Kolver K-DUCER Operator's Manual
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Kolver K-DUCER Operator's Manual

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KDU1 / KDU1A
Torque range: 0.1 - 70 Nm
OPERATOR
MANUAL

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Summary of Contents for Kolver K-DUCER

  • Page 1 KDU1 / KDU1A Torque range: 0.1 - 70 Nm OPERATOR MANUAL...
  • Page 2 POWER: 600W DECLARATION OF CONFORMITY KOLVER S.r.l. declares that the new tool here described: control units model KDU-1, KDU- 1A are in conformity with the following standards and other normative documents: 2006/42/CE, LVD 2014/35/UE, EMCD 2014/30/UE, EN 62841-2-2:2014, EN 62841-1: 2015, EN 60204-1, EN 61000-6-2, EN 61000-6-4.

  • Page 3: Table Of Contents

    QUICK START ........................... 13 TERMINOLOGY ..........................16 OPERATING THE KDS SCREWDRIVER ..................18 OPERATING THE K-DUCER CONTROL UNIT ................. 20 Main Screen – Program Mode ..................... 20 Main Screen – Program Mode – navigation tree ..............22 Main Screen – Sequence Mode ....................23 Main Screen –...
  • Page 4 Binary tables for sequence and program selection .............. 71 MODBUS TCP ..........................73 Introduction ..........................73 Usage ............................73 K-DUCER MODBUS map......................74 MODBUS TCP code examples and literature ............... 75 OPEN PROTOCOL ........................76 Introduction ..........................76 Terminology ..........................76 Supported MIDs ........................

  • Page 5: Introduction

    The AC 90÷260V - 50÷60Hz power supply is converted into 40VDC required by the KDS series screwdrivers through a switching board. IMPORTANT: K-DUCER is a highly accurate unit but it is critically important to select the appropriate settings to ensure that the desired and proper torque is being applied and that the screwdriver motor works efficiently.
  • Page 6 135007/ESD KDS-PL6P 0,5-6 135007/U/ESD KDS-PL6P/U 0,5-6 135106 KDS-PL6CA 0,5-6 135106/FN KDS-PL6CA/FN 0,5-6 135006/A/ESD KDS-PL6ANG 0,5-5,5 135010 KDS-PL10 0,8-10 135010/ESD KDS-PL10 0,8-10 135011/ESD KDS-PL10P 0,8-10 135011/U/ESD KDS-PL10P/U 0,8-10 135110 KDS-PL10CA 0,8-10 135110/FN KDS-PL10CA/FN 0,8-10 135010/A/ESD KDS-PL10ANG 0,8-9 135015 KDS-PL15 0,5-15 135015/ESD KDS-PL15 0,5-15 135016/ESD...

  • Page 7: Installation

    INSTALLATION Installation of KDU unit The K-DUCER is supplied with the following mounting bracket (all dimensions reported in mm): Vers. 062721...

  • Page 8: Connectors

    The bracket should be fixed to the four provided 8mm depth female threads on the back panel using the provided M4x8 screws. Also available separately: • table stand (part number 010400) • vertically and horizontally adjustable bracket (part number 010401). Connectors Vers.

  • Page 9: Installation Of Kds Screwdriver

    Reserved for servicing the unit and upgrading the firmware. CN2 male serial connector To connect with a compatible barcode scanner, such as Kolver Barcode P/N 020050, serial printers such as Kolver PRNTR1, or serial terminals (PC/PLCs). CN4 female serial connector To connect with Kolver accessories SWBX88/CBX880, serial printers such as Kolver PRNTR1, or serial terminals (PC/PLCs).

  • Page 10: Installation Of Reaction Arm

    Installation of reaction arm Note: a reaction arm is ALWAYS required for KDS screwdrivers size 20Nm and above. Kolver recommends always using a reaction arm for operator comfort, especially for applications with torques above 5 Nm. Fix the reaction arm to the indicated areas only.
  • Page 11 KDS series screwdrivers sizes 20Nm and above have only one position designed for connecting to the reaction arm: 1. The naked metal cylinder near the head of the screwdriver KDS series screwdrivers sizes 20Nm and above also provide four threaded M4 holes for fixing to a custom assembly.
  • Page 12 CA automation versions: Reaction arm connection for KDS series screwdrivers 20Nm and above: CA automation versions: Vers. 062721...

