EDU1AE Ver 1.4 for PLUTO Torque range: 2 – 15 Nm
IDENTIFICATION DATA OF THE MANUFACTURER KOLVER S.r.l. VIA MARCO CORNER, 19 36016 THIENE (VI) ITALIA
IDENTIFICATION DATA OF THE PRODUCT CONTROL UNIT MODEL: EDU 1AE CODE: 030000 YEAR OF CONSTRUCTION: 2007 TECNICAL DATA OF THE PRODUCT TRANSFORMER: 230V AC 50 Hz – 40 V DC 200 VA FUSE: 3,15 A DIMENTIONS: 185x124x95 mm WEIGHT: 2.550 Kg
EDU1AE power supply and control unit is an innovative system for controlling the torque of both our PLUTO10 and PLUTO15 electric screwdrivers either inline, pistol or for automation. EDU1AE and Pluto delivers all the advantages of precision torque control electric tools at a fraction of the price of transdurized tools. The state-of-the-art electronic control circuit cuts the power supply to the motor calculating the correct torque in response to 3 parameters; voltage, frequency and current, according to the selected options.
IMPORTANT: EDU1AE controller is a highly accurate unit but it is critically important to select the correct options to ensure that proper torque is being applied. Read the menu description carefully and in case you are unsure please contact Kolver for support information. Here are a few advantages of EDU1AE: • One controller only for a torque range from 2 to 15 Nm. On certain joints torque values between 0.5 and 2 Nm are also possible. Please contact Kolver for additional information. • User interface screens: walk through a few simple steps to input the parameters requested for your application and your fastening process can begin. • Slow start and adjustable speed. • Soft or hard joint application. • High speed rundown and slow speed tightening for improved accuracy. • Automatic reverse at cycle end possible. • Autostop on elapsed time. • Torque reached signal, lever signal. • Start and reverse contacts. • Remote torque selection possible (please contact Kolver for additional information). • Low noise level, only 55 dBA, low weight, less than 0.5 kg . Turn the unit on through the on/off switch on the back panel. The unit will carry a general system check and then display the main screen indicating the screwdriver model (Pluto10 or 15), the corresponding torque range (Range: 2-10 or 2-15 Nm), the joint type (J: Hard or J: Soft), the brake time (Z) and the torque level (Level).
To enter the menu push the ESC key for 3 seconds The menu consists of 8 lines. To move through the menu push the ∇ or Δ keys. Pusk the OK key to select a line ( the arrow → will start blinking). Push the ∇ or Δ keys to select the required value and then confirm thru the OK key (or ESC if you don’t want to save the value). The selected value will be immediately operational also if you are still in the menu screen. Repeat the sequence for all the parameters you wish to change and then push the ESC key to return to the main screen.
MENU 1) MODEL: you can select the screwdriver to be used (Pluto10 or Pluto15). Your choice will automatically change the default settings.
2) TORQUE LEVEL: you can select the desired torque as a percentage of the torque range of the selected screwdriver. For example, for a Pluto10, a 50% setting on hard joint will result in a torque in the area of 6Nm. Please confirm desired torque value with a Kolver digital torque tester. The torque level is indicated on the main screen by “LEVEL” .
3) JOINT: You can select the type of joint (soft or hard) you are working on. A soft joint is typically a self tapping screw on plastic or sheet metal, or a metric (machine) screw on a material subject to strain (for example: gasket, o ring etc) A hard joint is typically a fastener joining metal with metal. If you select the option SOFT the screwdriver will run the complete cycle at the selected speed (see point 6.). When selecting the option HARD the screwdriver will maintain the selected speed for a selected time after the start (see point 4.) and then the speed will be reduced automatically to apply a pretorque before reaching the preset torque (see point 2.).
IMPORTANT: An incorrect selection of the joint type can result in unaccurate torque output. 4) BRAKE TIME: This option can be selected only in combination with the option JOINT: HARD. You can select a time between MIN (function excluded) and 10.0 seconds indicating how long the selected speed (higher speed) will be on before switching to “pre-torque speed” (lower speed). The “pre-torque speed” will be automatically chosen by the unit depending on the preset torque. The user cannot adjust the “pre-torque speed”. This brake time is indicated on the main screen by letter “Z”.
CAUTION: The scope of the time “Z” is only to speed up the approach time in case of long screws. Reaching the torque at higher speed will result in inaccurate torque output. To avoid inaccurate torque we suggest selecting a shorter time, and then increase it step by step until finding the optimum time. Torque reached during the Brake Time will result in lever and error signals and 3 bip sounds.
