HIOS PG-3000 PG Series PG-01 Brushless Screwdriver with Built In Torque Sensor User Manual

HIOS PG-3000 PG Series PG-01 Brushless Screwdriver with Built-In Torque

Sensor

Product Information

The Brushless Screwdriver with Built-in Torque Sensor is part of the PG Series, specifically the PG-3000, PG-5000, and PG-7000 models. It comes with a Control Unit, the PG-01. The user manual for this product is labeled ET-A034 22A.

Table of Contents

• 03 Important Safety Instructions
• 04 Checking Supplied Accessories
• 05 Setting Up the Device
• 06 Parts and Their Functions
• 09 Start and Stop
• 09 Adjust Torque
• 10 Set Learning Values (Teaching)
• 11 Evaluation of Screw Tightening
• 14 Connect the ScrewDriver to PC
• 20 Troubleshooting
• 21 After-sales Service
• 21 Specifications

Important Safety Instructions

• Please read this manual and the power supply unit manual carefully before use to ensure proper operation.
• Do not use the product in a way not described in this manual.
• Do not install the device in places of high humidity or with a lot of dust, high temperatures, fire hazards, direct sunshine, or containing corrosive gas in the air.
• Be sure to install an earth leakage breaker and a safety breaker on the commercial power source before using it.
• Avoid wearing clothes with flippers on the cuffs, gloves, neckties, etc., as they may get caught in the rotating screwdriver and cause injury or failure.
• Wear suitable clothing and protective eye-wear for work. Cover long hair with a hat, etc., to ensure safety.
• Turn off power when leaving the workplace or when attaching/removing a bit or an optional item.
• Neutralize static electricity before use.
• Avoid an unstable place or an unreasonable posture for work to prevent injury.
• Avoid long-time work and take regular breaks to prevent strain on hands, neck, arms, or waist.

Installation

• Do not install the device at the places described below. Otherwise, it may cause a fire or a failure. A place of high humidity or with a lot of dust

  • A place where it becomes high temperatures
  • A place of fire
  • A place of direct sunshine
  • A place containing corrosive gas in the air
  • Unstable place

• Do not use the device where the ambient temperatures are out of the range of 5 to 40 °C.
  Power Supply

• Be sure to install an earth leakage breaker and a safety breaker on the commercial power source before using it.

• Connect the earth wire to the earth wire terminal of the outlet. You may have an electric shock without the earth wire connection in case of electric leakage.

• Avoid the octopus foot wiring and use of an extension cord. Otherwise, it may cause a fire or an electric shock.

• Do not connect anything other than specified to the connection part of this device. Otherwise, it may cause an electric shock or a failure.
  Handling

• Do not wear clothes with flippers on the cuffs, gloves, neckties etc. Otherwise, they may get caught in the rotating screwdriver and cause an injury or a failure.

• Wear suitable clothing and protective eyewear for work. Cover long hair with a hat etc. so that you can work safely.

• Turn off power when you leave the workplace, or when you attach/remove a bit / an optional item.

• If static electricity is charged, you need to neutralize it before use.

• Avoid an unstable place or an unreasonable posture for work. Otherwise, it may cause an injury.

• Long-time work or some types of work may cause strain on your hands, neck, arms or waist, causing an injury. Avoid long-time work and take a break regularly.

• We recommend use of a balancer to prevent the device from falling and to protect cords/wires.

• Hold the plug when you attach/remove the power cord, screwdriver and so on.

• Protect cords/wires by not giving damages to them; not remodeling them; not pulling them; not bending them forcibly; etc. Also, do not place heavy items on the power cord. Otherwise, it may cause a fire or an electric shock.

• If you detect an uneven rotation, strange noises, overheating or activation of a breaker, etc., stop using the device immediately and have it repaired. However, note that the device may be overheated depending on the frequency of the workpiece or screw types. As a countermeasure, prepare spare screwdrivers of the same model to extend the tact time and use them alternately, or review the selection of screwdriver models.