  • Page 13: Quick Start

    QUICK START Turn the unit on through the on/off switch on the lower panel. The unit will carry a general system check and the words “NO SCREWDRIVER CONNECTED” will appear if no screwdriver is connected. You can still enter the main menu without any screwdriver connected. When a screwdriver is connected, it will be recognized by the unit and the "CONNECTED SCREWDRIVER"...
  • Page 14 If the parameters set in the current program are outside the allowable range of the connected screwdriver, the following screen will appear: To resolve the error, select a program previously configured for the connected screwdriver model, or enter the main menu to modify the parameter out of range for the current program.
  • Page 15 In angle control: the minimum torque set in the program is equal or higher than the maximum torque already set. TorqueMinOverMaxLim In torque control: the minimum torque set in the program is equal or higher than the target torque already set. The reverse torque of this program is higher than the RevTorqueOverMax maximum torque of the screwdriver.

  • Page 16: Terminology

    TERMINOLOGY KDU/K-DUCER/control unit: the KDU1 / KDU1A control unit KDS/screwdriver: the transducerized screwdriving tool to be used with the KDU control unit Transducer: electronic component installed inside the KDS screwdriver which measures the torque in real time Rundown/tightening: the screwdriving cycle, from start (pressing of the lever or initiating...
  • Page 17 Program/batch: a set of one or more screws sharing the same parameters (torque, angle, speed, barcode, etc) Program number: the identifier of one of the 64 configurable programs (1 to 64) Current program: the program currently selected for rundowns Program mode: in this mode, the unit works according the selected program Sequence/Job: an ordered set of up to 16 programs, with the option to define how to transition between programs Sequence letter/number: the identifier of one of the 8 configurable sequences (A to H)

  • Page 18: Operating The Kds Screwdriver

    Lever Press and hold the lever to initiate a rundown. Warning: Kolver strongly recommends using a reaction arms when applying torques greater than 5 Nm. A reaction arm with higher Nm capacity is required for KDS screwdriver sizes 20Nm and above. Using KDS screwdrivers sizes 20Nm and above without a reaction arm or with an improperly sized reaction arm may result in severe injury or death.
  • Page 19 BUTTON). LEDs The two LEDs indicate the state of the screwdriver: • Blinking white: the screwdriver was just connected to the K-DUCER control unit • Off: the screwdriver is ready, or the screwdriver is not connected • Solid green: the last screw result was OK •...

  • Page 20: Operating The K-Ducer Control Unit

    OPERATING THE K-DUCER CONTROL UNIT Main Screen – Program Mode Program (“PR”) number currently selected Touch to select a different program (1 through 64). Screw count Counter: screws successfully completed / number of screws in current program Note: does not appear if NUMBER OF SCREWS parameter is set to zero. Number of screws is also referred to as “batch size”...
  • Page 21 Torque charts Tap to display the Torque-time and torque-angle charts for last screw. Torque measurement unit You can select a different unit from the GENERAL SETTINGS menu. (10) Status bar Shows the last screw result or error messages (ready, screw OK, screw NOK, errors). (11) Torque target Shows the target torque when in torque control mode, or the min/max torque bounds...

  • Page 22: Main Screen - Program Mode - Navigation Tree

    Main Screen – Program Mode – navigation tree Vers. 062721...

  • Page 23: Main Screen - Sequence Mode

    Main Screen – Sequence Mode Sequence (“SEQ”) currently selected Touch to select a different sequence (A through H). Screw count Counter: screws successfully completed / number of screws in current program Note: does not appear if NUMBER OF SCREWS parameter is set to zero. Number of screws is also referred to as “batch size”...
  • Page 24 Torque measurement unit You can select a different unit from the GENERAL SETTINGS menu. (10) Status bar Shows the last screw result or error messages (ready, screw OK, screw NOK, errors). (11) Torque target Shows the target torque when in torque control mode, or the min/max torque bounds when in angle control mode or timed rundown mode, for the current program.

