125725SingleController(HK998).pdf

INSTRUCTION MANUAL
HUCKSPIN
Single Tool Controller 125725
& 125725CE
HUCK
SPIN
Form HK 998
04-20-2004
Single Tool Controller 125725
Alcoa Fastening Systems
EU Declaration of Conformity
Manufacturer:
Huck International, Inc., Installation Systems Division, 1 Corporate Drive, Kingston, NY,
12401, USA
Description of Machinery:
Model 125725CE Controller
Relevant provisions complied with:
Council Directive related to Machinery, (89/392/EEC), (91/368/EEC), (93/44/EEC),
(93/68/EEC)
Council Directive related to EMC/EMI, (89/336/EEC)
European Representative:
Rob Pattenden, Huck International, Ltd. Unit C Stafford Park 7, Telford Shropshire TF3
3BQ, England, United Kingdom
Authorized Signature/date:
I, the undersigned, do hereby declare that the equipment specified above conforms to the
above Directive(s) and Standard(s).
Signature:
___________________________________
Full Name:
Henk Rosier
Position:
Director, Engineering,
Installation Systems Division
Place:
Kingston, New York, USA
Date:
February, 2001
2
Single Tool Controller 125725
Alcoa Fastening Systems
SAFETY
This instruction manual must be read with particular
attention to the following safety guide lines, by any
person servicing or operating this tool.
5.
When repairing or operating Huck installation
equipment, always wear approved eye
protection. Where applicable, refer to ANSI
Z87.1 - 1989
6.
Disconnect primary power source before doing
maintenance on Huck equipment.
7.
If any equipment shows signs of damage, wear,
or leakage, do not connect it to the primary
power supply.
8.
Make sure proper power source is used at all
times.
9.
Never remove any safety guards or pintail
deflector.
1. Safety Glossary
Product complies with requirements
set forth by the relevant European
directives.
Read manual prior to using
equipment.
Eye protection required while
using this equipment.
Hearing protection required while
using this equipment.
!
10. Never install a fastener in free air. Personal
injury from fastener ejecting may occur.
WARNINGS - Must be understood
to avoid severe personal injury.
11. When using an offset nose always clear spent
pintail out of nose assembly before installing the
next fastener.
CAUTIONS - show conditions that will
damage equipment and or structure.
Notes - are reminders of required
procedures.
Bold, Italic type and underlining emphasizes a specific instruction.
12. If there is a pinch point between trigger and
work piece use remote trigger. (Remote
triggers are available for all tooling).
13. Do not abuse tool by dropping or using it as a
hammer. Never use hydraulic or air lines as a
handle. Reasonable care of installation tools by
operators is an important factor in maintaining
tool efficiency, eliminating downtime, and in
preventing an accident which may cause severe
personal injury.
2. Huck equipment must be maintained in a safe
working condition at all times and inspected on a
regular basis for damage or wear. Any repair
should be done by a qualified repairman trained
on Huck procedures.
3. Repairman and Operator must read manual prior
to using equipment and understand any Warning
and Caution stickers/labels supplied with
equipment before connecting equipment to any
primary power supply. As applicable, each of the
sections in this manual have specific safety and
other information.
4.
14. Never place hands between nose assembly and
work piece.
15. Tools with ejector rods should never be cycled
with out nose assembly installed.
16. When two piece lock bolts are being used
always make sure the collar orientation is
correct. See fastener data sheet of correct
positioning.
See MSDS Specifications before servicing the
tool. MSDS Specifications are available from
you Huck representative or on-line at
www.huck.com. Click on Installation Systems
Division.
