SD25 Series
Electric Screwdrivers
User’s Manual
Rev B, June 2004
39-30-40409
24-Hour
Technical Support
Toll Free in the U.S. and Canada:
1-877-224-7377
All other countries:
(001) 248-596-0600
between 8 a.m. and 5 p.m.
Eastern Standard Time (EST)
NOTE: The part number for the Visual Supervisor (VS) software
program is 464000-03300.
NOTE: A variety of related technical manuals in .pdf format
may be downloaded from www.gsetechmotive.com.
Click on the Technical Info button in the red, left-hand
frame. Select Technical Documentation. Scroll through
the list to find the title of the product you require, and
click!
NOTE: View our latest product literature in .pdf format in
multiple languages at www.gsetechmotive.com. Click on
the Product button in the red, left-hand frame. Select
Product Brochures. Scroll through the list for the name
of the product for which you would like more information,
and click!
SPX GSE tech-motive tool manufactures products under the GSE and tech-motive tool® brand names.
Information and technical diagrams in this manual are subject to change without notice. tech-motive tool is
a registered trademark. Products and services referred to in this book may be either trademarks and/or
registered trademarks of their respective owners.
© 2003-2004 SPX CORPORATION. ALL RIGHTS RESERVED.
LIMITED WARRANTY
SPX GSE tech-motive tool warrants its PRODUCTS to be free from defects in materials and workmanship for the
lesser of (1) one year from the date of shipment from the manufacturing facility in Michigan, U.S.A. OR
(2) one-million cycles except for the products noted below:
GSE tech-motive crowfoot, tubenut and hold & drive heads 250,000 cycles
rd
3
-party crowfoot, tubenut, hold-and-drive torque multiplier or other heads manufacturer’s warranty
56 and 116 Series nutrunners 500,000 cycles
PRODUCTS include GSE tech-motive tool brand fastening tools, controllers and cables, GSE brand sensors an d
instruments, and anti-lock brake testing systems. Fuses and batteries are not covered under warranty.
For PRODUCTS verified as defective at SPX GSE tech-motive tool’s manufacturing facility,
SPX GSE tech-motive tool shall have the option, in its sole discretion, to repair or replace the products or
components. SPX GSE tech-motive tool shall not be liable for any installation charges, expenses of the Buyer for
repairs or replacement, damages from delay or loss of use, or other indirect or consequential damages of any kind.
The warranty does not cover any product that has been modified without the approval of SPX GSE tech-motive tool,
used for a purpose other than that for which it was intended, used in a manner inconsistent with any instructions,
subjected to unusual physical stress, environmental or electrical conditions, or whose original identification marks
have been removed or altered.
Whenever the PRODUCTS are to be incorporated in a system, the design of which originated with the Buyer,
SPX GSE tech-motive warrants only that the PRODUCTS shall be free of defects in materials and workmanship and
offers no other warranty.
In the event that a product is repaired or replaced under the terms of the warranty, the warranty period for the
repaired or replacement product shall be limited to the remaining portion of the original warranty.
Any warranty extended by the original manufacturer of peripheral equipment, such as printers, recorders, plotters,
etc., included with a SPX GSE tech-motive tool product or system shall be extended to the Buyer and shall be the
only warranty offered.
Transportation charges for materials shipped to the manufacturing facility for warranty repair are to be paid by the
Buyer. SPX GSE tech-motive tool will pay for shipping to return items repaired or replaced under warranty.
THIS LIMITED WARRANTY IS EXCLUSIVE, AND SPX GSE tech-motive tool MAKES NO OTHER WARRANTY OF
ANY KIND WHATSOEVER, WHETHER EXPRESSED, IMPLIED OR STATUTORY, WITH RESPECT TO THE
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MATERIALS OR WORKMANSHIP, OR FOR ANY DAMAGES RESULTING FROM ANY OTHER CAUSE
WHATSOEVER. SPX GSE tech-motive tool SHALL NOT, IN ANY EVENT, BE LIABLE FOR ANY SPECIAL,
INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, NATURE OR DESCRIPTION,
WHETHER FOR NONCONFORMITIES IN MATERIALS OR WORKMANSHIP UNDER ANY WARRANTY, IN
CONTRACT, TORT, NEGLIGENCE, STRICT LIABILITY, OR FOR ANY OTHER REASON.
CUSTOMER SATISFACTION
Please Read This!
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tool. Please let us know what you think of our product(s).
Write the part number and serial number of the product(s) you have purchased before you begin our
brief online survey. The numbers are located on a sticker affixed to the handle of the nutrunner or
screwdriver, and exterior or interior of the controller.
Tool Label
Controller Label
Part Number
Serial Number
Part Number
Serial Number
To complete the survey:
1. Visit our website www.gsetechmotive.com
2. Click the Customer Satisfaction Survey link located below the gray buttons in the red, left-hand frame.
3. Fill in the fields and click the appropriate choices.
4. Click the “Submit to GSE tech-motive tool” button.
Preface
Our GSE tech-motive tool SD25 Series Screwdriver is easy to operate and comes with a manual that
includes instructions to help you use it safely, make minor adjustments, and perform routine
maintenance.