• Do not overload the device so much that it cannot clutch. Otherwise, it may cause a failure of the motor.

• Do not touch the screwdriver while it is rotating. Otherwise, it may cause an injury or a failure.

• Keep your hands and face away from the rotating section while in use. Otherwise, it may cause an injury.

• Remove the bit from the screwdriver when you  are not working.

• If you cannot attach/remove the bit in the way described in this document, please make contact with our service section.

• Fix the workpiece with jig/clump while in working.

• Do not use the switch lever as a hanger. Otherwise, it may cause an accident or an injury.

• Do not give a strong impact or excessive force. Otherwise, it may cause a failure.

• Do not operate the screwdriver with wet or oiled hands.

• Do not operate the FOR / REV switch before the screwdriver completely stops. Otherwise, it may cause a failure.

• Do not disassemble/remodel this device. Otherwise, it may cause a failure.

• High torque has a large recoil on the hand or arm. Hold the driver firmly to avoid being swung around.

• Remove the accessories from the screwdriver and store them in the package box when it is not in use them for a long time.

• I nspect the device regularly to confirm there are no damages. If you use it with damage, it may cause a fire or an electric shock.

• When you clean the device, turn off the power and remove the power plug from the outlet. Otherwise, it may cause a fire or an electric shock.

• Use dry cloth to wipe of dust or stains. The dust may absorb moisture to allow current to flow, causing a fire.

• Store the device in a place where the appropriate temperatures and humidity are controlled.

• Do not store the device in an unstable place or a place with vibrations. Otherwise, it may cause a failure.

• Keep the device out of reach of anyone but people involved in the workpiece.

• We recommend genuine HIOS parts for replacement.
  Maintenance and Inspections

• Turn off power and remove the power plug from the outlet when the device is not in use for a long time.

Checking Supplied Accessories

If an item is missing or damaged, contact the store where you purchased the product.

• Screwdriver
• Bit
• Screwdriver Cord (2m)
• Sensor Cord (1.7m)
• PG-01
• AC Adapter
• RS-232C Cable
• USB to RS-232 Conversion Cable*
• Manual
• User Software CD-ROM

Product Usage Instructions

Setting Up the Device

1. Connect the cords.

2. Connect the plug and screwdriver cord to the power supply.

3. Connect the screwdriver and sensor cords to the screwdriver and connect the sensor cord to PG-01.

4. Connect the AC adapter to PG-01.

5. Install the bit.

   • Insert the bit while pushing the joint shaft collar into the body.
   • Release the collar and check if the bit is locked.
     Pull the bit gently to confirm it does not come out.

6. Remove the bit.

7. Pull out the bit while pushing the collar against the body.

8. Turn on the power.

9. Turn on T-70BL and PG-01.

Connect the AC adapter to PG-01.

PG-3000/PG-5000/PG-7000

1. Joint shaft collar
   Operate the collar to install or remove the bit.

2. Nut protection cover
   This protects the torque adjustment nut. Turn it counterclockwise for removal.

3. Torque adjustment nut
   Use this for adjustment of the output torque.

4. Switch lever
   Start the screwdriver with the lever.

5. Forward / reverse switch
   You can switch the screwdriver’s rotational direction.
   Clockwise
   OFF: no rotation(PG-5000/PG-7000)
   Counterclockwise

6. Screwdriver cord connector
   To connect the screwdriver cord.

7. Hanger
   To hang the screwdriver on the balancer or like.

8. Sensor cord connector
   To connect the sensor cord.

PG-01
The measurement result of tightening a screw will be informed by the indicator and sound.

1. L.NG Indicator
   This indicator is lit when the measured value is no good (smaller than the minimum pass value).

2. L.G Indicator
   This indicator is lit when the measured value is good (larger than the minimum pass value and below
   the minimum learning value).