3
Single Tool Controller 125725
Alcoa Fastening Systems
CONTENTS
EU DECLARATION
OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
PRINCIPLE
PUT
OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
INTO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SERVICING
THE CONTROLLER
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Resetting to Default P.I.N. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Resetting System Default Settings . . . . . . . . . . . . . . . . . . . . . . . . .7
Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12
Additions for 125725CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
TIMER & ERROR
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4
Single Tool Controller 125725
Alcoa Fastening Systems
SPECIFICATIONS
TURN OFF POWER BEFORE
DISCONNECTING POWER
SUPPLY CABLE
• WEIGHT: 26 LBS. / 11.7 kg
• INPUT: 24 VDC
• OUTPUT - RIG: RELAYED
• OUTPUT - TOOL: 24 VDC
PRESSURE
F1
F2
F3
F4
MENU
DIGIT
SELECT
DIGIT
CHANGE
DIGIT
SELECT
HuckSpin
TRIGGER
6.00
152
8.00
203
14.99
381
LIMIT SWITCH 1
LIMIT SWITCH 2
TOOL CONNECTED
OFF
ON
TURN OFF POWER BEFORE
DISCONNECTING POWER
SUPPLY CABLE
7.00
178
3.00
76
PRINCIPLE OF OPERATION
When the tool’s trigger is depressed, the controller starts
the tool’s air motor, causing the tool’s thimble to thread on
the bolt. As the thimble threads on the bolt, the tool’s
actuator rod is pushed rearward, activating the tool’s limit
switch one and limit switch two. At this point the controller
stops the air motor, and activates the Powerig’s hydraulic
valve, causing the piston to move rearward. This will draw
the fastener in the anvil, swaging the collar. When the
swage pressure is met the valve will deactivate, causing
the piston to move forward. This will push the collar out of
the anvil. At this point the controller will start the air motor,
threading the thimble off the bolt.
5
Single Tool Controller 125725
Alcoa Fastening Systems
PUT INTO SERVICE
How to change settings:
Upon turning on the unit, the controller will
display either Tool Not Selected, or will display
the tool and fastener size which has been
selected ( EX: TOOL: HS52 -5/8 ). To change
settings, the system will require a pin code entry.
The default pin code as shipped is F1, F1, F1,
F1.
This code can be changed to any
combination of 4 key strokes, using F1, F2 or
F3.
1. Pressure: (EX: Swage Pressure)
a) Press menu.
b) Enter pin code.
c) Go to pressure settings (F3).
d) Go to swage pressure (F2).
e) Use the left and right arrow keys to select
the digit to be changed. Use the up arrow
key to make a change to that digit.
f) Press F4 to accept the change.
g) Press F4 to go to the main menu.
1. Attach hydraulic hoses from Powerig, power
supply cable and air supply lines to the top of
the controller.
2. Timers: (EX: TIMER 3)
a) Press menu.
b) Enter pin code.
c) Go to other (F4).
d) Go to timer changes (F2).
e) Select timer to be changed (F3).
f) Use the left and right arrow keys to select
the digit to be changed. Use the up arrow
key to make a change to that digit.
g) Press F4 to accept the change.
h) Press F4 to go to the main menu.
2. Attach the tool by connecting the suspension
cable, hydraulic disconnects, air lines and
control cable to the underside of the
controller.
3. Add tool to controller:
a) Press menu.
b) Enter pin code.
c) Press F1 for new tool.
d) Select tool size.
e) Select fastener size.
f) Exit to main menu.
3. Counts: (EX: Anvil Count)
a) Press menu.
b) Enter pin code.
c) Go to service tool (F2).
d) Go to anvil change (F1).
e) Go to revise counts (F1)
f) Use the left and right arrow keys to select
the digit to be changed. Use the up arrow
key to make a change to that digit.
g) Press F4 to accept the change.
h) Press menu to go to the main menu.
4. Check and set powerig pressures:
a) Press menu.
b) Enter pin code.
c) Go to other (F4)
d) Go to other (F4)
e) Go to other (F4)
f) Go to rig presr info (F1)
g) Record pull & return pressures for tool size
and fastener diameter being used.
h) Using a pressure gauge (T-124833) set the
powerig to your recorded pull and return
pressures.
4. Zero Thimble Count:
a) Press menu.
b) Enter pin code.
c) Go to service tool (F2).
d) Go to thimble change (F2).
e) Press reset to zero (F2)
f) Press F4 to go to the main menu.
The system is now ready for fastener
installation.
5. Install a fastener and check for full swage.
NOTES:
1.The tool will not operate while in any of the
Menu Set up Screens.
2.If the tool does not function properly, pressure
and timer settings may need to be changed.
Please refer to “How to change settings or
Trouble Shooting Sections”.
6
Single Tool Controller 125725
Alcoa Fastening Systems
SERVICING THE CONTROLLER
General
Daily
1. The efficiency and life of any equipment
depends upon proper maintenance. Regular
inspection and correction of minor problems
will keep equipment operating efficiently and
prevent downtime. The controller should be
serviced by personnel who are thoroughly
familiar with how it operates.
1. Check the controller for damage or
air/hydraulic leaks, tighten or replace if
necessary.
2. A clean, well lit area should be available for
servicing the controller. Special care must be
taken to prevent contamination of electronic,
pneumatic and hydraulic systems.
3. Bleed the air line to clear it of accumulated
dirt or water before connecting air hose to
the tool.