  • Page 25: Main Screen - Sequence Mode - Navigation Tree

    Main Screen – Sequence Mode – navigation tree Vers. 062721...

  • Page 26: Retrieving And Storing The Screwdriving Results

    The K-DUCER will create a folder named as the serial number of the connected screwdriver. Inside this folder, the K-DUCER will save the results of each rundown inside a text file. The name of the text file will be the date of the first rundown contained.
  • Page 27 Target The target torque or angle TARGET: 2.0Nm Screw The duration of the rundown in seconds ST: 1.23 Time Speed The closing speed of the rundown S: 600rpm Screw Number of successfully tightened screws / total Screw: 1/8 count number of screws in program Sequence Current sequence and program within Seq: 1/3...

  • Page 28: Connecting A Barcode Scanner

    Connecting a barcode scanner The K-DUCER is compatible with RS-232 capable barcode scanners such as Kolver P/N 020050. All barcode types are supported provided the total length of the barcode is 16 characters. The barcode scanner should be configured with the following serial parameters and connected to the CN2 serial port connector: RS232 –...
  • Page 29 To use the accessories for sequence selection instead of program selection, first activate SEQUENCE toggle, then select “On Seq” instead of “On Prog” in the general settings menu field SWBX88/CBS880. The K-DUCER will now match sequences A through H to the accessory bit or button positions 1 to 8. Vers. 062721...

  • Page 30: Configuring The K-Ducer

    Touch to enter the general settings menu, to configure general parameters such as passcode lock, I/O and MODBUS settings, kolver accessories, language, etc. Touch to enter the USB menu to save or load settings from a USB drive. Note: if a USB drive is connected, the unit automatically saves all screwdriving results in a text file.

  • Page 31: Programs Menu

    Programs represent batches of one or more screws sharing the same parameters (torque, angle, speed, etc). With the K-DUCER series, you can define up to 64 different programs as well as assign a barcode to each for automatic selection with a barcode scanner.

  • Page 32: Programs Menu Tree

    PROGRAMS menu tree Vers. 062721...
  • Page 33 Vers. 062721...
  • Page 34 Vers. 062721...

  • Page 35: Torque & Angle Menu

    TORQUE & ANGLE menu Program Number Indicates the program that is currently being edited. You can select a different program to edit from the previous screen. TORQUE CONTROL / ANGLE MONITORING flag Tap to select Torque Control and Angle Monitoring mode. In this mode, the screw is tightened down to the target torque, and the angle (the number of revolutions of the screw, in degrees) reached at the target torque is measured.
  • Page 36 WARNING: carefully choosing the right combination of speed and downshift settings for the application will maximize the precision and lifetime of the tool while minimizing your assembly cycle time. While the appropriate settings can be highly specific to each application, there exist a few rules of thumb: A high approach speed minimizes motor strain and assembly cycle time, but can mechanically stress and even break the part or the tool if the joint is hard.

  • Page 37: Ramp & Time Menu

    Lever: the angle measurement starts as soon as the screwdriver level is pressed Ext In: the angle measurement starts after the IN-ANG external I/O signal is received (13) Exit/Save key Tap to return to the previous menu and save or discard any changes made. RAMP &...
  • Page 38 stops will be displayed and will be used to determine whether the result was OK or NOK depending on the min/max limits set on torque, angle, and/or time. If OFF, the screwdriver will turn indefinitely until the target or max limits set on torque, angle, and/or time are reached.

  • Page 39: Rev & Pre-Rev Menu

    REV & PRE-REV menu Program number Indicates the program that is currently being edited. You can select a different program to edit from the previous screen. REVERSE SPEED Tap to select the untightening speed of the screwdriver, in RPM. WARNING: This setting also applies to the PRE-TIGHTENING REVERSE and AUTO- REVERSE AFTER TORQUE functions.