3. GOOD Indicator
   This indicator is lit when the measured value is good (larger than the minimum learning value and
   smaller than the maximum learning value).

4. H.G Indicator
   This indicator is lit when the measured value is good (larger than the maximum learning value and
   below the maximum pass value).

5. H.NG Indicator
   This indicator is lit when the measured value is no good (larger than the maximum pass value).

6. Teaching Indicator
   This indicator is lit when in the teaching mode (for setting of learning values).

7. Teaching Button
   This is for setting to the teaching mode. Pressing and holding this button (2 seconds or longer) in the
   teaching mode will cancel the mode. For details of teaching, refer to “Set Learning Values (Teaching)” (P.10).

8. OPERATION OK Indicator
   This indicator is lit while the screwdriver is rotating positively.

9. OPERATION NG Indicator
   This indicator is lit when the operation ends without torque up. This blinks when the operation ends
   due to an abnormal measurement time.

10. Power Button
    This switch turns power on and off. Press and hold the button for 2 seconds to turn off the power.

11. Power Indicator
    This indicator is lit when power is supplied.

12. Sensor Cord Connector
    This is used to connect the sensor cord.

13. I/O Connector
    The I/O flat cable is connected here for the evaluation result to be output. The output format is an open
    collector. Use this when you cannot connect with RS-232C.PIN No.| Output signal| Description
    ---|---|---
    12| COM GND| —
    13| L.NG (NG)| Output when the measurement value is NG (below the minimum pass value)
    14| L.G (OK)| Output when the measurement value is OK (equal to or larger than the minimum pass value and smaller than the minimum learning value)

15

|

GOOD (OK)

| Output when the measurement value is OK (equal to or larger than the minimum learning value and smaller than the maximum learning value)

16

|

H.G (OK)

| Output when the measurement value is good (equal to or larger than the minimum learning value and smaller than the maximum learning value)
17| H.NG (NG)| Output when the measurement value is no good (larger than the maximum pass value).
14. RS-232C Connector
An RS-232C cable is connected here.

15. AC Adaptor Connector
    An AC adaptor is connected here. Power will be automatically supplied when an AC adaptor is connected.

Start and Stop

• To start the screwdriver, follow the instructions provided in the manual.
• To stop the screwdriver, follow the instructions provided in the manual.

Start the Screwdriver

1. Pull the switch lever to start the bit turning. Release it to stop turning.

Stop the Screwdriver

1. When the set torque is reached, the clutch in the screwdriver works to stop turning.

Adjust Torque

CAUTION The “reference table of output torque” and the torque adjustment scale are approximate and do not guarantee actual setting values.
For accurate torque check, please use an HIOS torque meter and Fidaptor.

1. If the torque is determined beforehand, turn the torque adjustment nut and nut fixing ring referring to the “reference table of output torque”.
   • Turn the torque adjustment nut clockwise to increase the torque and turn it counterclockwise to decrease the torque.
   • Adjust it so that the end face of the nut fixing ring is right above the scale.
   • After the nut fixing ring is positioned, fit the torque adjustment nut accordingly.
2. Try to fasten a screw and check how it is fastened after the screwdriver stops and adjust the most appropriate torque.

Reference Table of Output Torque

Set Learning Values (Teaching)

Measure the “tightening torque” and “working time” by using screws and materials actually used to set the reference values for work. The two values recorded are the minimum and maximum, respectively. Also, after teaching, it is possible to change the error tolerance of the learning values and the learned values in the attached application or Excel file.

CAUTION
Teaching should be done under the same conditions as actual operation.
An error may occur in the measured value if the screw to be used, the materials to be fastened, the attaching method of the screw, etc., are different from actual operation.

