A Guide to Using

Tensor DS and Tensor DL Drive

with Tools Talk DS/DL
Atlas Copco Tools and Assembly Systems AB

Edition 3 Atlas Copco Tools and Assembly SystemsAB - 9836 1716 01

Page 1 (162) 2003-09
 Contents

1. SAFETY INSTRUCTIONS ....................................................................................................... 4

2. INTRODUCTION ................................................................................................................... 4
2.1 General............................................................................................................................. 4
2.2 DS/DL Drive .................................................................................................................... 4
2.3 System Functionality ........................................................................................................ 4
2.4 ToolsTalk DS/DL ............................................................................................................. 4
3. DS/DL DRIVE ...................................................................................................................... 4
3.1 Connectors DS ................................................................................................................. 4
3.2 Connectors DL ................................................................................................................. 4
3.3 Inputs/Outputs Schematic ................................................................................................ 4
3.4 Installation of DS hardware ............................................................................................. 4
3.5 Installation of DL hardware............................................................................................. 4
3.6 Installing new software into the DS/DL Drive ................................................................. 4
3.7 DS Drive Dimensions ....................................................................................................... 4
3.8 DL Drive Dimensions ....................................................................................................... 4
3.9 Display / Key Pad DS Drive ............................................................................................. 4
3.10 Display / Key Pad DL Drive ............................................................................................ 4
3.11 Different models of DS/DL Drive ..................................................................................... 4
3.12 Functions, D302 / D303 and D312 / D313 ........................................................................ 4
3.13 Functions, D312 / D313 only ............................................................................................ 4
3.14 Key Pad Functions ........................................................................................................... 4
3.15 Remote Start .................................................................................................................... 4
3.16 Inputs and Relays ............................................................................................................. 4
4. PROGRAMS .......................................................................................................................... 4
4.1 Selection of program ........................................................................................................ 4
4.2 Tightening strategies ........................................................................................................ 4
4.3 Special Functions.............................................................................................................. 4
5. TOOLS TALK DS/DL ............................................................................................................ 4
5.1 Installation........................................................................................................................ 4
5.2 Working in Tools Talk..................................................................................................... 4
5.3 Programming Window ..................................................................................................... 4
5.4 Run Window .................................................................................................................... 4

3
Contents

5.5 Torque Tuning Window................................................................................................... 4

5.6 Configuration Window, Tensor DS & DL ....................................................................... 4
5.7 Configuration Window, Tensor DL only ......................................................................... 4
5.8 Diagnostics ....................................................................................................................... 4
6. PROGRAMMING ................................................................................................................... 4
6.1 Hints ................................................................................................................................. 4
6.2 Full Programming of pset................................................................................................. 4
6.3 Quick Programming ......................................................................................................... 4
6.4 Auto Set............................................................................................................................ 4
6.5 Torque Tuning ................................................................................................................. 4
6.6 Configuration ................................................................................................................... 4
7. ACCESSORIES ...................................................................................................................... 4
7.1 RE Alarm ......................................................................................................................... 4
7.2 Selector, only for D312 / D313 ......................................................................................... 4
7.3 I/O Expander ................................................................................................................... 4
7.4 IR Key .............................................................................................................................. 4
8. TROUBLE SHOOTING ........................................................................................................... 4
8.1 Error Messages in ToolsTalk DS/DL .............................................................................. 4
8.2 Error codes on Drive ....................................................................................................... 4
8.3 What might have happened… .......................................................................................... 4
9. PART LIST ........................................................................................................................... 4
9.1 DS Drive, Part List .......................................................................................................... 4
9.2 DL Drive, Part List .......................................................................................................... 4
9.3 Tensor DS, Tool List........................................................................................................ 4
9.4 Tensor DS, Tool List........................................................................................................ 4
9.5 Tensor DL, Tool List ....................................................................................................... 4
10. TECHNICAL SPECIFICATIONS .............................................................................................. 4
10.1 DS Drive........................................................................................................................... 4
10.2 DL Drive .......................................................................................................................... 4
10.3 Tools Talk DS/DL ............................................................................................................ 4
11. ABBREVIATIONS .................................................................................................................. 4

4
 Safety Instructions

1. Safety Instructions
WARNING
Read and understand all instructions. Failure to follow all the instructions listed below may result in electric
shock, fire and/or serious personal injury.
SAVE THESE INSTRUCTIO NS
IMPORTANT
All locally legislated safety rules with regard to installation, operation and maintenance must be respected at all
times. Refer installation and servicing to qualified personnel only.
Work Area
Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.
Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or
dust. Power tools create sparks, which may ignite dust or fumes.
Keep bystanders, children, and visitor s away while operating a power tool. Distractions may cause you to lose
control.
Electrical Safety
Earthed tools must be plugged into an outlet that has been properly installed and earthed in compliance with
all relevant codes and ordinances. Never remove the earthing prong or modify the plug in any way. Do not
use any adapter plugs. Check with a qualified electrician if you are in any doubt as to whether the outlet is
properly earthed. Should the tools suffer electronic malfunction or breakdown, earthing p rovides a low resistance
path to carry electricity away from the user. Applicable only to Class I (earthed) tools.
THIS MUST BE EARTHED !
Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an
increased ris k of electric shock if your body is grounded.
Don't expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric
shock. This instruction does not apply to tools classified as watertight or splash proof.
For minimum electrical interference, place the instrument far away from possible sources of electrical noise, e.g. arc
welding equipment etc.
Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an outlet. Keep cord away
from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged cords increase the
risk of electric shock.
Personal Safety
Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool
while tired or under the influence of drugs, alcohol, or medication. A momentary lapse in concentration whilst
operating power tools may result in serious personal injury.
Dress properly. Do not wear loose clothing or jewellery. Tie long hair back. Keep your hair, clothi ng, and
gloves away from moving parts. Loose clothes, jewellery, or long hair can be caught in moving parts.

5
Safety Instructions

Avoid accidental starting. Be sure switches are in the off position before plugging in. Carrying tools with your
finger on the switch or plugging i n tools that have the switch set to on invites accidents.
Remove adjusting keys or switches before turning the tool on. A wrench or a key that is left attached to a
rotating part of the tool may result in personal injury.
Do not overreach. Keep proper foo ting and balance at all times. Proper footing and balance enables better
control of the tool in unexpected situations.
Tool Use and Care
Use clamps or other practical means to secure and support the work piece to a stable platform. Holding the
work by hand or against your body is unstable and may lead to loss of control.
Do not force the tool. Use the correct Atlas Copco Tensor tool for your application. The correct tool will do the
job better and safer at the rate for which it is designed.
Do not use tool if switch does not work. Any tool that cannot be controlled by the switch is dangerous and must be
repaired.
Disconnect the plug from the power source before making any adjustments, changing accessories, or storing
the tool. Such preventive safety measures reduce the risk of starting the tool accidentally. The mains plug is
considered to be a disconnecting device. Disconnect the tool from the mains by pulling the plug from the socket in
order to cut the power.
Store tools out of reach of children and other untrained persons when not in use. Tools are dangerous in the
hands of untrained users.
Check for misalignment or binding of moving parts, damage, and any other condition that may affect tool
operation. If damaged, have the tool serviced before using. Poorly maintained tools cause many accidents.
Only use accessories that are recommended by the manufacturer for your model. Accessories that may be
suitable for one tool may become hazardous when used on another tool.
SERVICE
Tools should only be serviced by q ualified repair personnel. Service or maintenance performed by unqualified
personnel could exposes users to serious personal injury.
When servicing a tool, only use original replacement parts. Use of unauthorised parts or failure to follow
Maintenance Inst ructions may create a result in electric shock or personal injury.
CAUTION
There is a danger of explosion if batteries are incorrectly replaced. Replace only with the same or equivalent type
recommended by the equipment manufacturer. Discard used batteries in accordance with manufacturer's
instructions.

6
 Introduction

2. Introduction
2.1 General
Tensor S electric nutrunners brought a minor revolution to controlled tightening. They are now
the industry standard for critical joints with safety applications, though not economically feasible
for use on joints throughout a whole plant.
Tensor DS is the alternative that lets you apply the benefits of advanced electric systems for
controlled tightening on all the joints in your product. With Tensor DS you do not need to depend
on mechanical devices or human repeatability to safeguard your joint integrity. Tensor DS means
you can afford Tensor levels of operator acceptance, operator feedback, productivity,
dependability, low service cost, multi-torque and joint control for all your tightening operations.
Tensor DL is the electric tool choice for small screw assembly. Its small size and good
performance will increase productivity and reduce costs in your assembly operations. Tensor DL
incorporates all the functionality of the Tensor DS, e.g. operator guidance, process control and
rundown monitoring functionality.

2.2 DS/DL Drive

The Tensor DS/DL electric nutrunners and screwdrivers are extremely fast and
light. The Tensor DS/DL Drive does not use a torque transducer, instead it uses
the unique Atlas Copco DigiTork system, proven to achieve excellent
repeatability.
The Drive is programmed using the ToolsTalk DS/DL programming tool wich
runs on a normal Windows based pc or lap top.
It is also possible to program the drive to a limited extend directly on the key
pad, see section Key Pad Programming, chapter 3.10.
The Tensor DS Tools come in three different motor sizes DS4, DS7 and DS9,
and can handle torques from 1 to 2000 Nm. Each tool requires its own drive
unit.
The Tensor DL tools come in two different motor sizes: DL11 and DL 21, and
can handle torques from 0,2 to 10 Nm. Each tool requires its own drive unit.

7
Introduction

Two different Drive versions

There are two different functionality levels of the Tensor DS/DL system, the D302 / D303 Basic
drive and the D312 / D313 Advanced drive with the possibility to program up to ten different
parameter settings.
For DS Tools, each drive version comes for different tool sizes: DS4, DS7 and DS9.
For DL tools, there is only one drive version for all tool sizes: DL.
If you have multi-torque applications, you should definitely consider the benefits of D312 / D313.
With ten different parameter sets on each tool you as much as halve your initial investment cost.
You also benefit from lower installation costs and reduced backup inventory costs.
Besides the Multi Torque capability the D312 / D313 / 313 version is also equipped with: Digital
Inputs, Relays, I/O-bus, Line Control, PLC functions, Rotate Spindle, Rundown Monitoring, Self
Tap, High Speed Rundown and a Lock on Reject option.
ToolsTalk DS/DL fits with all drive versions (DS & DL) and will automatically detect the version
of the drive, D302, D303, D312 and D313 and open up the appropriate functions.

8
 Introduction

2.3 System Functionality

The DS/DL System has no transducer in the tool. Instead of having an electrical signal from a
strain gauge, the DS/DL Tool derives the torque from different relevant parameters in the motor,
such as voltage, speed, temperature and current.
A complete system consists of:
The main power supply cable included with the drive
Tensor DS/DL Tool
Tool Cable
DS/DL Drive
Programming Cable
ToolsTalk DS/DL
PC / Lap Top

9
Introduction

The DS/DL System

DS/DL
Drive
RE-Alarm

115/230 volts
Socket Tray I/O
Selector
Expander
DS/DL Tool

External Torque
Reference / IRTT PC
/LapTop
Application
/Joint

10
 Introduction

2.4 ToolsTalk DS/DL

When programming the Drive a specially designed windows program is used for that purpose,
ToolsTalk DS/DL. ToolsTalk is ordered as a single item and is needed in order to get full access
to all functions in the drive.
ToolsTalk DS/DL (TTDS/DL) is an Atlas Copco made software running on a normal PC or Lap Top under
Windows 95 (i.e. 32 bit Windows which includes Windows 95, 98, 2000 and NT but not Windows 3.X). It
is used to program the Drive unit. Tensor DS is a system consisting of one Tensor DS/DL Tool, one cable
and one Drive.

Important When Programming the Drive

When programming the Drive, It is o f greatest importance to have a well developed second
stage. The fastener/socket should allow some angle rotation in the second stage of the tightening,
or else the torque may overshot. The best way to determine this is simply by observing the angle
rotation during the second stage.
If the tool overshoots a red toggling led will show on the tool. The criteria for high torque is a short or
a non-existing second stage in combination with a high speed in the first stage. On the display the
message E003 will be shown.
Low torque is anything less than 98% of final target and occurs due to accidental release of the tool trigger
during the tightening. It is indicated with a yellow toggling led on the tool. The torque value will be shown
on the display.