2. Check all electrical cables, hoses and
couplings for damage or leaks, tighten or
replace if necessary.
3. Proper hand tools, both standard and special,
must be available.
4. Check the tool and nose assembly for
damage or air/hydraulic leaks, tighten or
replace if necessary. Refer to tool manual
or nose data sheet.
4. If Huck Spin tool needs servicing please refer
to tool manual.
Weekly
!
1. Check the Controller, tool and all
connecting parts for damage or oil/air
leaks, tighten or replace if necessary.
WARNING: Inspect controller for damage or
wear before each use. Do not operate if
damaged or worn, as severe personal injury
may occur
2. Disassemble and clean nose assemblies
and reassemble per applicable NOSE
ASSEMBLY DATA SHEET.
Resetting to default P.I.N.
The controller is shipped with a default P.I.N. of F1, F1, F1, F1. If this P.I.N. is changed
and lost it is possible to reset the controller to this default pin. To reset to default enter
pin code screen from status screen then enter F1, F3, F2, Right Arrow, Left Arrow, Up
Arrow. The controller should be reset to its default P.I.N.
Resetting system default settings
The controller is shipped with default settings for pressures, timers and counts. These
settings will likely need to be changed for each a particular application. If it is necessary
to return to the default settings enter the menu system by entering the P.I.N. From the
menu screen enter F4, F4, F3, F4, F4, F4, F2, F3, Left Arrow, Up Arrow and Right
Arrow.
7
Single Tool Controller 125725
Alcoa Fastening Systems
ASSEMBLY DRAWING
FIG. 1
39 (4)
40
41 (4)
6
7
8 57(2)
48
42 (2)
49
37
38
(2) 50
56
5
66
67
57
TO XMITTER
2
(2) 3
4
(2) 50
1
35 (2)
49
48
47
46
68
Timer Codes
Timer 1
Timer 2
Timer 3
Timer 4
Timer 5
Timer 6
Timer 7
Timer 8
43 (2)
590434
-Spin ON to LS1
-Spin ON from LS1 to LS2
-Swage or Snub time (LS2 to Pressure)
-Delay after Hyd. Press. Off to Spin Off
-Start Spin Off to LS1 Open
-Spin On after Snub
-Hold Time
-Spin Off after LS1 Opens
44 (2)
Error Codes
51
Trig Rlsd Early
-TD-1 Timed out
-TD-2 Timed out
-TD-3 Time out SN
-TD-4 Time out SW
-TD-5 Timed out
-TD-6 Timed out
-Check Transducer-Thimble Cnt. Max.-Anvil Cnt. Max.-
-Trigger released BEFORE swage complete
-LS1 NOT reached during Spin ON
-LS2 NOT reached, go to snub
-Pressure NOT reached during Snub
-Pressure NOT reached during Swage
-LS1 not Released during spin Off
-LS2 not Made after Snub
-Transducer NOT connected or FAULTY
-MAX. thimble count has been reached
-MAX. anvil count has been reached
45
PRESSURE
F1
F2
F3
F4
MENU
DIGIT
SELECT
DIGIT
CHANGE
DIGIT
SELECT
TRIGGER
LIMIT SWITCH 1
LIMIT SWITCH 2
HuckSpin
TOOL CONNECTED
OFF
ON
TURN OFF POWER BEFORE
DISCONNECTING POWER
SUPPLY CABLE
60
8
42 (2)
38
67
Single Tool Controller 125725
Alcoa Fastening Systems
ASSEMBLY DRAWING
FIG. 2
25
(2)9
24
(2)23
26
27
28
29
9 (2)
MANUAL SPIN-OFF OVERIDE ASSY
MANUAL SPIN-OFF OVERIDE ASSY
AIR VALVE ASSEMBLY
(2) 22
30
5
55
(6) 14
62
53
(3) 52 16
TO
AMP CONN.
TO
INDICATORS
TO
AIR VALVE
TO
LEMO CONN.
TO
PRESS.