1. Press and hold the teaching button.
   • A buzzer sounds in about 2 seconds and the teaching mode is enabled.
   • The teaching indicator is lit.
   • L.NG indicator and H.NG indicator blinks.
2. Using the screws and materials to be actually used, perform tightening more than 3 times.
   • Every time after tightening is completed, a buzzer sounds once, and the measured value is recorded.
   • The measured values of the third to tenth trials are recorded and the values after the eleventh trial will overwrite the old values.
3. Press and hold the teaching button.
4. A buzzer sounds in about 2 seconds and the teaching mode ends.
5.  The teaching indicator, L.NG indicator and H.NG indicator turn off.

About Learning Values

• The learned values do not disappear even when the power is turned off.
• To reset the learned values, perform teaching again. The previous learned values will be deleted when the teaching mode is enabled.
• After purchasing, please perform teaching with PG-01 for the first time. Otherwise, it is not possible to set learning values with the attached application.

Evaluation of Screw Tightening

• It measures actual screw-tightening work in real-time, compares the measurement with the learning value, and informs the user of the evaluation result with an indicator and sound.
• The reverse rotation of the screwdriver is not evaluated.
• The allowable error range at the time of purchase is set to 10% for both upper and lower limits. If you want to change it, please use the attached application.

OK/NG Judgment of Tightening Torque Value
If no error is detected in the screw tightening work, one of L.G, GOOD or H.G indicators is lit and the buzzer sounds.

If the torque is within the learning values, the GOOD indicator will be lit, and if it falls within the allowable error range, either L.G or H.G indicator will be lit. Conversely, when the torque is less than the lower limit value, the L.NG indicator will be lit, and when the torque exceeds the upper limit value, the H.NG indicator will be lit, which means fail.

Evaluation of Operation Time

• The operation time from start of rotation to stop of the screwdriver is evaluated against the learning values.
• The blinking and lighting of the OPERATION NG indicator will turn off when the START signal is entered again.

Main reasons why OPERATION NG indicator is lit
No torque up signal is sent because of reasons like screwdriver idling.

Main reasons why the OPERATION NG indicator blinks

• A torque-up signal was not sent during the learning measurement period.
  If it is not necessary to strictly measure the operation time, by using the application, change the setting value so that the learning interval will become larger.

• Continuous ON/OFF operations at the end of tightening (pushing the button twice or three times in a row)

CAUTION
There is a nonintervention time of 100mS for torque measurement and evaluation after the START is input.

If the screwdriver output is given to a screw even after tightening, the value will be larger than the measuring value and not the expected tightening value.
To perform proper screw tightening, please do not perform continuous operations.

Flowchart of Judgment

Connect the ScrewDriver to PC

1. Connect the RS-232C cable to PG-01.

2. Connect the USB to RS-232C conversion cable to the RS-232C cable.

3. Connect the USB to RS-232C conversion cable to PC.

4. Download the device driver from the ATEN website and install it on PC.
   Check the website for how to install and supported OSs. https://www.aten.com/global/en/products/usb-peripherals/usb- converters/uc232a/

5. Turn on PG-01.

Check the Port
Open the device manager to check which port PG-01 is connected to.

In Case of Windows 10

1. Right-click the Start button and select Device Manager.
2. Click the port (COM and LPT) in the list and check COM number displayed in <ATEN USB to Serial Bridge (COMXX)>.

Data Output Format by Either RS-232C or USB Connection
The data for judgment is output for each measurement in the three formats in the sequence below.

• Measurement Data

  • Torque conversion value – 4 digits
  • Measurement time – 5 digits (unit: mS)

• Recorded Learning Value

  • Display learning number
    Display learning minimum value

  • Display minimum learning measurement time

  • Display learning maximum value

  • Display maximum learning measurement time

• Judgment reference values

  • Judgment error rate
  • Judgment minimum value
  • Judgment measurement time minimum value
  • Judgment maximum value
  • Judgment measurement time maximum value

Error-related Output

E90| End which cannot be detected by 0 areas, and judged| [Zero area detection/Impossible judgment ending]
---|---|---
E91| Abnormal termination at measurement time| [The abnormally end at the measurement time]