11
 DS/DL Drive

3. DS/DL Drive
3.1 Connectors DS

9 4

10 6

Displayed on the previous page is the back end of the DS Drive revealing all connectors. Each
number corresponds to a specific connector that is explained below and in detail where needed.
1. Tool cable connector 6. I/O bus. Only activated for D312 / D313
2. Digital inputs. Only for D312 / D313. 7 Remote control
See Detailed Description on next page 2.
8. Main power conne ctor
3. Relay outputs. See Detailed Description on
9. Ground fault interrupter, GFI, 30 mA
page 3 – 3.
10. Main fuse. 6.3 X 32 mm - Slow Blow, 15/20/25 A
4. RS 232
11. Main fuse: 5 X 20 mm – Slow blow 6.3A
5. I/O bus. Only activated for D312 / D313

12
 DS/DL Drive

3.2 Connectors DL

Displayed on the previous page is the back end of the DL Drive revealing all connectors. Each
number corresponds to a specific connector that is explained below and in detail where needed.
1. Tool cable connector 6. I/O bus. Only activated for D312 / D313
2. Digital inputs. Only for D312 / D313. 7. Remote control
See Detailed Description on next page 2.
8. Main power connector
3. Relay outputs. See Detailed Description on
9. Power switch
page 3 – 3.
10. Main fuse: 5 X 20 mm – Slow blow 6.3A
4. RS 232
5. I/O bus. Only activated for D312 / D313

13
DS/DL Drive

3.3 Inputs/Outputs Schematic

Inputs
There are four opto isolated inputs on the drive. It is possible to have an additional six inputs
through the CAN bus, but then you will need to have an I/O-Expander connected to the drive. The
inputs can be configured to have the functions listed below.
For more information and programming of the I/O’s, read chapter 5 and 6.
2a Fixed inputs Schematic on D302 / D303 / 303
Description
Fixed input
Input 1 Reset Batch
Input 2 Batch increment
Input 3 Batch decrement
Input 4 Not used

2b Digital Inputs Schematic - D312 / D313

# Function Description

0 Not used The input is not activated

1 Reset lock on If the checkbox “Lock On Reject” in the
reject configuration window is marked and the tool is
locked because of a faulty tightening, the tool will be
unlocked when this input is activated.
2 Batch increment When this input is activated the batch counter will be
increased one step, n=n+1.
3 Batch Decrement Decreases the batch counter one step, n=n-1.

14
 DS/DL Drive

# Function Description

4 Reset batch Resets the batch counter to zero. No batch OK (nxOK). If

batch OK is activated it will be deactivated.
5 Pset select bit 0 P-set select input. The drive will interpret the inputs binary.
Binary one will select p-set one, binary two will select p-set
6 Pset select bit 1
two etc. Binary 0=no p-set chosen.
7 Pset select bit 2
Please read chapter 7.2, Selector.
8 Pset select bit 3
9 Tool Tightening Disables the tool to perform a tightening. Loosening will not
disable be affected.
Note*
When CCW (counter clockwise) tightening direction is chosen
the tightening direction will be the opposite from when CW
(clockwise) tightening direction is chosen, and the tool
disabled in CCW direction.
10 Tool Loosening Disables the tool to loosen a fastener. Tightening will not be
disable affected.
Note*
When CCW (counter clockwise) tightening direction is chosen
the loosening direction will be the opposite from when CW
(clockwise) tightening direction is chosen, and the tool
disabled in CW direction.
11 Tool disable The tool will not start when this input is activated. If the tool
is running it shall immediately stop when this input is
activated. A new press on the start button is needed to restart
the tool.
12 Ack error Acknowledge of an error. If the display flashes with an error
message code the error code will be acknowledged with a signal on this
input.
13 Line control start Activates the tool if Line Control in configuration is chosen.
See also Line Control.

15
DS/DL Drive

# Function Description

14 Line control alert 1 Activates relay “Line Control Alert 1”. See also “Line
Control”.
15 Line control alert 2 Activates relay “Line Control Alert 2”. See also “Line
Control”.
16 Set mono. relay 1 Activates Monostabile relay 1.
17 Set mono. relay 2 Activates Monostabile relay 2.
18 Set bistab. Relay 1 Activates Bistabile relay 1.
19 Reset bistab. Relay Deactivates Bistabile relay 1 if Input Control under Relay
1 Time is chosen on this relay.
20 Set bistab. Relay 2 Activates Bistabile relay 2.
21 Reset bistab. Relay Deactivates Bistabile relay 2 if Input Control under Relay
2 Time is chosen on this relay.

Note! - Relay Type Selector / RE -Alarm

• As noted earlier, you may use Atlas Copco Tensor S series relay type selectors and RE-
Alarms.
• If choosing a relay type selector, you need to use adapter 4222 0417 00.
• If choosing a RE-Alarm, you need to use adapter 4222 0472 00.
• When combining both Re-Alarm and relay type selector, use adapter cable 4222 0486 00.

16
 DS/DL Drive

Outputs
Four output relays exists on the drive. It is also possible to have an additional eight relays by using
the
I/O expander through the I/O bus. The relays can be configured to have the functions listed below.
3 a) Relay Outputs Schematic - D302 / D303
Fixed Output Description
Relay 1 OK
Relay 2 NOK
Relay 3 nxOK
Relay 4 Not used
3 b) Relay Outputs Schematic - D312 / D313 / 313 – Programmable via ToolsTalk DS/DL
Relay time
There are four events that can make the relay drop.
“To next tightening”
When the start trigger is pressed and the tool is beginning the next tightening
“Time”
When the timer has run out. The time is programmed in TTDS/DL /Configuration
“Tracking”
The relay is following a certain event. For instance tool running. As long as the tool is running the
relay will be pulled
“Input Control”
There are two relays that can be deactivated through inputs. These two are Reset bistabile relay 1
and Reset bistabile relay 2.

17
DS/DL Drive

# in Function Relay Time Description

TTDS
/ DL
To next Time Tracking Input
tightening Control
0 Not used The relay will not be affected
1 OK X X The relay will be pulled when all
results are within limits.
2 nxOK X X The relay pulled when Batch OK,
the batch counter is equal with the
batch size programmed through
Tools Talk DS / DL.

3 NOK X X The relay pulled when one or more

results are outside limits or other not
acceptable event has occurred, for
example Rehit.

4 Low X X Relay pulled when the torque value

torque is too low. Possible reason due to
start trigger released too early.

5 High X X Relay pulled when torque value

torque possibly high. The reason is because
the second step angle is too small.

6 Tool X The relay is activated when the tool

tightening is running in the tightening direction.
The relay drops when target is
reached or the start trigger is
released.

18
 DS/DL Drive

# in Function Relay Time Description

TTDS
/DL
To next Time Tracking Input
tightening Control
7 Tool X The relay is activated when the tool
loosening is running in the loosening
direction. The relay drops when the
start trigger is released.

8 Tool X The relay is activated when the tool

Running is rotating in clockwise (CW)
CW direction.

9 Tool X The relay is activated when the tool

Running is rotating in counter clockwise
CCW (CCW) direction.

10 Tool X The relay is activated when the tool

Running is running.

11 Switch in X The direction switch on the tool is

CW position turned in CW direction.

12 Switch in X The direction switch on the tool is

CCW turned in CCW direction.
position

13 Tightening X The relay will be pulled when the

direction selected p-set has CCW chosen as
CCW tightening direction.

14 DS/DL X Relay pulled if the DS/DL Drive is

ready ready to perform a tightening. No
system errors occurs.

15 Tool ready X Relay pulled if the tool is ready to

perform a tightening.

19
DS/DL Drive

# in Function Relay Time Description

TTDS
/ DL
To next Time Tracking Input
tightening Control
16 Tool X Relay pulled when the tool is locked
locked due to one or more of following:
Line Control without Line Control
Start
Tool Disable
Tool Tightening Disable
Tool Loosening Disable
Lock On Reject
17 Service X Relay pulled until DS/DL Tool
indicator serviced.

18 Line X X Relay pulled when Line Control OK

control OK occurs.

19 Line X X Relay pulled when the Input Line

control Control Alert 1 is activated without
alert 1 having received Line Control OK.
This is Line control warning 1, the
first check point on the station.
20 Line X X Relay pulled when the Input Line
control Control Alert 1 is activated without
alert 2 having received Line Control OK.
This is Line control warning 2, the
second check point on the station.

21 Monostabil X The relay is pulled if there is a signal

e relay 1 on the input “Set Monostabile Relay
1”. The relay will follow the input and
drop when the input goes low.

20
 DS/DL Drive

# in Function Relay Time Description

TTDS
/ DL
To next Time Tracking Input
tightening Control
22 Monostabil X The relay is pulled if there is a
e relay 2 signal on the input “Set
Monostabile Relay 2”. The relay
will follow the input and drop when
the input goes low.
23 Bistabile X X X X The relay is pulled if there is a
relay 1 signal on the input “Set Bistabile
Relay 1”. The relay will drop when
there comes a signal on the input
“Reset bistabile 1” or when the
next tightening is started or when
the relay time is exceeded.
24 Bistabile X X X X The relay is pulled if there is a
relay 2 signal on the input “Set Bistabile
Relay 2”. The relay will drop when
there comes a signal on the input
“Reset bistabile 2” or when the
next tightening is started or when
the relay time is exceeded.

21
DS/DL Drive

3.4 Installation of DS hardware

Find a suitable place for the drive – see Safety Instructions.
1. Mount the back panel preferable on a wall, A. For dimensions and screw holes,
see chapter 3.5.
2. Hang the DS Drive on to the back panel, B.
3. Connect the cables, tool cable, power cable etc, to the connectors and fix the cables with
straps to the teeth on the back of the drive.
4. Check so that the GFI is switched on.
5. Fold the drive up and close it by turning the lock on the top of the drive, C.
6. Connect the power cable to a power supply, 115/230 V.
7. Connect a tool to the tool cable.
8. Turn the power on.

IMPORTANT!
Whenever replacing a tool, always turn the power off

DS Drive Back Panel Wall etc.

A B C

22
 DS/DL Drive

3.5 Installation of DL hardware

Find a suitable place for the drive – see Safety Instructions.
1. Mount the back panel preferable on a wall, A. For dimensions and screw holes,
see chapter 3.5.
2. Hang the Drive on to the back panel, attach the fixing screw in the lower right corner of the
drive.
3. Connect the cables, tool cable, power cable etc, to the connectors and fix the cables with
straps to the teeth on the inside of the protection plate.
4. Close the protection plate by attaching the plate screw to the drive.
5. Connect the power cable to a power supply, 115/230 V.
6. Connect a tool to the tool cable.
7. Turn the power on.

IMPORTANT!

Whenever replacing a tool, always turn the power off

DL Drive Back Panel Wall

23
DS/DL Drive

3.6 Installing new software into the DS/DL Drive

Installation guide for software versions 4.4 and higher
1. Connect a tool.

2. Turn the power on.

3. Turn your PC/Lap Top on.

4. Start Windows Explorer.

5. Create a new directory and put the drive sw on the hard drive/c:.

6. Go to the directory where the software is stored.

7. Double click on the dlds_com1.bat or dlds_com2.bat depending on what com port is used on
your PC/Lap Top*.

8. A dos-window will be opened and the drive software loaded automatically, it will take
approximately 2 minutes. The drive will power off while loading the soft ware.

9. When the software is loaded the drive will power up automatically and the display will show
four dots or four dashes.

10. If the drive does not power up, please retry the procedure, read chapter 7 “Trouble Shooting”
or contact your local Atlas Copco dealer.

*If you are using com port 3 or higher please do following:

1. Open a dos window

2. Go to the directory where the sw is located

3. Write dlds COM3 or dlds COM4 etc. and press enter. (This command will also work for
COM1 and COM2). Note! Use capital letters.

If you have software version 4.4 or higher start with number 8 and the init - command.

24
 DS/DL Drive

3.7 DS Drive Dimensions

25
DS/DL Drive

3.8 DL Drive Dimensions

26
 DS/DL Drive

3.9 Display / Key Pad DS Drive

1 4
2 7
3
20.68
8
5 11
6 12
9 13
10 14
TENSOR DS7
15

1. Display 9. Function
2. OK LED 10. Autoset
3. n x OK LED 11. Plus button
4. Lock LED 12. Question mark
5. NOK 13. Enter key
6. Alarm 14. Minus button
7. Graph 15. Power
8. IRDA

The DS Drive is primarily designed to be programmed using ToolsTalk DS. However, there are a
number of programming features available directly through the key pad on the Drive. See chapter
3.10 Key Pad Programming

27
DS/DL Drive

3.10 Display / Key Pad DL Drive

1. Display 8. IRDA
2. OK LED 9. Function
3. n x OK LED 10. Autoset
4. Lock LED 11. Plus button
5. NOK 12. Question mark
6. Alarm 13. Enter key
7. Graph 14. Minus button
The DL Drive is primarily designed to be programmed using ToolsTalk DL. However, there are a
number of programming features available directly through the key pad on the Drive. See chapter
3.10 Key Pad Programming

28
 DS/DL Drive

1. Display Displays numerical values up to 9999.

2. OK LED Lights up after each tightening producing correct torque
3. n x OK LED Lights up after a batch of OK tightenings (n) set through
ToolsTalk DS/DL. Not D302 / D303.
4. Lock LED Lights up when the DS/DL Drive key pad has been lock
unlocked by either the IR-Key or through ToolsTalk DS/DL.
5. NOK Lights up after each tightening reaching first target but not
correct torque.
6. ALARM Lights up to indicate triggered internal alarms, for example, time
to service the tool or errors that need to be acknowledged.
7. GRAPH Lights up when the SET button is pushed to indicate that. Auto-
Set, is activated through the drive key pad.
8. IRDA Underneath this window the IRDA transmitter and receiver is
located. When using the IR-key, point it towards this window.
9. Function The function key shall be used for selecting DS/DL Drive functions
Function key shall be operable when keyboard is in unlocked state.
When operator wants a function he activates the Function key .
10. Auto set Pushing this button allows Auto-Set programming to be
conducted; perform torque tuning, adjust final target and perform
motor tuning DS/DL Drive must first be unlocked.
11. +Torque Each push raises the final target by one increment, 0.1 or 1. By
pressing the button continuously final target final target will be
raised by one increment at an increasing speed
12. Question mark By pushing this button you can see:
Drive program software version
Drive size (DL, DS4, DS7, DS9)
Drive version (D302 / D303, D312 / D313)
13. Enter Enter key shall be used for execution of selected functions and
acknowledge of errors.
14. -Torque Each push lowers the final target by one increment, 0.1 or 1. By
holding the button pushed in the final target will be lowered by
one increment at an increasing speed.