Who Should Use This Manual
This manual is written for the engineers and technicians, who will set up, use and maintain
GSE tech-motive tool SD25 Series screwdrivers.
How to Use This Manual
This manual introduces you to the SD25 Series Screwdriver and provides general safety and electrical
safety guidelines for using it, and covers installation, adjustment, calibration and troubleshooting of
the screwdrivers.
For the latest revision of drawings, please contact our Technical Service Department at
1-248-596-0600.
Conventions
The following conventions are used throughout this manual for the safety of personnel, equipment,
software, and data. The conventions include warnings, cautions, and notes, as follows:
WARNING!
!
CAUTION!
NOTE:
?
It can be dangerous to personnel and/or machine systems,
if operating instructions are not followed. The information
appears in a box in italicized boldface type.
There may be damage to equipment, and loss of software
and data, if operating instructions are not followed. The
information is indented and in italicized boldface type.
Information that adds to your knowledge of the equipment
and/or software. The information is indented and italicized.
June 2004 T-40409-A Page i
SD25 Series Screwdrivers
Abbreviations
The most common abbreviations used throughout this manual are:
DCM device control module
EEPROM electrically erasable programmable read only memory
ESD electro-static discharge
ITI intelligent tool interface
LED light-emitting diode
STM standard test method
TCM tool control module
VS Visual Supervisor is the setup, fastening, data collection and diagnostics software
program designed by SPX GSE tech-motive tool
References
CS2000 Mini Controller Hardware Overview Manual (part number 39-30-38810)
CS2000/CS4000 Mini Controller and CS4100 Controller Network and Interface Supplement
(part number 30-30-40477)
Mobile Fastening System II (MFS II) User’s Guide (part number 39-30-37700)
Visual Supervisor User’s Guide (part number 39-30-34823)
Page ii T-40409-A 39-30-40409
Contents
Preface ..................................................................................................................................... i
Who Should Use This Manual..........................................................................................i
How to Use This Manual...................................................................................................i
Conventions.......................................................................................................................i
Abbreviations....................................................................................................................ii
References ........................................................................................................................ii
SD25 Series Screwdrivers..................................................................................................... 1
Electro-static Discharge (ESD) ......................................................................................2
Think Safety First!.................................................................................................................. 3
General Machine Safety.................................................................................................. 3
Electrical Safety............................................................................................................... 5
Contents
Getting Started....................................................................................................................... 6
Viewing Screwdriver Functions..................................................................................... 7
Installing the Screwdriver............................................................................................... 8
Using Visual Supervisor Setup...................................................................................... 9
Tightening a Fastener................................................................................................... 11
Loosening a Fastener ................................................................................................... 11
Reversing the Screwdriver........................................................................................... 12
Attaching a Pistol Grip Handle..................................................................................... 12
Mapping Screwdriver Functions ........................................................................................14
Disabling the Push-to-Start Function.......................................................................... 14
Enabling the Push-to-Start Function........................................................................... 15
Mapping Outputs for a Single-Spindle........................................................................ 16
Mapping Outputs for a Single-Spindle........................................................................ 17
Troubleshooting Your Screwdriver.................................................................................... 19
Maintaining Your Screwdriver ............................................................................................ 20
Reading the Screwdriver Part Numbers........................................................................... 21
Specifications and Parts ..................................................................................................... 22
Specifications................................................................................................................ 22
Screwdriver Accessories.............................................................................................. 23
June 2004 T-40409-A Page iii
SD25 Series Screwdrivers
(This page is left blank intentionally.)
Page iv T-40409-A 39-30-40409
SD25 Series Screwdrivers
Thank you for purchasing the GSE tech-motive tool SD25 Series Screwdriver, available in in-line and
pistol grip versions.
The SD25 Series In-line Screwdriver is a compact, lightweight tool of aluminum construction,
weighing one pound and measuring 9.4-in length. It provides a push-to-start output spindle and/or
trigger-start for operator preference, a forward/reverse direction button, high intensity headlights, and
torque good, high and low indicator lights. It also has a multi-purpose (auxiliary) button that can be
used for a variety of functions.
SD25 Series In-line Screwdriver
The SD25 Series Pistol Grip Screwdriver is the In-line screwdriver with an attached lightweight
aluminum pistol grip handle (part number 49-SD-10111).
Each SD25 Series Screwdriver has the capability to interface to a computer through a laptop computer
attached to the GSE tech-motive tool CS2000 Mini Controller or CS2100 Controller.
SD25 Series Pistol Grip Screwdriver
NOTE:
Other accessories are available for the SD25 Series screwdrivers.
For more information, please visit our website at
http://www.gsetechmotive.com
then click on the Products button.