XMITTER
31(2)
32 (3)
58
17
59
15
(6) 14
54
18
12
20
19
21
33(2)
36 (2)
13
9 (2)
(6)11
10
(2) 9
34
35 (4)
(2) 65
63
66 (2)
64 (2)
9
AIR VALVE ASSEMBLY
Single Tool Controller 125725
Alcoa Fastening Systems
PARTS LIST
ITEM
PART#
DESCRIPTION
QTY
ITEM
PART#
DESCRIPTION
QTY
1
119936
Indicator, Red
1
37
500690
Washer, Lock #4
1
2
506685
Alarm
1
38
507469
Terminal, Ring #4
2
3
505761
Terminal, Ring
2
39
502465
SHCS #4-40 X 5/8
4
4
125758
Housing, Controller
1
40
507434
Receptacle, Sq. Fl. 4-Contact
1
5
506606
Tubing, Twin 3/8"
2FT
41
507435
Contact, Pin
4
6
507040
Shackle
1
42
502500
BHCS 5/16-18 X 1"
4
7
507041
Wire, Locking
6IN
43
506684
Bulkhead Union, 3/8 Tube
2
8
507437
Transmitter, Pressure
1
44
502496
BHCS 5/16-18 X 1/2
4
9
500413
RHMS #8-32 X 3/8
8
45
125753
Bracket, Suspension
1
10
125757
Panel, Front
1
46
506515
Connector, Lemo 8-Contact
1
11
507443
Stud, #6-32 X 2
6
47
505298
Cable, 9-#20awg
2FT
12
507429
Connector, 4-Socket
1
48
110439
Coupling, Female
2
13
126109
Controller Board Set
1
49
110438
Coupling, Male
2
14
501049
Nut, Self Locking #6-32
12
50
505435
Nipple, 1/4 X 3/8 Npt Hex
4
15
125756
Cover, Controller Electronics
1
51
125730
Overlay/Keypad
1
16
507438
Cable, 4-#20awg
6FT
52
507440
Strain Relief
3
17
507439
Strain Relief
1
53
507442
Plug, Panel
1
18
507431
Connector, 6-Socket
1
54
500404
R.H.M.S. #6-32 X 3/4
1
19
507430
Connector, 5-Socket
2
55
504239
Cable Tie
1
20
507432
Connector, 8-Socket
1
56
125752
Manifold Block
1
21
507428
Connector, 2-Socket
1
57
503556
Terminal, Ring #6
3
22
500567
Nut, Self Locking 5/16-18
2
58
507444
Cable, 2-#22awg
2.5FT
23
507436
BHCS 5/16-18 X 1-1.5
2
59
507441
Strain Relief
1
24
125755
Panel, Rear
1
60
125774
Labels, Single Tool Controller
1
25
125795
Bracket, Manual Spin-Off
1
61
590059
Sticker, Huck
2
26
506847
Spring
1
62
590352
Sticker, Caution Electric ....
1
27
506848
Retaining Ring
1
63
507465
Switch, Slide - DPDT
1
28
125754
Rod, Manual Spin-Off
1
64
507466
Disconnect, .110-.125
2
29
506846
Knob
1
65
507467
#4-40 X 1/2 Binder HD. Screw
2
30
115436
Air Line
1
66
501047
Nut, #4-40
3
31
507433
Conn, Str 1/4 Npt-Fm X 3/8 Tube
2
67
507470
Wire, Green #20awg
32
505489
Nipple, 1/4 Npt X 2-1/2 Lg
4
68
126426
Label, Timer & Error Codes
1
33
507464
Elbow, 10-32 Male X 1/8 Tube
2
69
590435
CE Sticker
1
34
507463
Air Valve
1
70
507616
Ferrite with Case
3
35
507087
Wire Nut
6
36
506677
Elbow, 1/4 Npt Male X 3/8 Tube
2
10
1FT
PIN #
1
2
1
2
3
4
5
1
2
3
4
5
6
7
8
1
2
3
4
1
2
3
4
5
6
J10
J10
J1
J1
J1
J1
J1
11
J2
J2
J2
J2
J2
J2
J2
J2
J4
J4
J4
J4
J3
J3
J3
J3
J3
J3
J3
6 5 4 3 2 1
(GROUND) TO AIR VALVE CW SOLENOID
TO AIR VALVE CW SOLENOID
(GROUND) TO AIR VALVE CCW SOLENOID
TO AIR VALVE CCW SOLENOID
-24VDC (GROUND) INDICATOR
+24VDC INDICATOR
-24VDC (GROUND) AUDIO ALARM
+24VDC AUDIO ALARM
NOT USED +24VDC TO AUX. N/O TRIGGER FOR MANIPULAROR TOOLS
NOT USED +24VDC FROM AUX. N/O TRIGGER FOR MANIPULAROR TOOLS
-24VDC
+24VDC
-24VDC
+24VDC
+24VDC TO TOOL
EEPROM IN TOOL (FUTURE USE)
+24VDC TO CONTROLLER FROM N/O TRIGGER
+24VDC TO CONTROLLER FROM N/O LIMIT SWITCH 2
+24VDC TO CONTROLLER FROM TOOL (TOOL PLUGGED IN SIGNAL)
-24VDC (GROUND) TO TOOL (FUTURE USE)
NOT USED
+24VDC TO CONTROLLER FROM N/C LIMIT SWITCH 1
-24VDC (GROUND) FROM POWER SUPPLY (125727)
RELAYED CONTROL TO POWER SUPPLY BOX (125727) FOR POWERIG TRIGGER CORD
RELAYED CONTROL TO POWER SUPPLY BOX (125727) FOR POWERIG TRIGGER CORD
+24VDC FROM POWER SUPPLY (125727) SWITCHED
NOT USED
J4
4 3 2 1
(+) PRESSURE TRANSMITTER
(-) PRESSURE TRANSMITTER
J2
8 7 6 5 4 3 2 1
FUNCTION
J1
CONN.