5) RAMP TIME: You can select the slow start time (acceleration) from 0.2 to 2 seconds. This option is mainly used with self-tapping screws. Reaching the torque while the ramp is still on will result in inaccurate torque output. Torque reached during the Ramp Time will result in lever and error signals and 3 bip sounds.
6) SPEED: You can select any speed value of the screwdriver between nominal (max) speed and 30% of max speed (see also point 3.) NB. The torque range is ensured only at the nominal speed of the screwdriver (600 RPM for Pluto10 and 320 RPM for Pluto15). If you should set lower speeds, please check if the screwdriver stops correctly at the pre-set torque. See also point 4 (Brake Time) for speed in JOINT: HARD.
7) STOP TIME: You can select a time between 0.2 (function excluded) and 10 seconds in case you need to stop the screwdriver at depth, or time, and not at torque. At the end of the selected time the unit will release a “time out” signal (torque reached signal). Please note that the torque selected (see point 2) will stay on, should the screwing cycle be shorter than the stop time.
8) REVERSE TIME: This option will automatically start a reverse cycle after a torque reached signal or a time out signal (see also point 4 and 5). You can select a time between OFF (function excluded) and up to 10 seconds. During the reverse cycle, it is necessary to keep the lever pressed or the start signal otherwise the screwdriver will stop before the pre-set time.
I/O CONNECTION
On the back panel you’ll find only one connector I/O 10 pins which must be connected to the 90° connector coming from the unit. INPUT: PIN FUNCTION 1 COM 0VDC Common pin. By closing the contact between pin 1 and any of the other pins ( 2, 3, 4, 5) to start the function you need. 2 START Remote start. Clockwise. Torque control. 3 REVERSE Reverse remote start. Counterclockwise. No torque control 4 STOP Stop motor. “STOP ACTIVE”screen. Motor stops and starts again after the contact has opened. 5 NOT USED Only used in special versions.
OUTPUT: PIN 6 7 8
9 10
FUNCTION Torque reached signal. Signal is 24V 20 mA , max 0,5W. Lever signal: when lever is pressed or when the start is remote. No signal during unscrewing cycle. It resets after their release. Signal is 24V 20 mA , max 0,5W. ERROR Error signal. It starts when: - torque is reached before ramp time - torque is reached during brake time (only JOINT HARD) - screwdriver reached the stop time without reaching the torque After 3 bip sounds, it resets. Signal is 24V 20 mA , max 0,5W. COM0VDC Common pin for any output. Signals must take between pin 1 ( 0VDC common) and the other pins (6,7 and 8). NOT USED Only used for special versions. TORQUE LEVER
Output signals are protected. Overload of these 3 available signals (> 60 mA) or short circuit will result in the stop of the unit. To re-activate signals, it is necessary switch off the unit for 5-6 seconds, check connections outputs then switch on the unit.
TROUBLE SHOOTING ERROR
# 0 5
PROBLEM No connection between main PCB and display PCB Bus undervoltage (it happens when the supply +Vbus to the motor remains below 25V for more than 3 seconds)
6 Overload on bridge H (it happens when current on mosfets of bridge H > 10 A for more than 600 ms)
7
Motor not detected (it happens when the motor connection is missing)
8 Overload on bridge H (it happens when current on mosfets of bridge H > 14,5 A for more than 10 ms)
ACTION / SOLUTION Check flat connector inside the unit - Make sure that 110/230 (depending on Country) VAC input is supplied - Reduce cycle rate - Avoid motor stalling - Unscrewing too heavy (> tool torque range) - Check cable and connection between screwdriver and controller - Reduce cycle rate - Avoid motor stalling - Unscrewing too heavy (> tool torque range)
EDU1AE power supply and control unit is a maintenance free unit. Should you need any assistance please call the nearest Kolver dealer in your Country or contact directly Kolver at kolver@kolver.it or call +39 0445 371068. In the US call 978-692-2468.