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June 2004 T-40409-A Page 1
SD25 Series Screwdrivers
Electro-static Discharge (ESD)
The SD25 Series Screwdriver is well suited for use in electro-static discharge (ESD) safe work areas.
The screwdriver has been tested and meets the requirements of ESD Standard (S) 20.20, and also
section 5.1.3 of ESD Standard Test Methods (STM) 13.1.
Page 2 T-40409-A 39-30-40409
Think Safety First!
Working with fastening tools can be dangerous if safe and proper procedures are not followed. As
with all machinery, certain hazards can be involved with the operation of the product. Using these
tools with caution will considerably lessen the possibility of personal injury. If, however, safety
precautions are overlooked or ignored pers onal injury to the operator can result.
Always use common sense and exercise caution when using these tools. They can produce torque that,
unless properly compensated for, could cause personal injury. Remember, your personal safety is your
responsibility.
Only GSE tech-motive tool-qualified service technicians should perform the procedures covered in
this manual. If you are an operator or service technician, you should become familiar with the
contents of this manual before operating, servicing, or performing maintenance on any part of the
fastening system, including the SD25 Series screwdrivers. Familiarization with all components of the
system can minimize the possibility that an accident or injury might occur.
SPX GSE tech-motive tool assumes no responsibility for personal injury or damage to equipment
resulting from misuse of these tools. After reviewing this manual you should also review all safety
procedures provided by your company and the equipment installer.
WARNING!
!
Failure to follow these rules can result in serious personal
injury.
General Machine Safety
• FOR YOUR OWN SAFETY READ THE INSTRUCTION MANUAL THOROUGHLY
PRIOR TO OPERATING THE TOOL.
• DO NOT WORK IN A DANGEROUS ENVIRONMENT. Do not use power tools in a
damp or wet location or explosive atmosphere, or expose them to rain, oils, or corrosive
fluids.
• KNOW THE LOCATION OF POWER DISCONNECTS PRIOR TO OPERATING
THIS EQUIPMENT.
• KEEP ALL ELECTRICAL PANELS CLOSED DURING OPERATION. High voltage
present inside enclosure panels can result in personal injury. Do NOT bypass or defeat
electrical safety devices. Turn the power actuator to the OFF position prior to any
servicing or maintenance of the controller.
• OBSERVE ALL GOVERNMENT AND/OR COMPANY POWER LOCKOUT
STANDARDS.
• NEVER OPERATE SOLENOID VALVES, LIMIT SWITCHES OR RELAYS
MANUALLY as this practice can create dangerous, unexpected machine movements.
June 2004 T-40409-A Page 3
SD25 Series Screwdrivers
• SECURE THE TOOL. Tools that develop torque can produce hazardous torque
reactions. Always be sure that the tool is properly fixtured to absorb reaction as a
fastener is tightened. Never operate a tool capable of high torque without proper
fixturing.
• SECURE WORK. Avoid situations where the part being fastened breaks loose and can
cause damage.
• NEVER TOUCH OR ATTEMPT TO STOP MOVING MACHINERY OR PARTS
WITH YOUR HANDS, OTHER PARTS OF YOUR BODY, OR MAKESHIFT
DEVICES.
• DO NOT OPERATE THE TOOL WHILE UNDER THE INFLUENCE OF ALCOHOL,
DRUGS OR MEDICATION THAT CAN IMPAIR YOUR JUDGMENT.
• REPORT ALL UNSAFE WORKING CONDITIONS OR PRACTICES TO YOUR
SUPERVISOR AND / OR SAFETY DEPARTMENT FOR CORRECTION.
• WEAR APPROVED SAFETY GLASSES AT ALL TIMES.
• DO NOT WEAR JEWELRY, especially bracelets and rings, while operating the
fastening tools. Keep hands and fingers away from all rotating parts and avoid situations
where clothing can become tangled in the tool. Secure loose fitting clothing, neckties,
and long hair. Wear medical alert identification cautiously.
• DO NOT OVERREACH. Keep proper footing and balance at all times.
• KEEP YOUR WORK AREA CLEAN. Do not work on or near slippery floors or
surfaces. Avoid situations where the tool reacts against unexpected obstacles. Do not
operate electrical equipment while standing on a wet floor.
• MAINTAIN TOOLS IN TOP CONDITION. Keep tools properly lubricated and clean.
If any wires become frayed or exposed, replace them immediately. Prevent dirt, grease
or contaminants from getting into the tool.
• REDUCE THE RISK OF UNINTENTIONAL STARTING. Be careful how the tool is
left unattended. Avoid resting it on its throttle/trigger lever to prevent false starts.
• CONTROL THE DIRECTION OF ROTATION. The reaction torque changes direction
when going from forward to reverse. Always be aware of the direction the tool will
rotate prior to using it. If the tool is not fixtured this will allow you to brace for the
proper direction of torque reaction.