  • Page 40: Other Menu

    The speed and torque utilized in the PRE-TIGHTENING REVERSE phase are set in the REVERSE SPEED and REVERSE TORQUE settings above. This function activates only if the screw result from the tightening phase was OK. If there was an error in executing or completing the tightening phase, the screwdriver will not proceed with the AUTO-REVERSE AFTER TORQUE phase.
  • Page 41 (empty lines) printed between a results string and the next on the serial port and serial printer accessory. SWBX88/CBS880 Tap to enable and utilize the SWBX88 or CBS880 Kolver accessories with the current program being edited. Enter 1 through 8 to assign the current program (1 setting from above) number to the corresponding physical slot (1 through 8) of the Kolver accessory.
  • Page 42 This function is useful when the torque result measured by an external instrument is not in line with the result measured by the K-DUCER, provided you are sure that the external instrument is properly calibrated and showing the correct result.

  • Page 43: Sequence Settings Menu

    With the K-DUCER series, you can define up to 8 different sequences as well as assign a barcode (limited QR code support) to each for automatic selection via a barcode scanner.

  • Page 44: Sequence Settings Menu Tree

    SEQUENCE SETTINGS menu tree Vers. 062721...

  • Page 45: Current Seq. Menu

    CURRENT SEQ. menu Sequence letter Indicates the sequence that is currently being edited. Tap the arrows to select a different sequence to edit (A through H). Program number box Tap to change or insert a program into the sequence. The sequence flows left to right, top to bottom.
  • Page 46 screwdriving operation that is not otherwise possible within the parameters of a single program. WARNING: use this transition setting with care and only when strictly necessary, as the operator will not have any time to react to the program change. Exit/Save Key Tap to return to the previous menu and save or discard any changes made.

  • Page 47: General Settings Menu

    Tap the General Settings button from the main menu to enter the general settings menu. In this menu you can find information on the current KDS series screwdriver connected, configure Kolver accessories, configure I/O communications, add a password lock to the menu, and other settings that apply to all programs.
  • Page 48 FATc: the calibration value of the transducer, also available in the calibration certificate of the tool). Modifying this value requires a Service Passcode. Contact Kolver to schedule a factory re-calibration or to obtain the service passcode and calibration instructions to perform the re-calibration in-house.
  • Page 49 When the passcode is enabled, the lock icon on the main screen will have a red background, and the passcode will be required to access the configuration menu. Should you forget the passcode, contact Kolver to obtain a master passcode. (11) DATE &...
  • Page 50 OP: to interface with any device supporting Open Protocol via the ethernet port. IP ADDRESS: the ethernet IP address of the K-DUCER unit. Must be assigned manually and be available/reserved in the local network, if applicable. The unit does not support DHCP assignment.

  • Page 51: Usb Menu

    USB menu Tap the USB button from the main menu to enter the USB menu. From this menu you can save and recall the K-DUCER configuration containing all program parameters, sequence parameters, and general settings, from a USB drive connected to the USB type-A port on the bottom of the unit.
  • Page 52 USB drive. You will be prompted to enter a name for the configuration file. The file will have a .kdu extension and can be loaded onto this or other K-DUCER units or onto the freely available K-EXPAND software for PC.

  • Page 53: Usb Menu Tree

    USB menu tree Vers. 062721...

  • Page 54: K-Expand Software

    The parameters that are displayed are the same as those inside the K-DUCER unit and have the same functions, warnings, and limits described in this manual.

  • Page 55: Screwdriver

    , or switch to the ethernet interface. To use the ethernet interface, connect the PC using K-Expand and the K-DUCER to the same LAN network (or directly to each other), then enter the K-DUCER IP address in the corresponding K-Expand field:...

  • Page 56: General Settings

    General Settings The following parameters not found directly in the K-DUCER touch screen menu have the following functions: 1. Screw Mode: Program or Sequence. This is equivalent to activating or de-activating the SEQUENCE toggle on the K-DUCER. 2. Nr Program: the current selected program on the K-DUCER (for program mode) 3.