29
DS/DL Drive

15. POWER Main power switch.

30
 DS/DL Drive

3.11 Different models of DS/DL Drive

Both of the two tightening systems (DS & DL) are available in two different models which can be
programmed with one, D302 / D303, or eight, D312 / D313, different parameter sets, p-sets. A
(p-set) is the specific programming for a certain joint. In other words one Tensor DS/DL System
can do up to ten different torque levels. The p-sets are selected using the digital inputs a Turn
Selector or a Socket Tray. Of course, p-sets can also be changed through ToolsTalk DS/DL.

D302 / D303 Single P-Set Drive

The D302 / D303 Drive is a ”single torque drive”, handling one p-set. It has the following main
functions:
• OK Relay
• NOK Relay
• nxOK Relay
• Reset Batch Input
• Increment Batch Input
• Decrement Batch Input
• Auto Set
• Quick Programming
• Torque Tuning
• Tool Signal Lights
• Tool Service Indicator
• CCW, Counter Clockwise Tightening Direction
• Open End Spanner
• Batch Count
• Remote Start
• Lock on reject
• Rundown Monitoring
• Self Tap functionality
• High Speed Rundown

31
DS/DL Drive

D312 / D313 Multi P -Set Drive

The D312 / D313 is a ”multi torque drive” capable of handling up to ten different
p-sets. Except for the functions in D302 / D303 it is also equipped with:

• RE-Alarm
• PLC Functions
• Line Control
• Socket Tray/Selector
• I/O Expander
• Up to 12 I/O’s
• Rotate Spindle
• I/O Bus
• 10 Parameter Sets

32
 DS/DL Drive

3.12 Functions, D302 / D303 and D312 / D313

OK Relay
Pulls Relay 1 (D302 / D303) when an OK tightening is performed.

NOK Relay
Pulls Relay 2 (D302 / D303) when a tightening reaching at least first target but
NOT correct torque.

NxOK Relay
Pulls relay 3 (D302 / D303) when a batch of OK tightenings has been completed.

Reset Batch Input

Resets the batch counter (Input 1 on D302 / D303) when activated.

Increment Batch Input

Increases the batch counter (Input 2 on D302 / D303) one step when activated.

Decrement Batch Input

Decreases the batch counter (Input 3 on D302 / D303) one step.

Auto Set
Auto Set only requires the Final Target, the rest of the parameters are calculated and programmed
automatically by the Drive while you perform a number of test tightenings. The Auto Set function
does not require the PC to be connected, it can be done by using the keypad on the Drive. For
more information, see chapter 3.10, 4.1 and 6.4 Auto Set.

Quick programming
Quick programming is a function to be used through ToolsTalk. Two
parameters are given by the operator, stiffness of the joint and final target, and
the rest will be programmed automatically.

33
DS/DL Drive

Torque Tuning
Torque Tuning is performed either from the key pad on the drive or through
ToolsTalk. It allows an easy adjust to your reference system torque values and
compensates for tool-drive-programming and joint variations. One torque tuning
factor is stored with each p-set. For more information, see chapter 5 and 6.

Tool Signal Lights

Gives light signals on the tool and drive to indicate OK or NOK tightenings and other faults.
• Green light indicates OK tightening.
• Yellow light indicates low torque.
• Red light indicates high torque.
• Red and yellow light combined indicate all other faults.

Tool Service Indicator

Alarm lights up and a programmed relay is pulled when the programmed service
interval is reached.

Counter Clockwise Tightening Direction , CCW

All DS/DL Drives have a built in functionality for left hand threaded fasteners.

Open End Spanner

All DS/DL Drives have a built in functionality for open end spanner applications.

Batch Counter
By counting number of OK rundowns and give an nxOK signal when a certain
number n is reached you can assure that a job has been completed properly. The
number of rundowns n in the batch counter is set in ToolsTalk. It is also possible
obtain the nxOK signal on a relay. External input signals for batch increment and
reset batch are configured through ToolsTalk DS/DL.

34
 DS/DL Drive

RE Alarm
A RE-Alarm is possible to connect to the Drive. The RE Alarm is a portable device, connected to
the drive with a cable, that can be placed near the operator to give signals for OK, NOK and
nxOK.
There are two types of RE-Alarms. One connects to the Relays and one to the I/O-bus, see table
below.
Note that Type of RE Alarm.
Drive version the drive software needed for the I/O-bus to work must be v4.4 or higher.

Type of RE Alarm I/O Bus RE Alarm

Drive version Relay RE Alarm
8433 0560 03

D301 X

D311 X X SW v4.4 or higher

D302 / D303 X

D312 / D313 X X SW v4.4 or higher

In order to use RE-Alarm 8431 0455 36 you need a special adapter cable, no 4222 0472 00. When
using both Re-Alarm and Tensor S/PF 2000 relay type socket tray/selector in combination, then
use adapter cable 4222 0486 00.

IR Key
The IR Key is used to get access to the key pad on the drive. By pressing the button on the key
while pointing it towards the IR window on the drive, it will be unlocked.

35
DS/DL Drive

3.13 Functions, D312 / D313 only

I/O Bus RE Alarm
There are two types of RE Alarms, one I/O bus based and one that uses the relays. For RE Alarm
with digital input, please see chapter 3.8.
When using the relay based RE Alarm 8431 0455 36, please read chapter 3.8.
When using the I/O Bus based RE Alarm 8433 0560 03, please read chapter 7.1.

Line Control
The D312 / D313 Drive supports a special Line Control function. See chapter 5 and 6.

Socket Tray/Selector
The I/O bus based selector tray comes in two different versions, selector 4, 8433 0610 04 which
has four positions and selector 8, 8433 0610 08, with eight positions. For more information, see
chapter 7.2.

Lock on Reject
To assure that no faulty tightenings are passed on unnoticed, this function will lock the Tool/Drive
on rejected tightenings. The tool will not be able to run when locked and the operator must then
Reset Lock On Reject before next tightening.

36
 DS/DL Drive

3.14 Key Pad Functions

The DS/DL Drive can be programmed directly to a limited extent through the key pad on the front
panel. There are five functions available and also a possibility to change parameter sets:
F1 = Auto set
F2 = Final Target
F3 = Torque Tuning
F4 = Motor Tuning.
F5 = Copy Parameter set
+/- button = Change Parameter set (when the +/- button not is used for another
function)

Auto-Set Programming
This enables authorized personnel to program a Drive unit right out from a box without
ToolsTalk DS/DL. The Auto-Set Programming feature allows the Drive to recognize a joint’s
stiffness and adjust the tool for maximum performance for that particular joint accordingly.

How to program AutoSet

1. Press the AUTOSET button (= Dart Board button symbol) once.
2. Choose final target by pressing the +Torque or -Torque buttons on the drive key pad.
3. Press the ENTER button once to activate the Auto Set function. The Graph,
LED , lights up.
4. Resume tightening. The first tightening is performed at a very low speed as the
DS/DL Drive identifies the joint. The speed will gradually increase during the
following tightening as the DS/DL Drive is optimizing the performance for that
joint. When the Graph LED lights down, optimum performance has been found.
Note!
Every tightening will reach final target and the programmer can at any point
during this process press the SET button, when he or she is satisfied with the
tightening results, and thereby set the tightening characteristics at that point as
maximum performance. Again, this lights down the Graph LED and the DS/DL
Drive is programmed.
Lock the DS/DL Drive. It will also automatically resume a locked position
approximately 15 minutes after the last entry on the key pad.

37
DS/DL Drive

Fine-Tuning Final Target

This enables authorized personnel to fine tune the final target, on site, without assistance
from ToolsTalk DS/DL.

1. Unlock the DS/DL Drive with either an IR-Lock or

through ToolsTalk DS/DL.
2. Enter the mode to change final target by pressing the
FUNCTION button once and Ft/F2 appears on the
display.
3. Adjust the final target by pressing the +Torque or -Torque
buttons on the DS/DL Drive key pad.
Note!
Using this programming option, torque can be adjusted a maximum of
+15% or -5% from the original final target set through ToolsTalk
DS/DL or Auto-Set. All values are stored automatically in the DS/DL
Drive memory as they are entered.
4. Press the ENTER button and the display starts to twinkle.
5. When a new final target has been found within above limits, the
DS/DL Drive is ready to run that program. Lock the DS/DL
Drive. It will also automatically resume a locked position
approximately 15 minutes after last entry on the key pad.

38
 DS/DL Drive

Torque Tuning
This is used when a tool is controlled against an external torque reference for
calibration. There is one torque tuning factor each parameter set.

1. Unlock the drive.

2. Perform a number of tightenings with the external torque
gauge connected, preferably 20 tightenings or more so a
good mean value can be achieved.
3. Calculate the mean value from the tightenings.
4. Press the FUNCTION button twice and you see tunE/F3
on the display.
5. Press the + or - button until you have the external mean
value on the display.
6. Press the ENTER button, the display starts to twinkle.
7. Perform another set of tightenings to control your torque.
8. If the torque is OK you are ready to run, if not, do the
complete procedure over again.
9. Lock the drive.

Motor Tuning
This function will optimize the performance of the motor and minimize losses.
1. Unlock the drive.
2. Press the FUNCTION button three times until tool/F4 shows on the display.
3. Press the ENTER-button once again until the display starts to twinkle.
4. Press the trigger on the tool and run until it stops. The procedure will take
approximately 35-45 seconds. The tool has now been motor tuned and is
ready to use.

39
DS/DL Drive

Copy Parameter set

This option makes it possible to copy a parameter set.
1. Unlock the drive
2. Press the FUNCTION button four times until it says “Copy/F5” on
the display.
3. Press the + or – button to select the parameter set you want to
copy to another parameter set.
Confirm by pressing the ENTER buton.
4. Choose the parameter set that you want to copy the selected
parameter set to by pressing the + or – buttons again.
Confirm by pressing the ENTER button
5. Lock the drive

Change parameter Set

When neither of the described functions are selected, the + and –
buttons are used to change parameter set.
1. Press + or – button to select wanted parameter set
2. Confirm that you want to change Parameter set by pressing the
ENTER button.
Note!
If you don’t confirm with the enter button the tools will continue with
the former parameter set

Drive software, Drive hardware and Tool version

The question mark will give information on what software version and
drive version your drive has. Process as follows:
1. By pressing the QUESTION MARK button once you will get
information of the software version.
2. By pressing the QUESTION MARK button twice the drive
hardware version will bee shown, D302 / D303 or D312 / D313.
3. By pressing the QUESTION MARK button three times the display
will show the tool version.

40
 DS/DL Drive

Display Tool

DS4 ETV/ETD/ETP DS4

DS7 ETV/ETD/ETP DS7

DS9 ETV/ETD/ETP DS9

DL11 ETV/ETD/ETP/DL11

DL21 ETV/ETD/ETP/DL21

DF4 ETF DS4

DF7 ETF DS7

DF9 ETF DS9

Note! ETF = fixtured Tensor DS/DL Tool

41
DS/DL Drive

3.15 Remote Start

Note 1! When starting more than one Drive from the same start signal,
use start box 4222 0550 00
Note 2: When setting up a Tensor DL Drive for remote start, ensure that the start option ”Remote
start, tool button deactivated” is selected in the Tool Configuration menu in the Configuration
section of Tools Talk DS/DL. Then also rewire the the Remote Start connector according to
”Remote Control Wiring Schematic.

4 4

3 3

Tool running in clockwise direction (Remote

Remote Startswitch
direction Signal)
2 2 in counter clockwise
direction

1 1

4 Start 4

Start and direction controlled from tool itself

3
3 Rev
Remote Control 2
Wiring schematic
2
1

1
42
 DS/DL Drive

3.16 Inputs and Relays

The Figure below shows how to connect in order to obtain a signal on one of the inputs. The
power source can either be built in 24 VDC or an external power source.

0V 22
+24VDC 21

- 20
DI4
+ 19

- 18
DI3 2.2k
+ 17
-
- 16
DI2
+ 15
2.2k
+
- 14
DI1
+ 4

43
DS/DL Drive

The figure below shows how to connect to obtain OK and NOK signals using RE1 & RE2.

0V +24V

NC
12
RE4 C 11
NO 10

NC 9
RE4
RE3 C 8
RE3 NC
7

NC 6
RE2 C 5
NO 4 NOK

RE2 NC 3
RE11 C 2
NO 1 OK
RE1

44
 Programs

4. Programs
4.1 Selection of program
Full Programming

With Full Programming the most detailed programming can be made. Here you can choose
between the four different tightening strategies Two Stage, Quick Step, Ergo Ramp and Rotate
Spindle. See chapter 4.2 Tightening Strategies.
Full Programming enables you to fine tune all parameters in order for the tightening to perfectly
suit your specific application. The parameters are explained in chapter 5, Tools Talk DS / DL.

Two Stage
With the Two Stage strategy the tool will first perform the first step and then make a complete
stop during 50 ms to let the joint relax, thereafter the second step is performed. Since about two
thirds of the joint relaxation (on most joints) occurs during the first 30 ms, the two stage strategy
provides high quality joints with little joint relaxation. The acceleration in the second step is
determined by a ramp called Step 2 Ramp.