• CHECK DAMAGED PARTS. Before further use of a tool, any part of the tool that is
damaged should be carefully checked to ensure that it will operate properly and perform
its intended function. Check for alignment of moving parts, breakage of parts, mounting,
and any other conditions that may affect its operation. Never operate a tool that has
damaged or exposed wires. Never operate a tool that has any part of the powertrain,
other than the output spindle, exposed.
Page 4 T-40409-A 39-30-40409
User’s Manual
Electrical Safety
Only qualified and properly trained personnel should perform electrical/electronic
troubleshooting and repair. Consider the following electrical system safety guidelines:
• Before you troubleshoot or service a fastening system station, be sure you have an up-todate and appropriate set of electrical drawings for that station.
• Remove metal items, such as rings, metal necklaces, wristwatches and jewelry, as these
can create electrical hazards. Wear medical alert identification cautiously.
• Wear safety glasses, but avoid wearing those that have metal rims or metal side shields.
• It may be necessary to troubleshoot equipment while the power is ON. ONLY qualified,
trained personnel should do this. During these instances, open only the panels, doors, or
covers that need to be opened. Know the voltage present at all points before you begin
troubleshooting.
• Use properly insulated tools when working on electrical equipment to reduce the
possibility of shock. Make sure the insulation is adequate to safeguard against the high
voltages present.
• If you must work on the electrical system, make sure the Ground Fault Circuit
Interrupter (GFCI) is in the OFF position, or remove the plug from the AC outlet, or turn
off the circuit breaker.
• Do not attempt to modify or repair the machine without the approval of the proper
authorities.
• Use approved fuse pullers when changing fuses.
• Never use jumper wires or fuse substitutes to replace specified fuses.
• Always use fuses of a capacity smaller than or equal to the safe capacity of the line or
the equipment it serves.
• Before you work on any circuit, check it with an appropriate testing device to be sure
voltage is not present.
• Install temporary wiring as safely as possible and replace it with permanent wiring as
soon as possible. Install grounding wherever it is needed in the final installation. If
modifications are made to the system wiring, drawings must be revised to illustrate this
change.
• Know how to deal with electrical fires properly. Keep carbon dioxide and powder
extinguishers handy.
June 2004 T-40409-A Page 5
SD25 Series Screwdrivers
Getting Started
All SD25 Series handheld screwdrivers have the following features to provide torque information
right at your fingertips:
• Programmable multi-purpose pushbutton for Cycle Complete, multi-parameter set selection, Data
Send, etc.
• Forward / reverse direction button
• Multi-color light-emitting diode (LED) illumination ring that indicates acceptable, high and low
torque/angle
The SD25 Series Screwdriver can identify its maximum speed and torque capacities to the controller.
However, you may need to verify that the screwdriver you have is capable of generating the torque
specified in the active parameter set displayed on the controller. If the screwdriver you are connecting
to a controller is not capable of developing the torque specified in the parameter sets it will not run at
all. You should first verify that the screwdriver operates properly.
All SD25 Series screwdrivers have internal memory inside that identifies how the screwdriver was
configured upon manufacture. Because the SD25 Series screwdrivers are highly programmable -through both the factory settings contained in the screwdriver memory and the configuration of your
particular controller -- there are many possible combinations of screwdriver functionality.
• If your screwdrive r has a multi-purpose button installed, you may have it configured to perform
one of several functions.
The Visual Supervisor (VS)-based controller (CS2000 Mini Controller connected to a laptop
computer) allows you to look at all of the factory or configured settings inside the screwdriver. VS
also allows you to change the software selectable Inputs and Outputs, change torque settings, add
parameters, enable and define the function of all switches on the screwdriver. To use the VS setup
program, open it on the laptop computer connected to the CS2000 Mini Controller. Then click on the
tool icon in the menu tree on the left side of the screen. Refer to Using Visual Supervisor Setup on
page 9 for further details.
If you have any questions about the functionality of your screwdriver, contact your sales agent or the
SPX GSE tech-motive tool Technical Service Department for assistance.
Page 6 T-40409-A 39-30-40409
Viewing Screwdriver Functions
Before you operate your SD25 Series screwdriver, become familiar its functionality:
User’s Manual
NOTE:
?
• Th rottle/trigger lever or the push-to-start function starts and stops the screwdriver
• Forward/reverse switch runs the screwdriver in clockwise or counterclockwise direction
• LED illumination ring indicates acceptable, high and low torque/angle
• Headlights illuminate the fastening area
These are shown in the diagram below.
LED illumination ring
The factory sets the functions of the screwdriver and the
position of the buttons/lever in relationship to the head. Each
function can be re-assigned to a different button or switch using
VS.
Multi-purpose (auxiliary) button
Forward/reverse switch
Throttle/trigger lever
Headlight
Push-to-start
Customer supplied bits
NOTE:
Some screwdrivers, such as those designated for fixtured
remote usage, do not have a throttle/trigger lever, a
forward/reverse switch, or a multi-purpose button.