5 4 3 2 1
2 1
J10
Connectors on Controller Board Sets 125729, 125872, & 126109
DIGIT
SELECT
MENU
CONN.
J5
J5
J5
J5
J5
J5
J5
J5
J5
J5
DIGIT
CHANGE
F3
F4
DIGIT
SELECT
1
2
3
4
5
6
7
8
9
10
PIN #
HuckSpin
F2
F1
KEYPAD
KEPPAD
P/N: 125730
P/N:
125730
COMMON
MENU
F1
F2
MOVE CURSOR LEFT
NEXT DIGIT (UP)
F3
F4
MOVE CURSOR RIGHT
SHIELD
FUNCTION
TOOL CONNECTED
LIMIT SWITCH 2
LIMIT SWITCH 1
TRIGGER
PRESSURE
10 9 8 7 6 5 4 3 2 1
J5
10 9 8 7 6 5 4 3 2 1
Single Tool Controller 125725
Alcoa Fastening Systems
WIRING SCHEMATIC
FIG. 3
1
1a
1b
2b
12
8-PIN RECEPTACLE
P/N: 506515
3
1
2
RED
BLACK
BLUE
GREEN
RED
WHITE
BROWN
8 1 2
7
3
6 5 4
BLACK
YELLOW
CABLE 4-20AWG
P/N: 507438
GREEN
4
GREEN
8 7 6 5 4 3 2 1
CABLE 9-20AWG
P/N: 505298
5 4 3 2 1
2 1
J2
P/N: 507432
J4
4 3 2 1
P/N: 507429
J3
6 5 4 3 2 1
P/N: 507431
WHITE
CABLE 4-20AWG
P/N: 507438
RED
BLACK
GREEN
AIR VALVE
P/N: 506693
ALARM - AUDIO
P/N: 506685
(4) WIRE NUT
P/N: 507087
INDICATOR
P/N: 119936
(2) RING TERMINAL
P/N: 505761
(4) WIRE NUT
P/N: 507087
CABLE 4-20AWG
P/N: 507438
(+)
WIRE, GREEN
P/N: 507470
RED
WHITE
(2) RING TERMINAL
P/N: 507469
SQ. FL. RECEPTACLE
P/N: 507434
(4) PIN CONTACT
P/N: 507435
SWITCH
P/N: 507465
2
2a
BLACK
GREEN
WIRE, GREEN
P/N: 507470
(+)
(2) DISCONNECT
P/N: 507466
PRESSURE TRANSMITTER
P/N: 507437
J1
P/N: 507430
J10
P/N: 507248
GREEN
(3) RING TERMINAL
P/N: 503556
WHITE
CABLE 2-22AWG
P/N: 507444
(-)
BLACK
(-)
RED
Connectors to Controller Board Sets 125729, 125872, & 126109
Single Tool Controller 125725
Alcoa Fastening Systems
WIRING SCHEMATIC
FIG. 4
To Indicators
To Air Valve
To Pressure
Transmitter
590435
13
1.
(70)
To AMP
Connector
To LEMO
Connector
HUCK FASTENERS
1 CORPORATE DRIVE
KINGSTON, NY 12401
MODEL: 125725CE
MAX OPERATING PRESURE
PULL 8400 PSI
580 Bar
RETURN 6500 PSI
448 Bar
TURN OFF POWER BEFORE
DISCONNECTING POWER
SUPPLY CABLE
(69)
DIGIT
CHANGE
F3
125725 CONTROLLER
DIGIT
SELECT
F4
590434
TOOL CONNECTED
LIMIT SWITCH 2
LIMIT SWITCH 1
TRIGGER
PRESSURE
ON
TURN OFF POWER BEFORE
DISCONNECTING POWER
SUPPLY CABLE
OFF
125725CE
2. This assembly must use Controller
Board Set part number 126109 (Item
13 in Parts List).