45
DS/DL Drive

Quick Step
In Quick Step the tool shifts immediately down to a constant Step 2 Speed at the First Target
without stopping between the two stages. This is the fastest strategy and is best suited for joints
with constant joint hardness and very soft joints.

Ergo Ramp
Ergoramp is a two-stage tightening with constant speed during the second stage. It is set
automatically by the programmed value for ergoramp and the hardness of the joint. This strategy
has the ergonomical advantage that the user experiences both soft and hard joints as equal.
Ergoramp is the correct strategy where there are both hard and soft bolted joints.

Rotate Spindle
In the strategy Rotate Spindle the spindle rotates a pre-set number of turns and when finished, the
tool gives an OK signal. If the torque exceeds the rotating torque max, the tool stops and gives a
NOK signal.

Autoset
If you use the Auto Set, the Drive will do the programming automatically. You will find it in the
upper right corner of the programming window or in the Pull down menu under DS/DL Drive or
on the key pad on the drive. You do not have to do any programming at all, you only need to
perform a few test tightenings. During these test tightenings the Drive will do its own
programming. Each tightening will reach the Final target entered by the operator, but at different
speeds and strategies. The Drive will customise the programming to the specific joint you are
running on.

46
 DS/DL Drive

Note! The first test tightenings are performed at a very low speed.
The Auto Set is only available when a Drive is connected. When you click Auto Set a dialogue
window asking you to enter the Final target is displayed. When you have entered your value click
OK. A window asking you to perform the tightenings will appear. Normally 5-10 tightenings are
required for the Drive to find a program suitable for the particular joint characteristics.

While performing the test tightenings a green light on the Drive, marked with a graph, is activated.
When this signal light is turned off the Auto Set is finished and the Drive is now programmed
according to this specific joint. The Programming window in ToolsTalk DS/DL still displays the
old settings. To update the Programming window with the new settings from the Drive simply
click the Store button.

47
DS/DL Drive

Quick programming

Quick programming window

The Quick programming mode is meant to help you program the DS/DL Drive in a very simple
way. It only requires two pieces of information about your joint, the Final Target and the Joint
Angle from Snug. All other parameters are automatically calculated by the system. Quick
programming results in a Quick Step tightening. Quick Programming automatically sets the
Torque Tuning Factor to its default value, 100.
Angle from snug is the angle from when the head of the bolt reaches the surface and the torque
starts to increase.

48
 DS/DL Drive

Final Target and Angle from Snug

The Final Target is the specified torque for the joint.
The angle from when the bolt head encounters the work piece to when the final target is reached.
On hard joints it is advisable to set it on 10 degrees. For soft joints you can calculate this angle as
follows:
1. Enter the Final Target and set the Angle from Snug to 10. Click OK. Change the strategy to
Two Stage and press the Store button.
2. Make one tightening. The bolt will then be tightened to the correct torque using a very low
first target that is automatically set by the system to manage a hard joint.
3. Use a spanner, wrench or equal to untighten the bolt, and estimate how many degrees it takes
from fully tightened to the bolt is loose.
4. Enter the angle value found in step 3 as Joint Angle from Snug.
Note! It is recommended that the Angle from snug is set to 10 degrees or more.
As mentioned above, on hard joints it is recommendable to set the Angle from Snug to 10 straight
away. By setting the Angle from Snug to 10 the Drive will make a very careful rundown with a
low First Target. If you feel that the second stage is too long, just raise the angle until you are
satisfied.
However, it is important that there is a second stage otherwise you risk to get an overshoot. The
socket has to move a little in the second stage.
The Quick programming mode will get your tool running in no time, but to fully utilise the
performance of the Tensor DS/DL System we recommend that you dig into”Full programming” in
chapter 6. Full programming enables you to fine tune all parameters in order for the tightening to
perfectly suit your specific application.

4.2 Tightening strategies

When programming, it is important to have a well developed second stage. The socket shall make
an angle movement at the second stage, otherwise the torque may become to great. The best way
to see that there is a second stage is simply to observe the socket movement.
If the tool exceeds the torque, a red warning light will illuminate. The explanation is a short or no
second stage in combination with high speed in the first stage.
Insufficient torque is lower than 98% of the final torque and is probably caused by releasing the
trigger on the tool too early. A yellow light on the tool indicates an insufficient torque.

49
DS/DL Drive

Two stage

Torque
Final Target

First Target

Time

Soft Start Zoom Step Speed

Step 2 Speed
Step 2 Ramp

Step 1 Speed
Speed
For two stage tightening, the tool has a very high speed during the first stage and lower during the
second stage. The tool stops for about 50 ms between stages to reduce settings and then
accelerates up to the speed for the second stage.

50
 DS/DL Drive

Quickstep

Torque
Final Target
First Target

Time

Soft Start Zoom Step Speed

Step 2 Speed

Step 1 Speed
Speed
Quickstep is a two-stage tightening with high speed during the first stage and low speed during the
second stage. The other stage operates at constant speed. In the end, there is a zoom stage, which
reduces tool speed and results in a smoother finish.
In Quick Step the tool shifts immediately down to a constant Step 2 Speed at the First Target
without stopping between the two stages. This is the fastest strategy and is best suited for joints
with constant joint hardness and very soft joints.

51
DS/DL Drive

Ergoramp
Torque
Final Target
First Target
Ergo Ramp

Time

Soft Start Zoom Step Speed

Soft Joint

Step 1 Speed
Speed
Ergo Ramp on a soft joint
Torque
Final Target

First Target
Ergo Ramp

Time

Soft Start Zoom Step Speed

Hard Joint

Step 1 Speed
Speed
Ergo Ramp on a hard joint

Ergoramp is similar to Two Stage but the time for the second step is kept constant and the speed
in the second step is automatically set due to the ergoramp value and the stiffness of the joint.

52
 DS/DL Drive

This has the ergonomic benefit to make all joints feel the same for the operator
despite variations in joint hardness and is ideal for applications where soft and hard
joints are mixed.
With the Ergo Ramp strategy the tool will first perform the first step and then
make a complete stop during 50 ms to let the joint relax, thereafter the second step
is performed. While we in the Two Stage strategy fix the acceleration to be the
same for all tightenings within one p-set, the Ergo Ramp feature calculates the
speed in the second step with respect to a time set by the Ergo Ramp strategy
itself.
When the Ergo Ramp is programmed the Drive sets a time during which the
second step shall be performed. When the tool is running, the speed in the second
step is calculated during the actual tightening, making the time to complete the
second step the same regardless of joint hardness. This means that the speed in the
second step varies from joint to joint.
This is a very comfortable strategy for the operator and is perfect when the joint
characteristics varies. ErgoRamp will always give you the same reaction force, no
matter the joint hardness.

53
DS/DL Drive

Rotate Spindle

Rotate spindle is a function that allows the operator to get an OK signal when the
tool has turned a certain number of turns. The OK signal will be indicated with
the green LED’s on the tool, the OK lamp on the drive will be lit up and the OK
relay will be pulled. If an RE Alarm is connected the OK lamp will be lit up. The
function can for example be used for backing off an exact number of turns.
Rotating torque max
This is the maximum torque value while rotating the spindle. The max limit is
tool max torque and the min limit is 0. Minimum recommended value is
0.1*tool max torque.
Rotating speed
The speed with which the tool will rotate. Can be set between 0 and 100%.
Rotate number of turns
The number of turns which the tool will rotate before giving an OK signal.
Tightening direction
The direction in which the tool will be controlled and the number of turns
measured.

54
 DS/DL Drive

4.3 Special Functions

Rundown Monitoring

Rundown Monitoring is a function to detect bad rundowns. The angle in both

first and second step is monitored. See graph below

55
DS/DL Drive

Cycle Start
Cycle start is the torque limit from which the angle is measured. The maximum
limit for Cycle Start is First Target.

Search Speed
The search speed is the speed with which the tool will run until Cycle Start limit
is reached.
The min limit is 0%. Max limit is Step 1 Speed.
When Cycle Start is reached the tool immediately accelerates to Step 1 Speed.

Step 1 Turns
The angle in the first step is measured from cycle start level until 1st target is
reached.
It is possible to program min and max levels for when the angle is OK.
Min = 0 Turns
Max = 200 Turns
The angle is defined in 1/10 of a full turn.

Clamp Angle
The angle in 2nd step is measured from the point where 1st target is reached
until final target is reached. The angle in between is called Clamp Angle. It is
possible to program min and max levels for when the Clamp Angle is OK.
Min = 0 degrees
Max = 10000 degrees
The angle is defined in steps of 10 degrees.

56
 DS/DL Drive

Low angle
If the angle is lower than the min value a twinkling red-yellow light is given on the tool together
with the message LO° on the display. The tool stops immediately when the angle is out of range.
The same functionality for both 1st and 2nd step. The message on the display is LO°1 if the angle
in step 1 is low and LO°2 if the Clamp angle is too low.

High Angle
If the angle is higher than the max value a twinkling red-yellow light is given on the tool together
with the message HI° on the display. The tool stops immediately when the tool is out of range.
The same functionality for both 1st and 2nd step. The message on the display is HI°1 if the angle
in step 1 is too high and HI°2 if the Clamp angle is too high.

57
DS/DL Drive

Self Tap

The Self Tap function is used for thread forming screws and other fasteners with a torque pulse in
the beginning of the rundown higher than the desired 1st target or final target. See graph below

Following parameters have to be programmed:

• Cycle Start • Self Tap Torque max
• Search Speed • Self Tap Interval

58
 DS/DL Drive

Cycle Start
See Rundown Monitoring
It will be the torque level from which the self-tap interval is measured.

Search Speed
See Rundown Monitoring
Search speed is the speed until cycle start and through the Self Tap Interval.
After the Self Tap Interval the tool will accelerate to Step 1 Speed.

Self Tap Torque Max

Self tap torque max is the maximum thread forming torque allowed. If the
torque exceeds that level the tool immediately shuts off giving an error code
(E116) on the display.

Self Tap Interval

The Self Tap Interval is the thread forming angle. During this interval the torque
is allowed to go as high as Self Tap Torque Max. After the interval the speed
will be Step 1 Speed and the next torque level is 1st target.

59
DS/DL Drive

High speed rundown

High speed rundown allows the tool to make the rundown at a higher speed than
the actual Step 1 speed. The function is specially designed for fasteners with a
long rundown angle and the risk for overshooting due to a stiff joint is big. A
certain number of turns are programmed under which the tool will rotate with a
higher speed. When the number of turns is reached the tool will slow down to
step 1 speed which is so low so that the tool will not overshoot when reaching
first target. After this point the tool will finish the tightening like a normal two
stage, ergo ramp or quick step tightening.

Safety
If the tool shall start with the increased speed it is necessary that the previous
tightening was OK.
If the tool is restarted before having received an OK signal it will start at the
lower step 1 speed. The reason is to prevent an overshoot because of reaching
first target too early at the higher speed.

Speed
The “increased speed” during High Speed Rundown.

Number of turns
The number of turns with which the tool will rotate. The angle will be measured
from start of the tool.

60
 Tools Talk DS

5. ToolsTalk DS/DL
ToolsTalk DS/DL, TTDS/DL is an
Atlas Copco software for programming
the DS and DL drives. It is based on
and designed for Windows 95, 98,
2000, and NT, in other words 32 bit
Windows. TTDS/DL can be used to
configure the entire functionality of the
DS/DL drive.

5.1 Installation
Begin the installation procedure by checking that your PC or Lap Top has the
required capacity according to the following specification. Then, follow the
directions under the heading ”Proceed as follows”.

PC-specification
- Operating system Windows 95, 98, 2000, XP, NT
- Available memory: minimum 25 MB on the hard drive and
8 MB RAM
- RS 232 COM port for communication with DS/DL Drive
- Super VGA screen.

61
Tools Talk DS

Proceed as follows
1. Check that you have the CD-disc with the
Tools Talk program.
2. Insert the CD-disc in D:\drive or 3,5”
floppy disc in the A:\drive.
3. Select RUN in START-menu.

4. Type in D:\setup.exe or A:\setup.exe and

click on OK.

5. Follow the instructions in the installation

program.
6. Click on Ready when the installation is
finished.
7. Turn off and then re-start your PC.
The installation is now completed.

62
 Tools Talk DS

Shortcut to ToolsTalk
You can create a shortcut to ToolsTalk in the following way:
1. Open the Windows Explorer.
2. Go to the directory where you have the ToolsTalk program. In this
case: C:\program\atlas copco\toolstalk\.
3. Click on the file TTDS/DL.
4. Go to File and click on CREATE SHORTCUT.
5. Click on the icon with the right mouse button, keep the button pressed
down and move it to the desired position on the Desktop.
6. Then, by double-clicking on the icon, you can access ToolsTalk
directly.

Start up
When you start the program, TT DS/DL will automatically make contact with the DS/DL Drive. If
you have a Drive connected all the programming in the Drive will be read down by TTDS/DL .
When this is finished you will access the programming window in Tools Talk DS / DL.
If you wish to make your programming in advance and load it into the DS/DL Drive at a later
stage you probably want to run TT DS/DL without having a Drive connected. When you start TT
DS/DL without having a Drive connected TT DS/DL will at start up and try to connect to the
Drive, but as the Drive is not present TT DS/DL will not find the Drive and displays the following
dialogue box.