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June 2004 T-40409-A Page 7
SD25 Series Screwdrivers
r
Installing the Screwdriver
Use the following procedure to install SD25 Series screwdrivers to the CS2000 Mini Controller.
Installing the Screwdriver
1. Identify the slot on the screwdriver connector into which the screwdriver cable
plugs.
2. Align the red dot on the grip of the screwdriver cable connector to the slot on the
screwdriver connector.
Grip
Slot into screwdriver
connecto
3. Insert the screwdriver cable connector into the slot on the screwdriver connector
and push firmly. There is a click when the cable is correctly inserted.
4. Connect the large end of the screwdriver cable to the controller.
5. Turn on power to the controller.
You will see messages on the controller display during initialization, and the screwdriver
lights will flash momentarily.
If the screwdriver lights continue to flash, read the scrolling message on the controller
display. Typically, this will read “Invalid Parameter Set X.” Fix the parameter set in the
controller via VS.
NOTE:
?
Red dot
To remove the cable from the screwdriver, slide the grip on the
screwdriver cable connector away from the screwdriver and at
the same time firmly pull the screwdriver and cable connector
apart.
Screwdriver-tocontroller cable
To fix the invalid parameter set:
• Click on the Parameter Set that displays a red and black
the tab that also displays the
to the Visual Supervisor User’s Guide (part number 39-30-34823) for details.
If the parameter set does not need to be corrected, and a message other than “TRQ=” or
“ANG=” continues to scroll across the controller display, it is likely to be a message
indicating a data error or an operational problem. If a data error or operational problem
occurs, refer to Troubleshooting Your Screwdriver on page 19.
Page 8 T-40409-A 39-30-40409
. Correct the value that is highlighted in red. Refer
next to it and click on
6. Become familiar with how the screwdriver operates and feels.
Press the throttle/trigger lever and cycle the screwdriver in the air (not on a fastener).
Press the forward/reverse button, then press the throttle/trigger lever and watch the
output drive change direction.
OR
Press the throttle/trigger lever to enable the cycle, position the screwdriver on a fastener
and push down to start the cycle. Press the forward/reverse button, then press the
throttle/trigger lever and push down to start the cycle again and watch the fastener turn
in the opposite direction.
Using Visual Supervisor Setup
The information that appears under the General Information tab for the selected screwdriver is
displayed when a screwdriver is attached to the controller. The electrically erasable programmable
read only memory (EEPROM) chip inside the screwdriver transmits data to the analog intelligent tool
interface (ITI) board inside the controller.
User’s Manual
If there is no screwdriver attached, the General Information tab, the User Information tab, and all
parameter set and sequence tabs are unavailable.
The values on the General Information tab vary with the attached screwdriver.
June 2004 T-40409-A Page 9
SD25 Series Screwdrivers
In the following table, all of the left column fields are defined in the order they appear on your screen,
followed by all the second column fields.
1st Column Field Definition
Model Number
Build Date
Serial Number
Minimum Torque
Maximum Torque
Minimum Speed
Maximum Speed
Calibration Torque
Calibration Counts
Angle Counts/Rev
Last Calibration
Last Repair
GSE tech-motive tool part number for the screwdriver.
The date the screwdriver was manufactured.
Alphanumeric serial number of the screwdriver.
Minimum usable torque value (in Nm) for the screwdriver. The controller reads this
information from the screwdriver and prevents you from using it on any application
where the target torque is BELOW this value.
Maximum usable torque value (in Nm) for the screwdriver. The controller reads
this information from the screwdriver and prevents you from using it on any
application where the target torque is ABOVE the maximum usable torque value
of the screwdriver.
Minimum usable speed in revolutions per minute (RPM) of the screwdriver.
Maximum free speed value (in RPM) of the screwdriver.
The torque calibration value (in Nm) of the screwdriver.
The analog-to-digital reading (in A to D counts) that the controller reads from the
screwdriver when the shunt calibration circuit in the screwdriver is activated.
The angle scaling factor (in counts per revolution) for the screwdriver.
The date the screwdriver was last calibrated.
The date the screwdriver was manufactured or last repaired.
2nd Column Field Definition
Opposite Rotation
When checked, indicates the screwdriver is an opposite rotation screwdriver: for a
right-handed fastener torque cycle, the motor is run in the reverse direction, and
the torque and angle signals are negative going. When unchecked, indicates the
screwdriver is a standard rotation screwdriver: for a right-handed fastener torque
cycle, the screwdriver motor is run in the forward direction, and the torque and
angle signals are positive-going.
Left-Hand Tightening
Capable
Fixtured Tool
(Also known as Bi-Directional Tightening Capable.) When checked, indicates the
screwdriver has been modified for use in left-hand fastening applications (for
example, reverse torque cycles, such as tightening a left-hand threaded fastener).
When checked, indicates the screwdriver is designed for fixtured applications and
has no on-board controls for cycle start or direction.