E92

| ****

Study shortage and end which cannot be judged

| [The ending about which it is impossible to judge by the learning

lack]

E93| Judgment=LOW NG| [Judgment = Low NG]
E94| Judgment=HIGH NG| [Judgment = High NG]

Measurement Judgment Output****

PC Input

Hyper terminal (Example: Windows XP)
After the PC is turned on and the version information is displayed, auto-zero correction is performed. The following messages for debugging are displayed that are not directly related to measurement.
Ver3.04 2022/05/25
[Zero Adj A/D=7C2 G=1EA F=200] [Zero Adj A/D=806 G=1EB F=200] [Zero Adj A/D=808 G=1EC F=200] [Zero Adj A/D=803 G=1ED F=200] [Zero Adjustment end A/D=7FF Gain=1ED]

E90| End which cannot be detected by 0 areas, and judged| [Zero area detection/Impossible judgment ending]
---|---|---
E91| Abnormal termination at measurement time| [The abnormally end at the measurement time]

E92

| ****

Study shortage and end which cannot be judged

| [The ending about which it is impossible to judge by the learning

lack]

E93| Judgment=LOW NG| [Judgment = Low NG]
E94| Judgment=HIGH NG| [Judgment = High NG]

Example of a Measurement OK Message
In general, messages are either operation check messages or measurement data.

Abnormal Conditions
This displays the condition when judgment results are abnormal.

Data Taking-in Sheet (HIOS-PG-0611-V2-2_5)

By using the data taking-in sheet in the attached CD-ROM, you can check the OK/NG of screw tightening on the PC or record the measurement data.

CAUTION

• Enable macros.
• Start settings after turning on PG-01 and connecting it to the PC.
• When using USB, the PC may turn off PG-01 automatically in some cases. In that case, please disconnect and reconnect the screwdriver.
• There is no reaction to the reverse rotation of the screwdriver.
•  If you want to take in two types of data, create two files (for example, test1.xls and test2.xls) in advance. Then, start up two applications, and then open each file.
  If you open files by double-clicking them in Windows Explorer, two files are opened in the same application and the application cannot be used.

Operating Environment
The data-taking-in sheet was confirmed to be effective in the following environments:

• Microsoft Windows XP
• Microsoft Excel 2003
  If it is not functioning, select application type “screwdriver data collection”.
  Please be aware that maintenance and support services are unavailable since this is sample software.

Configuration of the Screen

1. Connection confirmation window
   The login information is displayed.

2. Disconnect button
   This ends data import.

3. Connect button
   This makes the data import standby. If the previous data is necessary, please save the current data first
   and then connect the screwdriver. (The previous data will be cleared upon connection.)

4. COM port
   Check the port number and enter it. Then, press [Enter] on the keyboard. Usually, select COM as the port.
   Cell colors

   • Gray: the screwdriver is not connected.
   • Yellow: the screwdriver is connected.

5. LAN settings
   Optional

6. Judge On/Off
   Errors E90/E91/E92 can be turned ON/OFF.
   ON: the measured values are entered in the datasheet.
   OFF: the measured values are entered in the irregular sheet.

7. Measurement settings processing table
   The table shows commands and settings processing that are displayed in the log.

8. Judgment
   This indicates OK/NG of screw tightening with colors.

9. Output data
   Torque equivalent value: this indicates values taken during actual operation.
   Measurement time: this indicates the time from screw tightening to torque-up.
   Number of learning: indicates the number of teaching operations performed.
   Minimum of the learning: indicates the minimum teaching value (modifiable).
   Maximum of the learning: indicates the maximum teaching value (modifiable).
   Measurement time of minimum: indicates the teaching minimum time (modifiable).
   Measurement time of maximum: indicates the teaching maximum time (modifiable).
   After inputting a number, press [Enter] on the keyboard.
   ・These learning-related values will be sent to PG-01 by clicking the [Write learn-value] button after
   entering a number.
   ・ If the [Learned value change] button is not pressed, the memory in PG-01 won’t be updated and the
   previous value will be recovered after the next torque-up operation.

