processes. The PTV-FM provides a
signal when a batch is complete. This is often used to signal a PLC to perform other programmed functions. We suggest consulting your internal PLC expert or your PLC supplier for
how best to take advantage of this feature in your specific facility.
Where can I obtain additional information on the PTV-FM and the FM Switch Wrench?
The first location to check is the S/R website: www.srtorque.com. The FAQ and Technical
Support sections are continuously updated and expanded. If the answer to your questions is not
found there, either e-mail, call, or fax us at your convenience using the contact information on
the front cover of this manual.
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