Connection with DS/DL Drive failure dialogue box

63
Tools Talk DS

Click Abort and continue with your programming, see “Programming without having the DS/DL
Drive connected”. The first thing you will have to do is to set the max. torque for the tool, see
“Tool List”, chapter 8, and also specify the Drive version to use, D302 / D303 or D312 / D313.
However, if you do have a Drive connected to the PC and still get this message there is a problem
in the communication between the PC and the Drive. Please check the following:
• That the Drive is powered on
• That you have the correct cable and that it is plugged in correctly, see “Cable”, chapter 8
• That the COM port on the computer used by ToolsTalk is not configured for something else.
Click Options and then Communications and select another COM port to check the
configuration. You might also have your COM ports under the control panel on your PC/lap
top.
• That your PC is OK
When you have checked this click Retry.

64
 Tools Talk DS

5.2 Working in Tools Talk

If you are familiar to using Windows, you will soon be comfortable with
TTDS/DL . The program layout, menus and the way of working is similar to
Windows.
If you are unsure of the way to work with Windows, ask for assistance from a
person who can instruct you and get you started with the program. After some
practise, you will be able to manage on your own.
Connection to local networks and serial connection of equipment requires
knowledge of addresses and experience from making such connections. Contact
your system administrator.
When you start the program, you will first see the window shown below.

Menu row

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Menu row
We will now look at the functions in the menu
line.

File
When you open File, you can open, save and
close files, print and close the program.

Edit
In the Edit menu, you have the functions Cut,
Copy and Paste.
You can also copy and paste parameter sets.

Drive
Drive, you connect the DS/DL Drive and read
data from or to the Drive.
When Read All Data From Drive or Store All
Data To Drive is selected, both programming
and configuration windows are read/stored.

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Drive Commands
If you click DS/DL Drive in the pull down menu
you can choose between DS/DL Drive
Commands:
• Do Motor Tuning
• Connect
• Read All Data from Drive and
• Store All Data to Drive
• Do Motor Tuning
In order for the motor to run smoothly it needs to
be correctly motor tuned. This is done in the
factory before delivery, but it is advisable to do a
Motor tuning on each specific combination of
Drive and Tool together. This can of course only
be done when a tool is connected.
When you click Do Motor Tuning a dialogue box asks
you if you really want to do the motor tuning.
If you click Yes another dialogue box telling you to
press the tool trigger will appear. It is important that
you keep the trigger pressed during the whole
procedure. The tool will turn in both direction s,
accelerate etc. in order to fine tune the position of the
rotor.
Do not release the trigger until you get a ”Motor
tuning Succeeded” message on the screen. If you
release the trigger too early you can click abort
and you are back where you started.

Open end Tuning

If you already have marked the Open End box, you can
perform Open End Tuning. The Open End Tuning will
re-perform the tuning and calculate a new gear ratio
and play in the gears. The reason for performing a
Open End Tuning could for example be if the tool does
not find the open space in the gear

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Connect
To connect the PC to the Drive you click
Connect. When a Drive is connected there is a
check mark before the text Connect. To
disconnect the Drive you can click Connect again.

Read All Data from Drive

Choosing this alternative will read all data,
including all p-sets and the configuration, from the
Drive into ToolsTalk DS/DL.

Store All Data to Drive

When you click Store All Data to Drive
everything that you have entered into ToolsTalk
DS/DL, all p-sets and the configuration, will be
stored in the memory in the Drive.

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Options
If you click Options in the pull down menu you
can choose between View Toolbar, Set max.
Torque/Drive Version and Settings.

View Toolbar
View Toolbar is an On/Off function that removes
the Toolbar from the screen when Off.

Set Max. Torque/DS Version

Set max. Torque/Drive Version is a function that
is only active when no tool and/or Drive is
connected.
When a tool is connected the Max. Torque for
that tool is automatically handled by ToolsTalk
DS/DL. If, however, you wish to do the
“Programming without having the DS/DL Drive
connected”, then you set the Max. Torque and
Drive version for your programming yourself with
this function.
See “Tool List”, chapter 8 for more information
about maximum torque values.

Settings
In Settings you can choose between
Communication, Options and Printout, all of them
are described below.

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Communication
Under Communication you can choose which
COM port ToolsTalk DS/DL will use. Be sure
that the COM port chosen is not configured for
something else since this will disturb the
functioning of ToolsTalk DS/DL.
If you have problems during start up, try to
choose another COM port.
Note! The choice of COM port can only be done
when the Drive is disconnected from the PC.

Options
Under Options you can decide whether the
communication between the PC/TT DS/DL and
the Drive should be logged or not logging. If for
some reason a problem would occur, the saved
logging could help the Atlas Copco software
specialists to find the reason for the problem and
chances increase that it can be solved.
Selecting Hints will give you small yellow Pop Up
hints that help you when working in ToolsTalk
DS/DL. For example explanations of icons.

Printout
Under Printout you can write your own printout
footer, i.e. your own notations on the bottom of
each side of the printout.
You might want to do some notations on the
printout specific for your workshop.
The printout footer enables you to create your
own standard for these notations.

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Window
Here, you can see the available functions. The
other alternative is to activate the functions by
clicking the icons.
The functions of the other commands are similar
to them in Windows.

Help
In the Help function, it is possible to open help
files for instructions.

Info
In Info you will find a short information about
Tensor DS/DL.

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Toolbars in TTDS/DL
Designation
Symbol Explanation
Open file If you want to open a file with programming that is saved on the
hard disc or on a diskette you click here. For more information
about programming from file see “Programming the Drive from
file ” in chapter 3.
Remember that when you open a file it will automatically
update the Programming Window with the new
programming. If you do not click Store the new
programming will not be stored in to the drive memory.
For more information about Store see chapter 6.
Save file To save programming on hard disc in or on a diskette
click here. For more information about saving
programming on file see in chapter 6.

Cut If you mark a value and click here, the value is copied
into the clipboard and disappears from the screen.

Copy If you mark a value and click here, the value is copied to
the clipboard while it remains on the screen.

Paste When you click Paste, whatever is copied to the clipboard

at that moment will be copied back in to the document
and placed where the marker is currently positioned.
Print The Print icon will print the information in the currently
selected window, except for the Main Window and the
Rundown Window, and is therefore only lit up when a
window is active. To print information from all windows
or to change printer, choose File and Print in the pull
down menu.
Open Programming Clicking here will open the Programming window, for
window more information see “Programming Windows” in chapter
5.

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Open Run window Clicking here will open the Run window, for more
information see “Run Window” in chapter 5.4.

Open Torque Tuning Clicking here will open the Torque Tuning window, for
window more information see “Torque Tuning Window” in
chapter 5.5.

Open Configuration Clicking here will open the Configuration window, for
window more information see “Configuration Window” in chapter
5.6.

Open Diagnostics Clicking here will open the Diagnostics window, for more
window information see “Diagnostic Window” in chapter 5.7.

Make contact with the When the PC does not have contact with the Drive the
Drive upper icon is visible. Clicking here will establish contact
between PC and Drive.
When the PC has contact with the Drive the lower icon is
visible. Clicking here will disconnect the PC from the
Drive. Remember to Store before disconnecting.

Help If you click here you will get into the ToolsTalk DS/DL
Help files that hopefully can help you solve any
programming problems you might have run into.
The function is not activated in this program version.

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5.3 Programming Window

The Programming window is the most important window in ToolsTalk DS/DL Here you set all the
torque parameters that the DS/DL Drive uses to control the tool. The programming can be done in
three different levels: Auto Set, Quick Programming and Full Programming. The Programming
window is different in the two Drive versions, D302 / D303 and D312 / D313. In D302 / D303
you do not have the possibility to change and open parameter sets.

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Auto Set only requires the Final Target, the rest of the parameters are calculated and programmed
automatically by the Drive while you perform a number of test tightenings. The Auto Set function
does not require the PC to be connected, it can be done by using the keypad on the Drive, see
“Auto Set” in chapter 6.4.
Quick programming: The Quick programming window does not require any knowledge about
the Tensor DS/DL System. All you need to know is the Target Torque and the approximate
hardness of your joint. The Quick programming window is shown when you click “Full
Programming ” on in chapter 6.2 and disappears when the programming is done.
Note! The “Quick programming ” in chapter 6.3 results in a Quick Step strategy for the
tightening, for more information on strategies see ”Full programming” in chapter 6.2.
Full programming: In the Full programming window the complete range of settings is accessible.
This is where the skilled programmer fine tunes his DS/DL Drive programming. The Full
programming window is the one that you open by clicking the Programming icon in the tool bar.

Important!
The values entered will not be active in the drive until the Store button is clicked. When a new
value is typed followed by Enter it is stored into the Drive directly.
The p-set performed by the Drive is always the selected p-set.
From the Programming window you manage your p-sets, see “Selecting Parameter” in chapter
5.3. Further you can reach the Torque Tuning window by clicking Torque Tuning. This can only
be done if the viewed p-set is the same as the selected p-set.

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Programming window, D302 / D303

Programming window, D312 / D313

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1. Tightening strategy
You can select strategy choices as shown
beside.
The strategy Rotate Spindle is only available
for D312 / D313 drive.

2. Soft Start Time

In order to facilitate screw engagement the tool starts by turning at a very low speed during the
soft start time.

3. First Target
At this torque level the tool will shift from Step 1 Speed to Step 2 Speed. What First Target to use
depends on the joint hardness. On a hard joint it must be quite low to prevent overshoot, while on
a soft joint it should be close to the Final Target in order to make the rundown time as short as
possible. Make sure that the First Target is set low enough to allow a two stage tightening. A one
stage tightening indicates a possible overshoot.

4. Final Target
At this level the tool stops and the tightening is finished. It is very important that the fastener turns
at least 10 degrees in the second step. This is easily determined by looking at the fastener while the
second step is being performed. If the fastener does not turn at all after the first step you should
first lower the First target and if this does not help you lower the Step 1 speed. It is recommended
to always keep the Step 1 Speed as high as possible.

5. Step 1 Speed
The speed with which the tool runs during the first step. On extremely hard joints it might not be
enough to lower the First Target to prevent overshoot. The next action to be taken in that case is
to lower the Step 1 Speed a little.

6. Step 2 Speed
The speed in the second step.

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7. Zoom Step Speed

The speed at which the tool will shut off when Final Target is reached.

8. Step 2 Ramp
In Step 2 Ramp you can select the acceleration of the tool in step 2 between 0 and 100%.

9. Batch Size
Batch Size defines the number of joints in a batch. See also “Run Window” in chapter 5.4.

10. Tightening Direction

Here you can choose between clockwise tightening, CW, and counter clockwise tightening, CCW.

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1
2

3
4

5
6
7
8

1 High speed rundown

You can select High Speed Rundown ON/OFF, see chapter 4.3 High Speed Rundown.

2 Options
You can select options as shown beside.
Rundown Monitoring: The rundown and tightening angles
during tightening are measured.
Self Tap: This function makes it possible to tighten bolted
joints where the torque during tightening is higher than the
final target. For example, this may be the case when
tightening self-tapping screws. For more information, see
chapter 4.3.

3 Auto Set
Auto Set only requires the Final Target, the rest of the parameters are calculated and programmed
automatically by the Drive while you perform a number of test tightenings. The Auto Set function
does not require the PC to be connected, it can be done by using the keypad on the Drive.

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4 Quick programming
The Quick programming window does not require any knowledge about the Tensor DS/DL
System. All you need to know is the Target Torque and the approximate hardness of your joint.
The Quick programming window is shown when you click Quick Programming button and
disappears when the programming is done. If Quick Programming has been used, this will be
indicated with a red frame around the Quick Programming button.
Note! The Quick Programming results in a Quick Step strategy for the tightening.

5 Selected Parameter Set, D312 / D313 only

By clicking here you get a list of all opened psets in the
drive. By marking one and releasing the mouse the pset is
selected in the drive.

6 New Pset
Here you open psets. New psets will be set to default
programming.

7 Reset Pset
Set all parameters to default values. Default values are
depending on the max torque value on the tool used.

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8 Delete Pset
Here you delete psets. New psets will be set to
default programming.

9 Torque Tuning
All Drives and tools are normalised from delivery. This means that you can use any tool with any
drive and the torque will be accurate.
However, sometimes variations in joint characteristics result in a need to fine tune the system in
order to get exactly the correct torque on that specific application. See also Torque Tuning in
chapter 5.5.

10 Read
Reads the current configuration from Drive.

11 Store
Stores the current configuration to Drive.

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5.4 Run Window

3
4
5
6

1. Torque
The resulting torque for each tightening.
2. Step 1 no. of Turns
The number of turns in 1/10 of a full turn, measured in Step 1. The angle is measured from cycle
start until end of Step 1. For more information, see Rundown Monitoring, chapter 4.3.
3. Clamp Angle
The angle from end of Step 1 until final target is reached. See also Rundown Monitoring, chapter
4.3.
4. Batch Counter
The Batch Counter is incremented by 1 for each OK tightening. When the Batch Counter reaches
the number in Batch Size the counter is reset to zero and the nxOK signal light on the Drive is
activated.
5. Number Of Rundowns
The number of rundowns performed since the window was opened or since Counter Reset was
activated
6. Counter Reset

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5.5 Torque Tuning Window

2
3

4
5

All DL Drives and tools are normalised from delivery. This means that you can use any tool with
any drive and the torque will be accurate. Of course the Drive has to be of the correct size, DS4
Drive for DS4 tools etc. However, sometimes variations in joint characteristics result in a need to
fine tune the system in order to get exactly the correct torque on that specific application. This is
done in the Torque Tuning window. To determine if you need to do a Torque Tuning or not you
can check the torque with an in-line transducer.