  • Page 57: Sequence Settings

    Sequence Settings It is possible to select up to 8 sequences of up to 16 programs each. You must select the position of each program and the transition to move from one program to another, the same way as described in the CURRENT SEQ.

  • Page 58: Programs

    Reverse and Other), simply click on the desired tab. Each parameter is the same as the corresponding parameter on the K-DUCER unit. To change it, simply enter the cell, select a number in the correct range, then press Enter. Or you can press the keyboard button and type the desired value.
  • Page 59 Vers. 062721...

  • Page 60: Actions

    To upload all the setting to the KDU unit. The K-Ducer must first be connected and recognized using the “Scan Port” button. Note: all of the settings of the K-DUCER will be overwritten with the ones from the K- Expand software.
  • Page 61 There are no constraints on the name. Open file Press to recall a file previously saved on a PC with K-Expand or on a USB key directly on the K-DUCER. Once the file is selected, the parameters will be loaded automatically on K- Expand. Open Terminal Press to display the print string and the status of the inputs/outputs in the KDU unit.
  • Page 62 Also, by pressing the SHOW CHARTS bar, you can view the torque-time and torque-angle graphs. The graphs show the values sampled during the screwing corresponding to the print string shown below them. Pressing on one of them with the mouse it is possible to visualize the x and y axis values.
  • Page 63 Finally it is possible to export the graphs in .csv format by clicking on the Save CSV. K-EXPAND can be downloaded for free at https://kolverusa.com/products-list/16-Industry- 40-KDUCER-Series Vers. 062721...

  • Page 64: Remote Control Interfaces

    • Interface with K-Expand software via mini-USB or ethernet port Additionally, a printout of each screwdriving result can be accessed as follows: • Through serial ports CN4 and CN2, for printing with Kolver printer accessory or receival with any serial terminal, automatically transmitted at the end of each rundown •...

  • Page 65: Pinout (Cn3)

    Pinout (CN3) To connect, simply push the cable or the ferrule directly onto the corresponding hole. To disconnect the cables, press lightly on the respective orange plate. Solid cable section min (mm²) 0.2 Solid cable section max (mm²) 0.5 Section of braided cable min (mm²) 0.2 Section of braided cable max (mm²) 0.5 Flexible cable section with min ferrule without sheath (mm²) 0.25 Flexible cable section with max ferrule without sheath (mm²) 0.75...
  • Page 66 INPUT SIDE (PINS 1-22) The input signals must be driven by a +24VDC potential with respect to pin 22 (GND). A +24VDC potential is provided for convenience at pin 21 (24V DC). When driving the inputs via an automated machine or PLC, it is recommended to program a delay of at least 30ms between each change of input signals.
  • Page 67 This pin serves the same function as the physical reverse button on the screwdriver. The behavior of the reverse button can be configured via General Settings > REVERSE BUTTON. IN ANG Input signal to initiate the angle measurement during a rundown, when using the external signal setting for angle measurement.
  • Page 68 Most significant bit indicating currently selected program. NOT USED DOCK05 Mirrors ‘BIT6 PR’, for use with DOCK05 dual screwdriver accessory. This pin does not blink when using Kolver CBS or SBX accessories or REMOTE PR with SEQUENCE toggle active. v34 and later only.

  • Page 69: Wiring Diagrams

    (Not-OK) This signal activates when the rundown (screw) completes unsuccessfully, outside of the parameters set for the current program, for example: torque reached under minimum time, torque reached outside angle bounds, etc. This signal remains active until the screwdriver changes state again, for example, when the operator or the PLC initiates another rundown.
  • Page 70 Example on how to enable Input signals using the internal tension on Pin 21: Outputs (pins 23-43) When active, an output pin will provide a 24V DC signal on the respective pins with respect to ground pins 22/44. The signals can be used to activate LEDs / sensors or read directly from an external PLC.