Intelligent Wrench
When checked, indicates the tool is not a screwdriver, but an intelligent hand
torque wrench.
Auto Retract
When checked, indicates that the tool is a tubenut tool and the output socket must
be retracted to the open position when the tool trigger is released. This option
does not apply to screwdrivers.
Retract Shutoff Torque
When Auto Retract is checked, defines the shutoff torque setting (in engineering
units) for tubenut tools. This option does not apply to screwdrivers.
Retract Speed
When Auto Retract is checked, defines the speed setting (in RPM) for tubenut
tools. This option does not apply to screwdrivers.
Has a display
When checked, indicates the attached tool has a digital display. This option does
not apply to screwdrivers.
Page 10 T-40409-A 39-30-40409
2nd Column Field Definition (continued from previous page)
Has auxiliary pushbutton
Locked Rotor Count
Overtemperature Count
When checked, indicates that a screwdriver with multi-purpose (auxiliary)
pushbutton is attached.
The total number of locked rotor faults the screwdriver has had.
The total number of motor overheating faults the screwdriver has had. Such faults
occur when the winding temperature is higher than 125 degrees Celsius.
Tightening a Fastener
For most fastening operations, make sure the screwdriver turns clockwise when running forward. For
left-hand fastening capable screwdrivers, make sure the screwdriver turns counterclockwise when
running forward.
Once the screwdriver is positioned on a part, you begin the rundown (cycle start) by:
• Pressing the trigger lever on handheld screwdrivers that have the push-to-start function disabled
OR
• Pressing the trigger lever on handheld screwdrivers that have the push-to-start function enabled,
then pushing down firmly on the screwdriver
User’s Manual
OR
• Asserting (activating) the remote start input on fixtured screwdrivers
The cycle start signal must remain active in order to complete the rundown. If the signal is interrupted
- if you release the trigger lever, for example - the screwdriver stops immediately.
When the rundown is complete, you can see the status of the rundown by:
• The illumination of the LEDs on the screwdriver - green for acceptable torque/angle, yellow for
low torque/angle, and red for high torque/angle
• The controller display
• VS software displays the final torque/angle
NOTE:
For details of asserting (activating) remote inputs and reading
the controller display, refer to the appropriate controller manual.
?
Loosening a Fastener
For unfastening operations, make sure screwdriver turns counterclockwise when running forward. For
left-hand fastening capable screwdrivers, make sure the screwdriver turns clockwise when running
forward.
Once the screwdriver is positioned on a part, you begin the rundown (cycle start) by:
• Pressing the trigger lever on handheld screwdrivers
• Asserting (activating) the remote reverse direction input on fixtured screwdrivers
The cycle start signal must remain active in order to complete the rundown. If the signal is interrupted
- if you release the trigger lever, for example - the screwdriver stops immediately.
June 2004 T-40409-A Page 11
SD25 Series Screwdrivers
r
r
w
Reversing the Screwdriver
When the screwdriver is put into reverse, by sliding the forward/reverse switch into the reverse settin g
or remotely activating the FWD/REV input, the screwdriver turns in the opposite direction to the
normal fastening direction. Reverse is indicated by the yellow, green and red LEDs chasing in a
counterclockwise direction while the headlights remain lit. For most fastening operations, the
screwdriver turns in a counterclockwise direction when in reverse, but for left-hand fastening
applications it is clockwise.
Attaching a Pistol Grip Handle
The diagram below shows the SD25 Series In-line screwdriver with the throttle/trigger lever and
spring removed and the Pistol Grip handle (part number 49-SD-10111) slid into place.
Multi-purpose (auxiliary) button
Forward/reverse switch
Push-to-start
LED illumination ring
5/32-in scre
Throttle/trigger leve
Throttle/trigger leve
Holds the In-line screwdriver
horizontally in the handle
Pin
Left inset: The pistol grip handle
(part number 49-SD-10111) in detail.
Page 12 T-40409-A 39-30-40409
User’s Manual
Use the following procedure to attach a Pistol Grip handle (part number 49-SD-10111) to an In-line
screwdriver. Refer to Viewing Screwdriver Functions on page 7 to view an illustration of the
In-line screwdriver that may help you with this procedure.
Attaching a Pistol Grip Handle
1. Remove the screwdriver-to-controller cable, if necessary.
2. Using a 5/32-in punch, hammer out the pin that attaches the throttle/trigger lever
to the In-line screwdriver.
3. Remove the throttle/trigger lever spring. It may fall out when you remove the
throttle/trigger lever so be prepared to catch it.
NOTE:
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4. Carefully slide the In-line screwdriver into the handle attachment with the
forward/reverse and multi-purpose (auxiliary) buttons positioned on the top.
5. Position the handle on the bottom of the screwdriver, on the side of the
screwdriver opposite to the forward/reverse and multi-purpose (auxiliary) buttons.
6. Slide the pin back into the handle attachment.
You will need to hammer it carefully back into place. Make sure the screwdriver does not
rotate or move in relation to the position of the handle during this process.