1. How to perform the Torque Tuning

Run the tool together with an in-line transducer on the specific application. It is important that it is
on the real application since a test joint might behave differently.

2. Reference Torque
The value from your reference system, in-line transducer, torque wrench etc.

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3. Update Chart
After each rundown input the reference torque (in-line transducer torque, NOT the torque shown
on the Drive unit) in the field Reference Torque and press Enter or click Update chart. For each
tightening the graph to the left will be updated and the mean value of the reference torques will be
displayed. Further a new tuning factor will be calculated and displayed in the lower right part of
the screen

4. Reference Torque Counter

The number of tightenings to ensure a good tuning factor must be at least 10, preferably 25.

5. Clear Last and

To erase the last entered Reference Torque simply click Clear Last.

6. Clear All
To restart the torque tuning procedure click Clear All and all entered values will be erased.

7. Tuning Factor
The Torque Tuning results in a Torque Tuning Factor, displayed in the bottom right corner of as
well the Torque Tuning window as the Programming window. The Torque Tuning Factor is
allowed to differ from the default value, 100 in a range from 20 to 220. If the Torque Tuning
Factor is outside this range the field containing the new Factor value will be marked red and it is
no longer possible to store the Torque Tuning Factor to the Drive.
The Torque Tuning Factor can also be altered manually, without performing any tightenings. This
requires good knowledge of how the Tensor DS works on the specific joint in question.
However, if you for example want a slight increase in the mean value of your tightenings in a
particular p-set without changing the programming, you can increase the Torque Tuning Factor by
a few units.
Note! The Torque Tuning Factor is specific for each combination of Drive and Tool. It is
recommended to perform a Torque tuning on each combination individually.

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8. Store Torque Tuning

When a sufficient number of tightenings has been made you click Store Torque Tuning and the
new Torque Tuning Factor will be stored in the Drive

Torque Tuning window, 25 tightenings made

If you would enter a value that is outside ±15% of target you will get an information dialogue box
that looks as follows

Information dialogue box, torque outside recommended values

If you click OK the value will be used by TT DS/DL when calculating the new Torque Tuning
Factor but if you click Cancel it is discarded.

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Important about Torque Tuning

If the program in ToolsTalk DS/DL is not the same as the program stored in the Drive, then a
dialogue window with the question ”Store changes before Torque Tuning?” appears. Clicking Yes
means the programming in ToolsTalk DS/DL will be stored into the memory in the Drive and you
can proceed with your Torque Tuning. This procedure is designed to prevent operator mistakes,
since the Torque Tuning function is performed with the values in the drive as a basis, not the
values in ToolsTalk DS/DL / DL.
When Store Torque Tuning has been done you can not retrieve the old tuning factor from the
Drive. However, the default tuning value from delivery is always 100.
When service has been made to the tool remember to make some rundowns on a joint and run the
tool in the air for some 30 seconds before the Torque Tuning is performed. This will make the
grease in the gears settle first so the output torque will not change over time.
The Torque Tuning Factor is closely related to the programming used when the Torque Tuning
was performed. If you change the programming substantially you should also redo the Torque
Tuning in order to get a perfect result.
Note! If you choose Quick Programming the Torque Tuning Factor is always set to its default
value, 100.

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5.6 Configuration Window, Tensor DS & DL

In the Configuration window you set the configuration for the DS/DL Drive. The Configuration
window has three different subgroups: System Administration, I/O Configuration (containing I/O
Setup and RE-Alarm Setup) and Tool Service Setup. you define the operator interface and in.
In System Administration you define the operator interface.
In I/O Configuration –I/O you define how to use the different input and output connections on the
DS/DL Drive.
In I/O Configuration - RE-Alarm Setup you set the carachteristics for the external alarm, see
chapter 7.1.
Note! The Configuration looks different in the different Drive versions D302 / D303 and D312 /
D313. The I/O Setup and the Lock On Reject do not exist in the D302 / D303 version.
The third group, Tool Service Setup, gives you information about the service status of the tool
and also a possibility to program your own service interval.

System Administration
4
1
5

2 6
7
3
8
9
10
11
12
13

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1. Subgroups
Shows the available selections.

2. Selector Source

In this window you can choose Selector

Source, i.e. how the change between different
p-sets should be done. You can choose
between None, Digital input and I/O-bus

None:
None means that you select p-set in the Programming Window.
Digital inputs:
When you use a selector on the Digital Inputs you have the possibility to use Selector 15, Selector
15S or Rotary Selector 15. There are three Digital inputs on the Drive, corresponding to the three
cables necessary to represent six different binary codes.
I/O-bus:
The I/O-bus will be used for RE-Alarm, Selector and I/O-Expander. The selector used on the I/O-
bus will have p-set 1 connected to position 1 in the socket tray, p-set 2 connected to position 2
etc. When using the I/O-bus it is necessary to set the selector source to I/O-bus (when you use
RE-Alarms on the I/O-bus you do not have to change any configurations).
Read more about the I/O bus under chapter 7, Accessories.

3. Line Control
Line Control is a built-in feature that is usually done with a PLC. When using Line Control all p-
sets in the Drive are configured for Line Control. Line Control is used when the operator wants to
control his station on the line and also make it impossible to go on with the next job before the
current job is completed.
Note! Following Inputs must be used for a Line Control:
• Line Control Start, enables the tool
• Line Control Alert 1, connected to Relay Line Control Alert 1
• Line Control Alert 2, connected to Relay Line Control Alert 2
• Reset Alarm, resets Line Control Alert

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Following Relays must be used with Line Control:

”Line Control Alert 1”, Line Control OK must be on before Line Control Alert 1, else Line
Control Alert 1 is activated.
”Line Control Alert 2”, Line Control OK must be on before Line Control Alert 2, else Line
Control Alert 2 is activated.
”Line Control OK”, Line Control OK will be pulled when nxok is fulfilled. Line Control OK
disables the tool in its tightening direction (CW or CCW). The tool will then be enabled again next
time Line Control Start is on.
Other I/O-s that are suitable to use together with Line Control are Batch Increment (Input) and
DS Ready (Relay), see chapter 5 and 6.

4. Lock On Reject
If you want the Tool/Drive to lock on rejected tightenings you mark ”Lock On Reject”. The tool
will not be able to run when locked and the operator must then reset Lock On Reject before next
tightening. To reset the Lock On Reject you need an external signal on one of the Inputs, which
should be configured as ”Reset Lock On Reject”.

5. Alarm On Rehit
Alarm on Rehit will give the operator an alarm if a rehit occurs, i.e. if the operator runs the tool on
an already tightened bolt.

6. Drive Keypad
Drive Keypad gives you the possibility to lock the keypad on the Drive. You have three possibi-
lities. You can choose Open, then the keypad will be open to use for the operator. If you choose
Locked you lock the keyboard and you will have to use ToolsTalk DS/DL to open the keypad for
use again. The IR-control alternative enables you to lock and unlock the Drive using a remote
control. To lock or unlock you press the button on the remote control at the same time as you
point it at the front of the Drive. This changes the status from locked to unlocked and the other
way around.

7. Torque Unit
In the field Torque Unit you choose the unit in which the torque should be programmed and
presented. The default unit is Newton meter (Nm).
Note! If you have done the programming in one unit and then, afterwards, change to another unit
the program will automatically recalculate all the programming you have done according to the
new unit you have chosen. The presentation on the Drive will be the same as in ToolsTalk DS/DL.

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8. Use Open End

In order for the tool to release after each tightening, the machine reverses when the trigger is
pressed the next time. The tool will remain in that position each time that the trigger is pressed and
until the socket has released. Only following this is the machine able to operate forward.
This means that the forward/reverse switch can remain in the same position all the time. If the
switch should be in the reverse position, the tool will rotate in reverse, of course.
In reverse, the tool turns slowly and at low torque in order to not damage the socket.
Note! Which direction is forward and reverse depends on the selection rotational direction.

9. Open End Play

Open End Play is the play in the gears in the open end front part on the tool.
The play is automatically measured in the Open End Tuning, see chapter 5.2.
The play can also normally be adjusted by changing the valve in the
configuration window. The play is measured in degrees.

10. Inverted Motor Rotation

If you are using an Open End front part that changes the rotating direction on the spindle, you
need to mark this check box.

11. Open End CCW

For left hand fasteners.

12. Read
Reads the current configuration from DS/DL Drive.

13. Store
Stores the current configuration to DS/DL Drive.

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5.7 Configuration Window, Tensor DL only

For the Tensor DL system, the System Administration section will have more options than for the
DS system. The number of open fields will depend on whether you have a push-to-start or lever
tool connected.
In System Administration you define the operator interface and behavior of the tool and here you
can configure the push-to-start functionality and front lights of the push-to-start tools in the DL
series.
Note!: The Configuration looks different for the different Drive versions, D303 and D313. The
I/O Setup and the Lock On Reject do not exist on the D303 version. Also if you connect a push-
to-start tool, a menu for configuring the push-to-start function and the front lights will be opened.

System administration, Tensor DL

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1. Start configuration
This menu configures the behavior of the start button.

• Tool start button

Tool starts by pressing the start button
• Tool Push-to-start
Tool starts by pushing the tool towards the working piece
• Tool start button or push-to-start
Tool starts by pressing the start button or by pushing the tool towards the working piece
• Tool start button and push-to-start
Tool starts by pressing the start button and at the same time pushing the tool towards the
working piece
• Remote start, tool tool button deactivated
Tool is started by an external input signal Note: This option has to be selected if the remote
start option is used

2. Function button continuous

This menu configures the function button when it is pressed continuously. By holding the function
button down continuously and press the start button, the tool will behave according to any of the
options below:
• Deactivated
Function button continuous is deactivated
• Change pset to next open pset
Function button continuous lets you toggle between open psets with the start button

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• Tightening / loosening
Button is dedicated to tightening / loosening direction.

3. Function button single push

The tool can be set up for different behaviors when the function button is pressed once. The mode
can be set up in three different options:

• Deactivated
Function button single push is deactivated
• Next run a loosening, then tightening direction again
Tool will change direction when button is pressed. When start button is released the tool will
automatically change to the tightening direction.
• Toggle tightening/loosening
Tool will change direction when function button is pressed and run in that mode until the same
button is pressed on more time.
• Change pset to next open pset
When button is pressed, the tool will automatically change the pset setting to the next
programmed pset in the drive. In this way, you can toggle through the psets to quickly choose
the appropriate one for your application.

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4. Function button double push

The tool can be set up for different behaviors when the function button is pressed twice. The
function mode with two button pushes can be set up in the same three different ways as for the
single push.

• Deactivated
Function button double push is deactivated
• Next run a loosening, then tightening direction again
Tool will change direction when button is pressed. When start button is released the tool will
automatically change to the tightening direction.
• Toggle tightening/loosening
Tool will change direction when function button is pressed and run in that mode until the same
button is pressed on more time.
• Change pset to next open pset
When button is pressed, the tool will automatically change the pset setting to the next
programmed pset in the drive. In this way, you can toggle through the psets to quickly choose
the appropriate one for your application.

5. Illuminator setup
The illuminator setup enables configuration of the four, bright illuminator lights in the front of the
tool. There are three different operating modes of the illuminator:
• Illuminator off
The illuminator is deactivated
• Startbutton enables illuminator
Illuminator is turned on when the startbutton is pressed
• New pset turns on illuminator
Illuminator is turned on when a new pset is selected, either by digital I/O or by I/O-bus.

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6. Illuminator end configuration

• Turn off at time

Illuminator is turned off at a specific time, which is set in the ”Illuminator on time” field below
• Turn off at OK
Illuminator is turned off at OK tightening result
• Turn off ot nxOK
Illuminator is turned off at a batch OK (nxOK) tightening result

9. Illuminator on time

• This field specifies the illuminator on time in seconds from when the illuminator is started.

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I/O Setup, D312 / D313 Version only

1. I/O Setup on Drive

Up to eight additional inputs and relays (giving a total of 12 inputs and relays) can be used with
the help of an external I/O-device for the I/O-bus. The number of listed inputs and relays in the I/O
Setup window will then be 12. Inputs and relays number 1 to 8 are connected via the I/O-bus.

2. I/O Expander
The I/O expander increases the number of relays and Opto inputs when more than those already
built-in are needed See also chapter 7, Accessories.

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You can make following selections:

Input

Relay

Relay Time

For a complete list of inputs and relays, see chapter 3.2 Inputs/Outputs.

Tool Service Setup

Here you get information about date for last service and number of tightenings after service. Also
service interval is displayed and the default value is 2500.000 tightenings = our maximum
recommended interval between service for a tool tightening a normal joint.
When pressing “Tool Service Reset” –buton you find an option to set your own service interval,
between 10.000 and 2.500.000 tightenings, as well as service date. When pressing OK and
thereafter STORE the counter will be reset to 0.
Detailed description of Tool Service Setup, see chapter 6.6.