1. Location of Ferrites (70) on cable is
optional.
Notes:
DIGIT
SELECT
F2
HuckSpin
MENU
F1
Trig Rlsd Early
-TD-1 Timed out
-TD-2 Timed out
-TD-3 Time out SN
-TD-4 Time out SW
-TD-5 Timed out
-TD-6 Timed out
-Check Transducer-Thimble Cnt. Max.-Anvil Cnt. Max.-
-Trigger released BEFORE swage complete
-LS1 NOT reached during Spin ON
-LS2 NOT reached, go to snub
-Pressure NOT reached during Snub
-Pressure NOT reached during Swage
-LS1 not Released during spin Off
-LS2 not Made after Snub
-Transducer NOT connected or FAULTY
-MAX. thimble count has been reached
-MAX. anvil count has been reached
-Spin ON to LS1
-Spin ON from LS1 to LS2
-Swage or Snub time (LS2 to Pressure)
-Delay after Hyd. Press. Off to Spin Off
-Start Spin Off to LS1 Open
-Spin On after Snub
-Hold Time
-Spin Off after LS1 Opens
Error Codes
Timer 1
Timer 2
Timer 3
Timer 4
Timer 5
Timer 6
Timer 7
Timer 8
Timer Codes
Single Tool Controller 125725
Alcoa Fastening Systems
ASSEMBLY DRAWING 125725CE
FIG. 5
Single Tool Controller 125725
Alcoa Fastening Systems
TROUBLESHOOTING
Always check out the simplest possible cause of a malfunction first. For example, an air hose not
connected. Then proceed logically, eliminating each possible cause until the cause is located.
Where possible, substitute known good parts for suspected bad parts. Use this Troubleshooting
section as an aid in locating and correcting the malfunction.
1. Controller fails to power up.
a)
b)
c)
d)
3. Tool spins off when trigger is pressed.
Outlet circuit breaker turned off.
Power supply not plugged in.
Switch on controller not is turned on.
Cable between controller and power
supply not connected properly.
a) Limit switch1 is out of adjustment (only if
limit switch 1 indicator is on).
b) Reversed air lines (only if limit switch 1 is
not on).
4. Tool spins on pin but does not swage.
2. Tool fails to operate when trigger is
depressed.
a) Controller power not plugged in or turned
on. (Screen should be illuminated).
b) Tool is not plugged in properly to the
controller. Check all connections.
c) Bad trigger. If trigger indicator light fails
to come on, check continuity of trigger
switch.
d) Air not plugged into manifold. (Check
only if trigger indicator light comes on
when switch is depressed).
a) Powerig is not on or plugged in.
b) Electrical control cord is not connected
properly.
c) Hydraulic hoses are not connected
properly. (Check disconnects.)
5. Incomplete swage.
a) Improper powerig pressure setting. (See
Put Into Service)
b) Improper controller pressure setting. (See
Put Into Service How to change
settings:)
TIMER & ERROR CODES
Timer Codes
Error Codes
Trig Rlsd Early
TD-1 Timed out
TD-2 Timed out
TD-3 Time out SN
TD-3 Time out SW
TD-5 Timed out
TD-6 Timed out
Check Transducer
Thimble Cnt Max.
Anvil Cnt Max.
-
Trigger released before swage is complete
LS1 Not reached during Spin ON
LS2 Not reached, go to Snub
Pressure Not reached during Snub
Pressure Not reached during Swage
LS1 not Released during Spin Off
LS2 not Made after Snub
Transducer not connected or faulty
Max. thimble count has been reached
Max. anvil count has been reached
14
Timer
Timer
Timer
Timer
Timer
Timer
Timer
Timer
1
2
3
4
5
6
7
8
-
Spin ON to LS1
Spin ON from LS1 to LS2
Swage or Snub time (LS2 to Pressure)
Delay after Hyd. Press. Off to Spin Off
Start Spin Off to LS1 Open
Spin On after Snub
Alarm On time or Hold Time*
Spin Off after LS1 Opens
*Dependent on revision of program.
Single Tool Controller 125725
Alcoa Fastening Systems
ACCESSORIES
• Cable Assembly & Parts
WIRE BOTH CONNECTORS AS INDICATED:
1
2
3
4
WHITE
RED
GREEN
BLACK
3
2
6
1
6
5
4
1
3
1
2
4
VIEW FROM REAR
OF PLUG
VIEW FROM REAR
OF PLUG
CABLE ASSEMBLY P/N
ITEM
PART#
DESC.