7. Using a 5/32-in Allen wrench, tighten the fastener on the handle attachment until it
is secure.
You are now ready to use your Pistol Grip screwdriver.
Put the throttle/trigger lever and spring into a safe place. If, in
the future, you remove the handle attachment, you will need
the throttle/trigger lever and spring to convert the screwdriver
back to the In-line model.
June 2004 T-40409-A Page 13
SD25 Series Screwdrivers
•
•
Mapping Screwdriver Functions
This section describes how VS is used to map screwdriver functions to the buttons and switches on
the screwdriver. You can also use VS to change the default mapping. To do this, refer to the Visual
Supervisor User’s Guide (part number 39-30-34823).
Disabling the Push-to-Start Function
Typically, to start a fastening cycle when the push-to-start function on a handheld screwdriver is
disabled:
• Press the throttle/trig ger lever to start the fastening cycle.
• Release the throttle/trigger lever to stop the fastening cycle.
Push-to-start
• Disabled
Throttle/trigger lever
Forward/reverse button
• Press and release to
change the direction
Press to start the fastening cycle
• Release to stop the screwdriver
Multi-purpose (auxiliary) button
Press and release 2 times to change the
parameter set
Page 14 T-40409-A 39-30-40409
User’s Manual
The screwdriver inputs are software selectable using VS. To di sable t he p ush-t o -st art fu nc t i on, assi g n
the Cycle On input, Cycle Enable input and the Clear Outputs input to the Trigger. The typical inputs
for a screwdriver with push-to-start fu nct i o n di sabl ed are shown below.
Enabling the Push-to-Start Function
Typically, to start a fastening cycle when the push-to-start function on a handheld screwdriver is
enabled:
• Press the throttle/trigger lever to enable the fastening cycle.
• Push down firmly on the screwdriver to start the fastening cycle.
• Release the throttle/trigger lever to stop the fastening cycle.
OR
• Release the pressure on the screwdriver to stop the fastening cycle.
June 2004 T-40409-A Page 15
SD25 Series Screwdrivers
•
•
Push-to-start
• Push to start the fastening cycle
• Release to stop the screwdriver
Throttle/Trigger lever
Forward/reverse button
Press to enable the fastening cycle
• Release to stop the screwdriver
Multi-purpose (auxiliary) button
• Press and release to
change the direction
Press and release 2 times to change the
parameter sets
The screwdriver inputs are software selectable using VS. To enable the push-to-start function, assign
the Cycle On input to Input 8, and assign the Cycle Enable input and Clear Outputs input to the
Trigger. The typical inputs for a screwdriver with push-to-start function enabled are shown below.
Page 16 T-40409-A 39-30-40409
Mapping Outputs for a Single-Spindle
Typically, the LEDs and headlights on the screwdriver work in the following way:
• Headlights turn on while the screwdriver is running in forward or reverse.
User’s Manual
NOTE:
Yellow, green and red LEDs chase each other in a
counterclockwise direction while the screwdriver is in reverse.
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• Green LEDs turn on to indicate a successful cycle completion achieving target torque/angle
within acceptable range.
• Yellow LEDs turn on to indicate lower than acceptable torque/angle.
• Red LEDs turn on to indicate higher than acceptable torque/angle.
The screwdriver outputs are software selectable using VS. To operate the screwdriver as a singlespindle tool, assign the Cycle Good output to Output 2, Cycle Bad output to Output 3, Output 8
(Timed Copy) to Output 7 and the Ready output to Output 8. The typical outputs for operating the
screwdriver as a single-spindle tool are shown below.
NOTE:
The time delay for Output 8 (Timed Copy) can be adjusted
using the Timers tab in VS. For details, refer to the Visual
Supervisor User’s Guide (part number 39-30-34823).
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June 2004 T-40409-A Page 17
SD25 Series Screwdrivers
The typical outputs for screwdriver LEDs are shown below.
Page 18 T-40409-A 39-30-40409
Troubleshooting Your Screwdriver
The CS2000 Mini Controller used with the screwdriver has many configurable features and
programmable parameters that control the operation of the fastening system equipment.
GSE tech-motive tool supply the VS software program that provides you with a way to change
parameters that affect operation of the controller and attached screwdriver. If you apply these features
or program the parameters improperly, erroneous data and manufacturing problems can result. Proper
setup of the controller is essential in preventing such situations.
Whenever the data seems to be in error or operational problems occur, refer to one of the following
manuals:
⇒ CS2000 Mini Controller Hardware Overview Manual (part number 39-30- 3 88 1 0)
⇒ CS2100 Controller Hardware Overview Manual (part number 39-30-41886)
⇒ CS2000/CS4000 Mini Controller Network and Interface Supplement (part number 39-30-40477)
⇒ CS4100/2100 Controllers Technical Reference (part number 39-30-41994)
⇒ The online help manual that is part of the VS software
June 2004 T-40409-A Page 19
Maintaining Your Screwdriver
Generally, there is no preventive maintenance required for GSE tech-motive tool screwdrivers.