10. Judgment comparison data
    Torque value: indicates the value output on the graph sheet.
    Judgment minimum value: indicates the amount minus the % setting for the learning minimum value.
    Judgment maximum value: indicates the amount plus the % setting for the learning maximum value.
    Meas. Time of judge minimum: indicates the amount of the time minus the % setting for the learning
    minimum measurement time.
    Meas. Time of judge maximum: indicates the amount of the time plus the % setting for the learning
    maximum measurement time.

11. Judgment error rate (%)
    This sets the acceptable evaluation threshold before a screw-tightening operation.
    Selecting the judgment error rate while the screwdriver is connected transmits the selected rate to
    PG-01. Even after disconnecting the PC, the selected rate will be retained.
    The selectable rates: 0%, 2%, 5%, 10% or 20% (02=2%)

12. Work On
    Normally this turns on automatically when an operation is performed.

Collection of Screwdriver Data (Application)
The operation data is collected in the same way as the data-taking-in sheet. The data is saved in the CSV
format.
For details, click [Instructions] on the screen of screwdriver data collection.

Troubleshooting

Refer to the troubleshooting section in the manual for assistance in resolving any issues or problems you may encounter.

If you have any problem while using this machine, please check the items in this section before making inquiries.
Then, if the problem persists, please contact your dealer or us.
The L.NG or H.NG indicator blinks when the power is turned on.
There is a possibility that the learning values are not set correctly. Repeat teaching 3 times or more to set the learning values.
The L.NG or H.NG indicator flashes even when the teaching mode is ended and
measurement cannot be performed.
There is a possibility that data for evaluation comparison is insufficient. If the learning count is less than 3, the indicator will keep flashing even if the teaching mode ends. Repeat teaching 3 times or more again to set the learning values.
In the following cases it is difficult to make an evaluation, and it may not be counted as learning.

• Torque value is 10 or less (“E90” [Zero area detection/Impossible judgment ending])
• Idling of the screwdriver occurs or the measurement time is 100 mS or shorter. (“S01” [Lever switch Off(no torque up)])

Setting cannot be changed from the tabulation software.
Click the [Write learn-value] button after input of a number. The settings in PG-1 will be updated by clicking the [Write learn-value] button.

The torque is abnormally low or high.
Turn off the power to check if the cords are connected correctly and then turn on the power again. If the problem persists, replace the sensor cord.

When a Problem Cannot Be Solved
When contacting us, have the following information ready: .

• Product name
• Description of the problem (detailed description of the operation performed and its result, etc.)
• Serial number (on the label of the product)

After-sales Service

If you require after-sales service, refer to the manual for information on how to proceed.

Specifications

Model| PG-3000|  | PG-5000| PG-7000|
---|---|---|---|---|---
Start Type| Lever|
Output Torque Range (N·m)| 0.2–0.55|  | 0.4–1.2| 1.0–2.8|
Unloaded Rotation

Speed (rpm) ±10% [HI/LOW]

| 980/680|  | 900/590| 960/630|
 | Machine Screw| 1.7–2.3|  | 2.3–3.0| 2.6–5.0|
Screw Size (mm)|  |
 |  |  |  |
 | Tapping Screw| 2.0–2.3|  | 2.0–2.3| 2.6–4.0|
Weight (g)| 345|  | 509| 807|
Power supply| T-70BL|

Bit Drive

|

Standard

Option

|  |

H4

—

|  | Ｈ5 and 5HEX

（compatible）

1/4HEX

|

External Dimension Drawing

Specifications of PG-01

www.hios.com

References

• HIOS
• USB to RS-232 Adapter (35cm) - UC232A, ATEN Converters | ATEN Corporate Headquarters

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