QTY.
125728-25 = 25' Cable
125728-50 = 50' Cable
125728-75 = 75' Cable
125728-100 = 100' Cable
125728-125 = 125' Cable
125728-150 = 150' Cable
125728-175 = 175' Cable
125728-250 = 250' Cable
1
2
3
4
5
6
--------507457
507435
507458
507453
507459
Cable
Plug
Pin
Plug
Socket
Clamp
----1
4
1
4
2
• Hydraulic Hose Assembly
125772HS
125926-12
125926-26
125926-38
125926-52
3
2
4
=
=
=
=
=
5.5
12
26
38
52
• Power Supplies
FT
FT
FT
FT
FT
125727 One tool Supply
125727-2 Two Tool Supply
15
Single Tool Controller 125725
Alcoa Fastening Systems
SERVICE NOTES
16
Single Tool Controller 125725
Alcoa Fastening Systems
LIMITED WARRANTIES
Tooling Warranty: Huck warrants that tooling and other
items (excluding fasteners, and hereinafter referred as
"other items") manufactured by Huck shall be free from
defects in workmanship and materials for a period of
ninety (90) days from the date of original purchase.
Warranty on "non standard or custom manufactured
products": With regard to non-standard products or
custom
manufactured
products
to
customer's
specifications, Huck warrants for a period of ninety (90)
days from the date of purchase that such products shall
meet Buyer's specifications, be free of defects in
workmanship and materials. Such warranty shall not be
effective with respect to non-standard or custom products
manufactured using buyer-supplied molds, material,
tooling and fixtures that are not in good condition or repair
and suitable for their intended purpose.
THERE ARE NO WARRANTIES WHICH EXTEND
BEYOND THE DESCRIPTION ON THE FACE HEREOF.
HUCK MAKES NO OTHER WARRANTIES AND
EXPRESSLY DISCLAIMS ANY OTHER WARRANTIES,
INCLUDING
IMPLIED
WARRANTIES AS
TO
MERCHANTABILITY OR AS TO THE FITNESS OF THE
TOOLING, OTHER ITEMS,
NONSTANDARD OR
CUSTOM MANUFACTURED PRODUCTS FOR ANY
PARTICULAR PURPOSE AND HUCK SHALL NOT BE
LIABLE FOR ANY LOSS OR DAMAGE, DIRECTLY OR
INDIRECTLY, ARISING FROM THE USE OF SUCH
TOOLING, OTHER ITEMS,
NONSTANDARD OR
CUSTOM MANUFACTURED PRODUCTS OR BREACH
OF WARRANTY OR FOR ANY CLAIM FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Huck's sole liability and Buyer's exclusive remedy for any
breach of warranty shall be limited, at Huck's option, to
replacement or repair, at FOB Huck's plant, of Huck
manufactured tooling, other items, nonstandard or custom
products found to be defective in specifications,
workmanship and materials not otherwise the direct or
indirect cause of Buyer supplied molds, material, tooling
or fixtures. Buyer shall give Huck written notice of claims
for defects within the ninety (90) day warranty period for
tooling, other items, nonstandard or custom products
described above and Huck shall inspect products for which
such claim is made.
Tooling, Part(s) and Other Items not manufactured by
Huck.
HUCK MAKES NO WARRANTY WITH RESPECT TO
THE TOOLING, PART(S) OR OTHER ITEMS
MANUFACTURED BY THIRD PARTIES.
HUCK
EXPRESSLY
DISCLAIMS
ANY
WARRANTY
EXPRESSED OR IMPLIED, AS TO THE CONDITION,
DESIGN, OPERATION, MERCHANTABILITY OR
FITNESS FOR USE OF ANY TOOL, PART(S), OR
OTHER ITEMS THEREOF NOT MANUFACTURED BY
HUCK. HUCK SHALL NOT BE LIABLE FOR ANY LOSS
OR DAMAGE, DIRECTLY OR INDIRECTLY, ARISING
FROM THE USE OF SUCH TOOLING, PART(S) OR
OTHER ITEMS OR BREACH OF WARRANTY OR FOR
ANY CLAIM FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGES.
The only warranties made with respect to such tool, part(s)
or other items thereof are those made by the manufacturer
thereof and Huck agrees to cooperate with Buyer in
enforcing such warranties when such action is necessary.