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5.8 Diagnostics
In the Diagnostics window you can read information from the tool and Drive memories. The
Diagnostics Window has four different subgroups: History, Tool Information, Drive information
and I/O Status
History

1
2
3
4
5
6

1. No tightenings: Drive
The number of tightenings that has been performed with the current DS/DL Drive.
2. No tightenings: Tool
The number of tightenings that has been performed with the connected tool.
3. Service date: Tool
The date for the latest performed service on the tool connected.
4. Service indicator
Tell the user if the service indicator is on or off
5. No tight since service
The number of tightening that has been performed since service
6. Service internal
The number of tightenings that the service internal set for

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Tool Information

1
2
3

1. Tool serial number

This an identification number unique each tool.

2. Tool max. Torque

This is the maximum torque for the connected tool.

3. Gear Ratio
This number is the Gear Ratio of the connected tool.

4. Motor type
This indicates whether the tool is a DL, DS4, DS7 or DS9.

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Drive Information

1. Drive Program Version

This indicates the program version that is used in the Drive, not to confuse with the program
version of ToolsTalk DS/DL.
2. Drive HW revision DC
Indicates the revision of the Drive Card (DC).
3. Drive HW revision MC
Indicates the revision of the Motor Card (MC).
4. Drive type
This information gives you the type of Drive connected, i.e. DS4, DS7 or DS9.

5. Drive Serial Number

This is an identification number specific for each Drive. This number is also marked at the back of
the Drive.

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I/O Status, D312 / D313 version only

The I/O Status shows you the configuration of the inputs and the relays that is chosen in I/O.
You can also see the current status of the inputs and the relays, i.e. if they are On or Off.

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6. Programming
6.1 Hints
In this section we present some hints meant to support you in your work with ToolsTalk DS/DL /
DL.

Programming without having the Drive connected

If you wish to make your programming in advance and load it down to the Drive later this is no
problem. At the start up of ToolsTalk DS/DL the following window is displayed.

Establishing contact with the Drive dialogue box

You can enter the Main window by clicking Abort in the above window. If you do not click OK
the following happens. As the Drive is not connected the attempt to connect the PC to the Drive
will fail and this window is displayed:

Connection with DS/DL Drive failure dialogue box

Just click Abort.

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Note! Since no drive is connected you now need to set the max. torque value and the Drive
version (D302, D303, D312 or D313) yourself. For more information see “Options” and “Tool
List” in chapter 3 and 8.
You now end up in the main window and you can continue with your programming. When no
Drive is connected some of the functions in the Programming window are disabled. For example:
• It is not possible to select p-sets
• It will of course not be possible to Store, since Store is a command towards the Drive (it is
however both possible and advisable that you Save your programming on file.
When no Drive is connected the Run, Torque Tuning and Diagnostics windows will have no
practical use.
Important
Remember to save all your programming on diskette or hard disc before connecting to the Drive,
otherwise the values in the Drive will overwrite the values you have entered on the ToolsTalk
DS/DL screen.

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Saving programming on file

When saving files of programming either choose Save As under File in the pull down
menu or click the Save File icon.

Save File

The file saving routine is standard in Windows. You can use four different formats when saving:
dru Drive Unit All programming is saved, all the p-sets as well
as the configuration.
dap All p-sets All opened p-sets in the Programming window
are saved (only D312 / D313).
dop One p-set The viewed p-set is saved.
Note! Not the selected p-set!
dcn Configuration parameters This format saves all the configuration
parameters in the Configuration window.
To save a file you choose format and then you type the name of your file. You create your own
file names, however it is recommended to create a certain structure when naming the files to make
it easier finding them.

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Programming the Drive from file

Programming from file means that you use a previously done ToolsTalk DS/DL programming
stored in your PC or on a diskette to program your Drive. When programming from file just
choose Open under File in the pull down menu or click the Open File icon and choose what file
you want to use.

Open File

To program from file is the same as just opening the file. This means that when you have found the
file you want to use double click on it (or mark it and click OK). Now the file will automatically
overwrite whatever programming is on the screen in that moment.
When you click Store the chosen file will be stored into the Drive. However, as long as you do not
click Store the old programming will still be in the Drive.

Store in drive
In the Programming, Torque Tuning and Configuration windows, and in their pull down menus,
you will find a possibility to choose Store. Store means storing programming into the Drive’s
memory.
Store is a function that is connected to a particular window, i.e. the Store button in the
Programming window, for example, stores everything that is in the Programming window into the
Drive’s memory. As soon as you change a value or a configuration setting a yellow frame will
appear around the Store button in the window(s) where you have done the changes. This yellow
frame means that the current programming in ToolsTalk DS/DL differs from that in the Drive and
that you have to Store the changes before they will be active in the Drive.

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6.2 Full Programming of pset

Explanations of respective programming parameter can be found in the section 5
Tools Talk DS / DL.

1. Open the list Window at the menu row.

Select Programming or click the
Programming icon.
The Programming window becomes
active and the corresponding icons are
illuminated.

2. Click the New Pset button.

3. Now you can name the Pset

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Programming

4. Select tightening strategy by clicking on

the arrow to the right of Tightening
Strategy. You are given four available
selections.

5. Continue programming by setting values

for the parameters.
Enter desired values in respective column.
Follow the instructions below.

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 Programming

Soft Start
In order to facilitate screw engagement the tool starts by turning at a very
low speed during the soft start time.

First Target
At this torque level the tool will shift from Step 1 Speed to Step 2 Speed.
What First Target to use depends on the joint hardness. On a hard joint it
must be quite low to prevent overshoot, while on a soft joint it should be
close to the Final Target in order to make the rundown time as short as
possible.
Make sure that the First Target is set low enough to always result in a two
stage tightening. A one stage tightening indicates a possible overshoot.

Final Target
At this level the tool stops and the tightening is finished. It is very
important that the fastener turns at least 10 degrees in the second step. This
is easily determined by looking at the fastener while the second step is being
performed.
If the fastener does not turn at all after the first step you should lower the
First target and if this does not help you lower the Step 1 speed.

Step 1 Speed
The speed with which the tool runs during the first step. On extremely hard
joints it might not be enough to lower the First Target to prevent
overshoot.
The next action to be taken in that case is to lower the Step 1 Speed a little.
It is important to always keep the Step 1 Speed as high as possible.

Step 2 Speed
The speed in the second step.

Step 2 Ramp
The Step 2 Ramp function is set as a percentage where 100% is the slowest
acceleration and 0% is the fastest.

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Programming

Ergoramp
The Ergoramp defines the time for the second stage. The time in the second
stage is kept constant, regardless of the stiffness of the joint. 0% is a very
short time (high speed) for the second stage and 100% is a long time (slow
speed).

Zoom Step Speed

The speed at which the tool will shut off when Final Target is reached.

Batch Size
Batch Size defines the number of joints in a batch. See also “Run Windows” in chapter 5.4.

Tightening Direction
Here you can choose between clockwise tightening, CW, and counter clockwise tightening, CCW.

7. If you select ON at High Speed Rundown,

the following selections are available.
See chapter 4-3.

8. Options give you selections as shown

beside.
See chapter 4-3.

8.1 Rundown Monitoring

See chapter 4-3.

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8.2 Self Tap

See chapter 4-3.

8.3 Self Tap/Rundown Monitoring

See chapter 4-3.

10. After finished programming, the only task

remaining is to save the p=sets.

11. Click on File in the menu row at the top of

the screen and then Save As.
Save the Pset in the desired directory.

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6.3 Quick Programming

1. Open the list Window at the menu row.
Select Programming or click the
Programming icon.
The Programming window becomes
active and the corresponding icons are
illuminated.

2. Click the Quick Prog button.

3. Set the value for Final Target and Angle

from Snug.
Click the OK button.

4. After finished programming, the only task

remaining is to save the psets.

5. Click on File in the menu row at the top

of the screen and then Save As.
Save the Pset in the desired directory.

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6.4 Auto Set

1. Open the list Window at the menu row.
Select Programming or click the
Programming icon.
The Programming window becomes
active and the corresponding icons are
illuminated.

2. Click the Auto Set button.

3. Set the value for Final Target.

Click the OK button.
Now 5-10 tightenings are required for
the Drive to find a program suitable for
the particular joint characteristics.
While performing test tightenings, a
green LED is lit on the DS/DL Drive, the
LED is marked with a graph.
When the LED is turned off the AutoSet
is completed and the programming
optimized to the specific joint.
All tightenings, also during the test
AutoSet tightenings are considered OK if
the Drive shows a green light OK.

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6.5 Torque Tuning

1. Open the list Window at the menu row.
Select Torque Tuning or click the Torque
Tuning icon.
The Torque Tuning window becomes
active and the corresponding icons are
illuminated.

2. Run the tool together with an in-line

transducer on the specific application. It
is important that it is on the real
application since a test joint might
behave differently.
3. After each rundown input the reference
torque (in-line transducer torque, NOT
the torque shown on the Drive unit) in
the field Reference Torque and press
Enter or click Update chart.
For each tightening the graph will be
updated and the mean value of the
reference torques will be displayed.
Further a new tuning factor will be
calculated and displayed in the lower
right part of the screen.
The minimum tuning factor is 80. It is
not possible to program and store a valve
less than 80.
The maximum tuning factor is 220. At
120 a warning is displayed.
Normally, the tuning factor is in between
the intervall 80-120.

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4. When a sufficient number of tightenings

has been made you click Store Torque
Tuning and the new Torque Tuning
Factor will be stored in the Drive.
The number of tightenings to ensure a
good tuning factor, at least 10, preferably
25 tightenings.
5. If you would enter a value that is outside
±15% of target you will get an
information dialogue box that looks as
follows

Information dialogue box,

torque outside
recommended values

6. If you click OK the value will be used by

TT DS/DL when calculating the new
Torque Tuning Factor but if you click
Cancel it is discarded.
7. To erase the last entered Reference
Torque simply click Clear Last. To
restart the torque tuning procedure click
Clear All and all entered values will be
erased.

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6.6 Configuration
Note! The Configuration menu looks different in the different drive versions D302 / D312
(DS) and D303 / D313 (DL). ToolsTalk DS/DL will automatically launch the appropriate
Configuration window depending on the drive and tool attached.

1. Open the list Window at the menu row. Select

Configuration or click the Configuration icon.
The Configuration window becomes active and
the corresponding icons are illuminated.

2. The Configuration Window looks like this when

System Administration is chosen.

3. Read the current configuration, if any, from

DS/DL Drive.

4. In this window you can choose Selector Source,

i.e. how the change between different p-sets
should be done. You can choose between None,
Digital input and I/O-bus

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 Programming

5. Line Control is a built-in feature that is usually

done with a PLC. When using Line Control all
p-sets in the Drive are configured for Line
Control.
For additional information about use of Inputs
for and Relays with Line Control, see chapter 5.

System Configuration DS/DL Drive

1. If you want the Tool/Drive to lock on rejected

tightenings you mark ”Lock On Reject”. The
tool will not be able to run when locked and the
operator must then reset Lock On Reject before
next tightening. To reset the Lock On Reject
you need an external signal on one of the
Inputs, which should be configured as ”Reset
Lock On Reject”.
2. Alarm on Rehit will give the operator an alarm
if a rehit occurs, i.e. if the operator runs the tool
on an already tightened bolt.
3. Drive Keypad gives you the possibility to lock
the keypad on the Drive. You have three
possibilities.
You can choose Open, then the keypad will be
open to use for the operator.
If you choose Locked you lock the keyboard
and you will have to use ToolsTalk DS/DL to
open the keypad for use again.
The IR-control alternative enables you to lock
and unlock the Drive using a remote control. To
lock or unlock you press the button on the
remote control at the same time as you point it
at the front of the Drive. This changes the status
from locked to unlocked and the other way
around.

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4. In the field Torque Unit you choose the unit in

which the torque should be programmed and
presented. The default unit is Newton meter
(Nm).

5. Select ON/OFF or value for:

§ Use Open End

§ Open End Play
§ Inverted Motor Rotation
§ Open End CCW
For more info about Open End, see chapter 5.6.

6. Save the current configuration to Drive by

clicking Store button..

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System administration, Tensor DL

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1. Start configuration
This menu configures the behavior of the start button.

• Tool start button

Tool starts by pressing the start button
• Tool Push-to-start
Tool starts by pushing the tool towards the working piece
• Tool start button or push-to-start
Tool starts by pressing the start button or by pushing the tool towards the working piece
• Tool start button and push-to-start
Tool starts by pressing the start button and at the same time pushing the tool towards the
working piece
• Remote start, tool tool button deactivated
Tool is started by an external input signal Note: This option has to be selected if the remote
start option is used

2. Function button continuous

This menu configures the function button when it is pressed continuously. By holding the function
button down continuously and press the start button, the tool will behave according to any of the
options below:
• Deactivated
Function button continuous is deactivated
• Change pset to next open pset
Function button continuous lets you toggle between open psets with the start button
• Tightening / loosening
Button is dedicated to tightening / loosening direction.

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3. Function button single push

The tool can be set up for different behaviors when the function button is pressed once. The mode
can be set up in three different:

• Deactivated
Function button single push is deactivated
• Next run a loosening, then tightening direction again
Tool will change direction when button is pressed. When start button is released the tool will
automatically change to the tightening direction.
• Toggle tightening/loosening
Tool will change direction when function button is pressed and run in that mode until the same
button is pressed on more time.
• Change pset to next open pset
When button is pressed, the tool will automatically change the pset setting to the next
programmed pset in the drive. In this way, you can toggle through the psets to quickly choose
the appropriate one for your application.

4. Function button double push

The tool can be set up for different behaviors when the function button is pressed twice. The
function mode with two button pushes can be set up in the same three different ways as for the
single push.