SPX GSE tech-motive tool only recommends trained technicians to perform in-depth maintenance,
such as motor, transducer, or gearing replacement.
NOTE:
For the latest assembly drawing revisions, contact our
Technical Service Department at 1-248-596-0600.
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June 2004 T-40409-A Page 20
Reading the Screwdriver
Part Numbers
All SD25 Series Screwdrivers have an 8-digit prefix that helps you quickly identify the type of
screwdriver you are using, and a longer suffix that provides more details about the screwdriver.
Prefix example: SD25I010
SD 25 I 010
Screwdriver Series
Type: In-line
Capacity lbf-in
User’s Manual
And the suffix:
P
USH-TO-START
TRIGGER EVER
B
OTH TRIGGER AND PUSH-TO-START
M
OUNTED (PUSH-TO-START, NO TRIGGER LEVER, REMOTE START)
A
LUMINUM HEAD
QUICK RELEASE CHUCK, 1/4-IN
HIOS CHUCK, 4 MM
HIOS CHUCK, 5 MM
L
P, L, B, or M A Q2, H4 or H5
June 2004 T-40409-A Page 21
Specifications and Parts
This section lists the specifications of your SD25 Series screwdrivers under typical operating
conditions and available screwdriver-to-controller cables.
Specifications
This section lists general specifications, torque and RPM ranges, and length and weight ranges for
SD25 Series screwdrivers.
General Specifications for SD25 Series Screwdrivers
Description Specifications
Motor current
Motor commutation
Screwdriver logic power
Screwdriver pushbuttons*
Screwdriver connector
Screwdriver Display
Screwdriver Headlights
Ambient operating temperature
8A peak
Hall-based, brushless DC motor
24 VDC
Start, direction, auxiliary, push-to-start
High density 26-pin connector
Three indicator / status LEDs for torque/angle
Turn on when screwdriver is running in forward or reverse
0 to 60 C (32 to 140 F)
Relative humidity
* Not available on fixtured screwdrivers
Torque, RPM, Length and Weight Ranges of SD25 Series Screwdrivers
Screwdriver
Type
In-line
In-line
In-line
In-line
June 2004 T-40409-A Page 22
Nm lbf-in ozf-in kgfcm
1.1 10 160 11.5 1700 9.4 in / 239 mm 0.91 lb / 0.41 kg
3.3 20 320 23.0 1100 9.4 in / 239 m m 0.91 lb / 0.41 kg
3.9 35 560 40.3 800 9.4 in / 239 mm 0.91 lb / 0.41 kg
5.6 50 800 57.6 500 9.6 in / 244 mm 1.1 lb / 0.49 kg
Torque Range
0 to 85% R.H. (non-condensing)
RPM Range Length Range Weight Range
Screwdriver Accessories
This section lists part numbers for the screwdriver-to-controller cables, suspension bail, reaction
mounting plates, and foam grip available for the SD25 Series screwdrivers.
Screwdriver-to-Controller Cables
Part Number Straight Part Number Right Angle Length
299230-81050 299230-81050R 5 ft / 1.5 m
299230-81100 299230-81100R 10 ft / 3.0 m
299230-81150 299230-81150R 15 ft / 4.6 m
299230-81200 299230-81200R 20 ft / 6.1 m
299230-81250 299230-81250R 25 ft / 7.6 m
299230-81300 299230-81300R 30 ft / 9.1 m
299230-81350 299230-81350R 35 ft / 10.7 m
299230-81400 299230-81400R 40 ft / 12.2 m
299230-81450 299230-81450R 45 ft / 13.7 m
299230-81500 299230-81500R 50 ft / 15.2 m
Screwdriver Suspension Bail
User’s Manual
Part Number Description
49-SD-10112 Vertical Suspension Bail
Screwdriver Mounting Plates
Part Number Description
49-SD-10121 Reaction mounting plate, double flange, for fixtured mounting
49-SD-10125 Reaction mounting plate, single flange, for close fixtured mounting
Screwdriver Foam Grip
Part Number Description
31-80-39445 Foam grip for the SD25 Series In-line Screwdriver
Screwdriver Pistol Grip Attachment for In-line SD25 Screwdriver)
Part Number Description
31-SD-10111 Pistol grip for the SD25 Series In-line Screwdriver
June 2004 T-40409-A Page 23
SD25 Series Screwdrivers
(This page is left blank intentionally.)
Page 24 T-40409-A 39-30-40409
Part Number: 39-30-40409
SPX Corporation
42860 Nine Mile Road
Novi, MI 48375-4122 USA
Phone: (248) 596-0600
Toll free: (800) 795-7875
Fax: (248) 596-0601
Website: www.gsetechmotive.com
© 2003-2004 SPX Corporation. All rights reserved. 6/04
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