  • Page 71: Binary Tables For Sequence And Program Selection

    Binary tables for sequence and program selection Refer to the tables below for sequence or program selection via CN3, where “1” refers to an active +24VDC signal with respect to the GND pin and “0” refers to no signal. The REMOTE PR or REMOTE SEQ setting (General Settings > REMOTE PR REMOTE ) must be active for the input selection to work.
  • Page 72 PIN7 PIN 6 Note: for safety reasons, Kolver has chosen not to associate any program or sequence if no input is activate. This makes sequence H and program 64 not selectable via CN3 inputs. It is still possible to select sequence H or program 64 manually, with Kolver accessories, or via one of the communication protocols.

  • Page 73: Modbus Tcp

    Series Introduction The recommended way to interface with the K-DUCER unit is through the MODBUS TCP protocol on the ethernet port (CN5). MODBUS communication protocol provides a Client-Server interface between devices connected on an ethernet TCP/IP network.

  • Page 74: K-Ducer Modbus Map

    Changing program parameters such as target torque via MODBUS is possible but not recommended, and is never necessary except for the rare applications requiring more than 64 different programs. K-DUCER MODBUS map The K-DUCER, MODBUS data is organized and accessed as follows: Data Contents Access Associated...

  • Page 75: Modbus Tcp Code Examples And Literature

    KDUCER-Series MODBUS TCP code examples and literature We provide sample projects illustrating K-DUCER screwdriver control built by Kolver for various devices, as well as generic MODBUS TCP guides and literature produced by the manufacturers of these devices at https://kolverusa.com/products-list/16-Industry-40-...

  • Page 76: Open Protocol

    OPEN PROTOCOL Introduction The K-DUCER control unit supports a subset of the Open Protocol communication interface, based on the Open Protocol specification release 1.6, revision 3. The Open Protocol communication interface gives the K-DUCER plug-and-play compatibility with any MES software (Manufacturing Execution System) that supports Open Protocol 1.6 rev3.
  • Page 77 0031 Job ID upload reply Controller None 0032 Job data upload request Integrator 0033 or 0004 0033 Job data upload reply Controller None 0034 Job info subscribe Integrator 0005 or 0004 0035 Job info Controller None or 0036 0036 Job info acknowledge Integrator None 0037...

  • Page 78: Maintenance And Care

    MAINTENANCE AND CARE INTRODUCTION K-DUCER and KDS screwdrivers are precision tools. While built to withstand heavy use in industrial environments, good care and proper maintenance will go a long way in ensuring the best performance and lifetime of your instrument.

  • Page 79: Maintenance

    Maintenance consists of disassembling the screwdriver to clean and relubricate the gearbox, and checking the calibration of the screwdriver against a certified torque measurement tool. Contact your Kolver representative to schedule a maintenance service. Alternatively, Kolver can provide maintenance instructions.

  • Page 80: Exploded Views And Spare Parts

    EXPLODED VIEWS AND SPARE PARTS EXPLODED VIEW KDU-1/ KDU-1A: SPARE PARTS KDU-1/ KDU-1A: Position Description Quantity Part Number SPACER 22MM KDU 872522 MOTOR BOARD K-DUCER 852530 I/O BOARD (44 PIN CONNECTOR) - KDU 852533/B SWITCHING 872490 SCREW M4X8 ZN TX20 872534 SIDE PLATE...
  • Page 81 SCREW M3X10 ZN TX10 231530 FILTER AR13.6 A 800718 ANTI-UNTHREAD PLUGS 800719 FUSE 3,15A F-520LT3.15 800619 SCREW TSP M3X8 TX10 ZN 801009 CONNECTOR I/O 44PIN 872526 SCREW M3 X 5 ZN TX10 872444 CONNECTOR M12 8 POLI FEMALE 872537 CONNECTOR M16 10 PIN FEMALE 201668/HU FLAT CABLE 4 PIN 872539...

  • Page 82: Guarantee

    No one, whether an agent, servant or employee of KOLVER, is authorized to add to or modify the terms of this limited guarantee in any way. However it’s possible to extend the warranty with an extra cost.

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