Huck shall not be liable for any loss or damage resulting
from delays or nonfulfillment of orders owing to strikes,
fires, accidents, transportation companies or for any
reason or reasons beyond the control of the Huck or its
suppliers.
Huck Installation Equipment
Huck International, Inc. reserves the right to make
changes in specifications and design and to discontinue
models without notice.
Huck Installation Equipment should be serviced by trained
service technicians only.
Always give the Serial Number of the equipment when
corresponding or ordering service parts.
Complete repair facilities are maintained by Huck
International, Inc. Please contact one of the offices listed
below.
Eastern
One Corporate Drive Kingston, New York 12401-0250
Telephone (845) 331-7300 FAX (845) 334-7333
Canada
6150 Kennedy Road Unit 10, Mississauga, Ontario,
L5T2J4, Canada.
Telephone (905) 564-4825 FAX (905) 564-1963
Outside USA and Canada
Contact your nearest Huck International Office, see back
cover.
In addition to the above repair facilities, there are
Authorized Tool Service Centers (ATSC's) located
throughout the United States. These service centers offer
repair services, spare parts, Service Parts Kits, Service
Tools Kits and Nose Assemblies. Please contact your
Huck Representative or the nearest Huck office listed on
the back cover for the ATSC in your area.
For the Long Haul™
A Global Organization
Alcoa Fastening Systems (AFS) maintains company
offices throughout the United States and Canada,
with subsidiary offices in many other countries.
Authorized AFS distributors are also located in
many of the world’s
industrial and Aerspace centers, where they provide
a ready source of AFS fasteners, installation tools,
tool parts, and application assistance.
Alcoa Fastening Systems world-wide locations:
Americas
Alcoa Fastening Systems
Alcoa Fastening Systems
Aerospace Products
Tucson Operations
3724 East Columbia
Tucson, AZ 85714
800-234-4825
520-747-9898
FAX: 520-748-2142
Commercial Products
Kingston Operations
1 Corporate Drive
Kingston, NY 12401
800-431-3091
845-331-7300
FAX: 845-334-7333
www.hucktools.com
Alcoa Fastening Systems
Alcoa Fastening Systems
Alcoa Fastening Systems
Alcoa Fastening Systems
Aerospace Products
Carson Operations
PO Box 5268
900 Watson Center Rd.
Carson, CA 90749
800-421-1459
310-830-8200
FAX: 310-830-1436
Commercial Products
Waco Operations
PO Box 8117
8001 Imperial Drive
Waco, TX 76714-8117
800-388-4825
254-776-2000
FAX: 254-751-5259
Far East
Europe
Alcoa Fastening Systems
Alcoa Fastening Systems
Commercial Products
Australia Operations
14 Viewtech Place
Rowville, Victoria
Australia 3178
03-764-5500
Toll Free: 008-335-030
FAX: 03-764-5510
Commercial Products
Canada Operations
6150 Kennedy Road, Unit 10
Mississagua, Ontario L5T2J4
Canada
905-564-4825
FAX: 905-564-1963
Commercial Products
United Kingdom Operations
Unit C, Stafford Park 7
Telford, Shropshire
England TF3 3BQ
01952-290011
FAX: 0952-290459
Alcoa Fastening Systems
Aerospace Products
France Operations
Clos D’Asseville
BP4
95450 Us Par Vigny
France
33-1-30-27-9500
FAX: 33-1-34-66-0600
Commercial Products
Latin America Operations
Avenida Parque Lira. 79-402
Tacubaya Mexico, D.F.
C.P. 11850
FAX: 525-515-1776
TELEX: 1173530 LUKSME
For The Long Haul, The Future of Fastening Technology,
The Future of Assembly Technology, The Future of Tooling
Technology, and Tools of Productivity are service marks of Huck
International. Huck provides technical assistance regarding the use
and application of Huck fasteners and tooling.
NOTICE: The information contained in this publication is only for
general guidance with regard to properties of the products shown
and/or the means for selecting such products, and is not intended
to create any warranty, express, implied, or statutory; all warranties
are contained only in Huck’s written quotations,
acknowledgements, and/or purchase orders. It is recommended
that the user secure specific, up-to-date data and information
regarding each application and/or use of such products.
HWB898 1003-5M
One Great ConnectionSM
© 2003 Alcoa Fastening Systems
1 Corporate Drive, Kingston, NY 12401 • Tel: 800-431-3091 • Fax: 845-334-7333 • E-mail: [email protected] • www.alcoafasteningsystems.com
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