RIF DESCRIPTION
CODE
RIF DESCRIPTION
CODE
1
Connector 5 PIN M12 M
201666
15
Power Supply cable Schu/Vde
800620
2
s.t. screw 2,6 x 9,5 (12pcs)
800605
16
Plug w/fuseholder 230V
800618
3
Nut M2,5 h 12
872436
17
Earth cable
800090
4
Button for user interface
872437
18
Plug internal cable
5
Rubber support (4pcs)
800016
19
Back panel
832414
6
Screw M6 x 60
872430
20
Nut M3
800056
7
Alu box
812010/VB
21
Washer M3
800041
8
Internal connector
872438
22
Screw M3 x 8
806235
9
Main PCB
852421
23
Nut M6
872433
10
Connector 5 pin M
201066
24
11
Connector 3 pin M
203066
Transformer 230/36-18V 200VA w/fixing plate
848009
12
Connector 5 pin F
201064
25
PCB display
852422
13
Connector 3 pin F
203064
26
Nut M2,5 h 7
872435
14
Fuse 3,15 A
800619
27
Front panel
822426
800080/N
NB. TO RESET ERRORS, TURN OFF THEN SWITCH ON THE UNIT. RESET OF ERRORS #6 AND #8 COMES AUTOMATICALLY AFTER THE PROBLEM END IF THE PROBLEM PERSISTS, PLEASE CONTACT YOUR NEAREST KOLVER DEALER. TORQUE CHART TO BE USED AS INDICATION ONLY (TORQUE MAY VARY SIGNIFICANTLY ON DIFFERENT JOINTS):
TORQUE
MIN 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 MAX
PLUTO 10 600 rpm SOFT HARD Soft Hard K20 Joint Joint Joint 0.89 1.82 1.31 1.25 2.23 1.8 1.64 2.76 2.47 2.1 2.99 3.04 2.53 3.48 3.53 2.99 4.19 3.86 3.44 4.58 4.25 3.77 4.78 4.76 4.03 5.04 4.89 4.48 5.48 5.28 4.86 5.65 5.57 5.28 5.92 5.81 5.66 6.12 5.98 6.19 6.32 6.72 6.48 6.81 7.21 6.89 7.17 7.75 7.21 7.46 8.03 7.65 7.78 8.25 8.08 8.07 8.58 8.42 8.48 9.4 8.71 8.68 10.57
PLUTO 15 320 rpm SOFT HARD K20 Hard Soft Joint Joint Joint 0.67 0.99 3.14 1.57 1.87 3.34 2.33 2.75 4.35 3.12 3.52 5.21 3.95 4.48 5.97 4.61 5.05 6.74 5.49 5.87 7.49 5.99 6.88 8.11 6.78 7.46 8.8 7.70 8.37 9.26 8.23 9.53 9.68 8.78 10.01 10.17 9.56 11.41 10.57 10.21 11.96 11.55 10.97 12.32 12.25 11.64 14.16 13.68 12.6 14.83 14.76 13.13 15.04 15.87 13.48 15.25 16.43 14.09 15.61 16.81 14.45 15.60 17.02
12 washer springs inside the joint simulator (cod. 240800) of K20 torque tester:
GIUNTO ELASTICO = soft joint GIUNTO K20 = K20 joint GIUNTO RIGIDO = hard joint
SPECIAL VERSIONS EDU 1AE/C: all the features of EDU1AE model + a remote double torque selection.
On the back panel in the connector I/O 10 pins, pin #5 is “ext torque” contact, if this IS NOT used, the unit works as a standard EDU1AE. If contact between pin 1 and 5 is closed, the unit will change from LEVEL to L.EXT and the main screen will indicate the torque set through the trimmer on the back panel. EDU 1AE/RT: all the features of EDU1AE model + a remote multiple torque selection.
On the back panel in the connector I/O 10 pins, pin #5 is “ext torque” contact, if this IS NOT used, the unit works as a standard EDU1AE. If contact between pin 1 and 5 is closed, the unit will change from LEVEL to L.EXT and the main screen will indicate the torque set through the trimmer on the back panel (as in EDU 1AE/C). To set the external torque, an analogic tension on pin 1 (positive) and pin 2 common negative 0VDC), between 0 and 5 VDC, SHOULD BE APPLIED. As shown in the label, on 0V the minimum torque value will be set. HIGHER TENSION VALUES APPLIED WILL RESULT IN HIGHER TORQUE VALUES. The analogic tension is 0÷5VDC on pin 3 and 4 of ext. torque connector. This system enables the customer to modify the torque values in any moment and with the maximum flexibility. WARNING: NEVER exceed 5V on PIN 3.
SERIAL:
Serial port for data downloading available on request for all models. The configuration of the RS 232 port is: 9600 (bits per second), 8 (data bits), n (no parity), 1 (stop bits 1). Connection pin: PIN 2 = TX, PIN 3= RX, PIN 5 = GND Printed DATA will be as follows: Model: Pluto 10 Joint: Soft Torque: Min Rpm: 600 Result: OK Stop time: N Model: model of selected screwdriver (PLUTO10 or PLUTO15) Joint: type of joint (soft or hard) Torque: pre-set torque level Rpm: speed value
Result: OK= the torque has been correctly reached, all the selected parameters are satisfied and the control unit will give out a bip sound of 0,5 sec. Result: NOK= the torque has been reached during the ramp time or the brake time (only on hard joint). In this case, the unit will give out 3 bip sounds. Stop time: the torque has been reached before the stop time (N on the main screen) or at the stop time (Y on the main screen), in this case the torque result will always be NOK.