• Deactivated
Function button double push is deactivated
• Next run a loosening, then tightening direction again
• Tool will change direction when button is pressed. When start button is released the tool will
automatically change to the tightening direction.

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Programming

• Toggle tightening/loosening
Tool will change direction when function button is pressed and run in that mode until the same
button is pressed on more time.
• Change pset to next open pset
When button is pressed, the tool will automatically change the pset setting to the next
programmed pset in the drive. In this way, you can toggle through the psets to quickly choose
the appropriate one for your application.

5. Illuminator setup
The illuminator setup enables configuration of the four, bright illuminator lights in the front of the
tool. There are three different operating modes of the illuminator:
• Illuminator off
The illuminator is deactivated
• Startbutton enables illuminator
Illuminator is turned on when the startbutton is pressed
• New pset turns on illuminator
Illuminator is turned on when a new pset is selected, either by digital I/O or by I/O-bus.

6. Illuminator end configuration

• Turn off at time

Illuminator is turned off at a specific time, which is set in the ”Illuminator on time” field below
• Turn off at OK
Illuminator is turned off at OK tightening result
• Turn off ot nxOK
Illuminator is turned off at a batch OK (nxOK) tightening result

12. Illuminator on time

• This field specifies the illuminator on time in seconds from when the illuminator is started.

Tool Service setup

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 Programming

In this window you can see information about date for last service and number of tightenings after
service. It is also the starting window for setting the service date in the tool and the service
interval. You activate the service indicator by changing the pull down menu to ON.

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Programming

When clicking the "Tool Service Reset" button a new window is shown where you set your
service interval as well as service date. The service interval can be set between 10,000 to
2,500,000 tightenings. The default value is 250,000 tightenings which is also our max
recommended interval for a normal joint. Note that service interval value will be rounded off to
10,000. When pressing OK and STORE the counter will be reset to 0.

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7. Accessories
I/O Bus (D312 / D313 only)
The benefit of using I/O-Bus based accessories is that they can be hard-wired in series - from
accessory to accessory rather than hard-wire each accessory to the DS/DL Drive. This
arrangement increases flexibility, allows quick installation and decreases stoppage. See example
shown below.

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7.1 RE Alarm
An RE-Alarm is possible to connect to the Drive. The RE-Alarm is a portable device, connected
to the drive with a cable, that can be placed near the operator to give signals for OK, NOK and
nxOK.
There are two different type of RE Alarms for Tensor DS312 / D313. One is the RE Alarm
designed for Tensor S/PF 2000, 8431 0455 36 and one for Tensor DS, 8433 0560 03.
In order to use RE-Alarm 8431 0455 36 you need a special adapter cable, no 4222 0472 00. When
using both Re-Alarm and Tensor S/PF 2000 relay type socket tray/selector in combination, then
use adapter cable 4222 0486 00.

RE Alarm, 8431 0455 36

The Drive communicates through the relays with the RE Alarm. There are three different functions
on the RE Alarm, OK, NOK, nxOK. The relays shall be configured according to the table below.
In the D302 / D303 drive the relays are hard coded to this configuration.

Relay Function
RE 1 OK
RE 2 NOK
RE 3 nxOK

I/O-Bus RE Alarm, 8433 0560 03 (D312 / D313 only)

This RE Alarm do not use any of the digital inputs, instead it communicates with the drive through
the I/O-Bus.

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 Accessories

Configuration
The drive is configured in TTDS/DL /Configuration window/RE Alarm Setup. Chose which
function shall light up the lamp on the RE Alarm in the list underneath RE and what type of sound
and light you want to have with that function.

Hex Switch default value

When connecting the RE-Alarm to the drive it is necessary to have the hex switch in the right
position. Make sure that the device # is set to default value. The RE-Alarm only work for DS
when the device # is set to default.
Device Default
RE Alarm 3

Cables and Connectors

When installing the RE Alarm use I/O-Bus cables 4222 0470 xx together with termination 4222
0443 00, xx is the length of the cable, for example:
Cable length Part no.
0.5 meter 4222 0470 00
1 meter 4222 0470 01
3 meter 4222 0470 03
5 meter 4222 0470 05
10 meter 4222 0470 10
15 meter 4220 0470 15
For more information about available lenghts of the cable, see the Tensor DS or Tensor DL
brochure.
Everywhere where there is a “free” connector there has to be a termination put in. There can not
be any “loose ends” in the system. So in order to install one Selector it is necessary to use one

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cable and two termination plugs. The termination plugs are included with every I/O-Bus
accessory.
For more information of the selector please read the selector ASL.

7.2 Selector, only for D312 / D313

When using multi p-sets it is very convenient to use a socket tray. When using selector it has to be
configured through ToolsTalk.
If using the Tensor S/PF 2000 relay type socket tray/selector use adapter cable 4222 0417 00, and
if combining above with an Re-Alarm, use adapter cable 4222 0486 00. In order to enable the tool
a parameter set has to be chosen, e.g. socket lifted, when the selector function is activated.
Four inputs and four relays are hardwired with individual connectors on the back of the drive.
There are three different ways of choosing p-set. One is through TTDS/DL , the second is through
the inputs on the back of the drive and the third is through a Selector connected to the I/O-bus.
In TT DS/DL /Configuration it is possible to chose these three types of selector sources.

Selector source “None”

The p-set is selected through TTDS/DL . In the programming window you can chose p-set under
“Selected Parameter Set”.

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Selector source “Digital inputs”

The p-set is selected through the digital inputs. By programming the inputs with Selector bit 0,
Selector bit 1, Selector bit 2 and Selector bit 3 it is possible to have up to eight different p-sets.
The inputs are interpreted binary according to the table below.

Parameter Selector Selector Selector Selector

Set bit 3 bit 2 bit 1 bit 0
0 0 0 0 0

1 0 0 0 1

2 0 0 1 0

3 0 0 1 1

4 0 1 0 0

5 0 1 0 1

6 0 1 1 0

7 0 1 1 1

8 1 0 0 0

Example:
P-set 7 uses three inputs and Selector bit 0,1 and 2. Bit 0 binary is equal to 1, bit 1 is 2 and bit 2 is
4. When we have a signal on each one of Selector bit 0-2 this is equal to 1+2+4=7. This gives us
P-set 7.
If we are only using three P-sets it is only necessary to use two inputs and Selector bit 0 on one
input and Selector bit 1 on the other.

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Selector 15 and Selector 15 R

There are two Selectors normally used together with Tensor S/PF2000 that can
be connected to Tensor DS / DL. These two selectors uses the digital inputs to
communicate with the drive. Configure the drive according to the table below
and use adapter cable 4222 0417 00 or 4222 0486 00.

Input Function
Digital Input 1 Selector bit 0

Digital Input 2 Selector bit 1

Digital Input 3 Selector bit 2

Digital Input 4 Selector bit 3

Product Ordering no.

Selector 15 8433 0601 13

Selector 15R 8433 0606 41

The selector 15 is a socket tray with six positions and Selector 15R is a rotary selector with up to
15 positions. Note that Tensor DS/DL only handles up to ten p-sets.

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Selector source “I/O -Bus”

There are two different type of selectors developed for Tensor DS / DL, Selector 4 and Selector 8.
8. Only one Selector at a time can be connected to the DS or DL drives.

Selector 4

Position 1
P-Set 1

Selector 8

Position 4
P-Set 4

Parameter Set number

On Tensor DS the P-Set no. is the same as the socket position. P-Set no one is
to the left on the socket tray.

Default value
When connecting the selectors to the drive it is necessary to program the
Selector Source to “I/O-Bus”. After this make sure that the device # is set to
default value. The Selectors only work for DS/DL when the device # is set to
default.
Selector Default
Selector 4 5
Selector 8 6

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Cables and Connectors

When installing Selector 4 or 8 use I/O-Bus cables 4222 0470 xx shall be used
together with termination 4222 0443 00. xx stands for the length of the cable

Cable length Part no.

0.5 meter 4222 0470 00

1 meter 4222 0470 01

3 meter 4222 0470 03

5 meter 4222 0470 05

10 meter 4222 0470 10

15 meter 4222 0470 15

Everywhere it is a “free” connector there has to be a termination. There can not

be any “loose ends” in the system. So in order to install one Selector it is
necessary to use one cable and two terminations.
For more information of the selector please read the selector ASL.

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7.3 I/O Expander

The I/O Expander increases the number of relays and Opto inputs when more than the four hard
I/O are needed. It consists of up to eight extra programmable inputs and relays. The I/O Expander
communicates with the drive through the I/O-Bus.

I/O Expander, 8433 0564 38

Configuration
For configurations for the inputs and relays please see how the hard I/O’s are programmed in
Chapter 5.

Default value
When connecting the I/O Expander to the drive it is necessary to have the hex switch in the right
position. Make sure that the device # is set to default value.
Device Default
I/O Expander 2

Cables and Connectors

When installing the I/O Expander use I/O Bus cables 4222 0470 xx together with termination
4222 0443 00, xx is the length of the cable, for example:
Cable length Part no.
0.5 meter 4222 0470 00
1 meter 4222 0470 01
3 meter 4222 0470 03
5 meter 4222 0470 05
10 meter 4222 0470 10
15 meter 4220 0470 15

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7.4 IR Key
IR Key = Infra red key. This accessory is an infrared remote control key, 8092 1141 00, similar in
size and shape of a laser pointer that allows authorised personnel to unlock the KeyPad of the
DS/DL Drive for limited manual programming.
The IR Key enables the user to lock and unlock the DL Drive unit, without having to connect a
PC to the DL Drive and start ToolsTalk DS/DL.

Configuration
When using the IR Key the drive has to be set into IR Control mode. This is
done in TT DL/Configuration window/System Administration shown below.

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Operating the IR Key

The IR Key shall be pointed against the IRDA window on the drive. The range
for the IR Key is approx 0.5 meters, and the angle 30 degrees. This
limitation of range is to prohibit locking/unlocking of the wrong DS/DL Drive
when several drives are mounted side by side.
After opened the Key Pad will lock automatically after 15 minutes from the last
entry on the Key Pad.

IRDA
window

There are three different states for the keypad set through TT DL, Open, Locked and IR
Control.
Open
Open means that the keypad is set in a opened state and will remain that way. It is always
possible to get access to the keypad. The drive will not be affected with the Remote
Control
Locked
Locked means that the keypad is set in a locked position. The keypad will not respond to
any presses on the buttons. The drive will not be affected with the remote control.
IR Control
By setting the drive in the IR-Control position it is possible to lock and open the drive from a
remote control. When set in this state the drive will automatically resume a locked position 15 min
after the last entry was made.

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8. Trouble Shooting
8.1 Error Messages in ToolsTalk DS/DL
The error messages from the ToolsTalk DS/DL program presented below are arranged under the
different ToolsTalk DS/DL windows where they would occur. Here we have only listed the error
messages from ToolsTalk DS/DL.
For further information concerning error messages from the running Operative System on your PC
we refer to the manual for the system used.

Main Window
Message Reason
Unknown File type File with extension ≠ dru, dap, dop, dcn

No programming is done If invalid values are entered

… is now out of limit! If the values entered are outside checking-
limits
Motor Tuning failed The Motor Tuning has failed. Press Abort.
Programming / Torque Tuning Window
Message Reason
The Quick programming Value not valid or outside the limits
value is not correct!
Not a Valid Number! If a value ≠ integer, or name ≠ text
…is outside the If the value is outside warning limits
recommended values for
…is not valid If the value is outside error limits

137
Trouble Shooting

Communication Messages
Message Reason
Not able to write value to If the PC cannot connect to the Drive
DS/DL Drive, Check
DS/DL Drive, COM port
and cables
Connection failure with the If the PC tries to make connection with the
DS/DL Drive Check DS/DL Drive and does not succeed within a certain
Drive, COM port and cables time, or you try reconnect and still no contact
is made
Check COM port. No COM If no COM Ports are available to the program
ports available.

8.2 Error codes on Drive

System features
Error codes are displayed with 4 characters. All error codes begin with E to
indicate error code, and comprise of a three-digit number, where the first digit
defines an error code group.
All error codes are sent to Tools Talk DS/DL and can be read here with a short
explanation.

Error acknowledgment
Certain errors require a user acknowledge (ack). On the display this is indicated
by flashing the error code.
The ALARM led is lit for every error code that has to be acknowledged.

138
 Trouble Shooting

Help text
A small text toggled with the error code. Only for group 0. Timing is 500ms error code 500ms
help text.
§ Group 0 Rundown failures, E000-E031
§ Group 1 Event related errors, E100-E131
§ Group 2 User input error, E200-E231
§ Group 4 Communication errors, E400-E431
§ Group 5 Hardware errors TOOL, E500-E531
§ Group 6 Hardware errors DC3000/MC3000, E600-E631

Errcode Short description Ackowledge What to do? Help text

E000
E001 Torque LO No Start button was probably “Torque
released to early. Let the tool value”
“finish” the tightening.
E002 Torque HI No The programming is bad. Please “Torque
check the programming and value”
make sure that you have some
movement on the socket in the
second stage.
E003 Torque No The programming is bad. Please
measurement check the programming and
possibly invalid make sure that you have some
movement on the socket in the
second stage.
E004 Angle1 LO No Check programming or the joint. LO°1
E005 Angle1 HI No Check programming or the joint. HI°1
E006 Angle2 LO No Check programming or the joint. LO°2
E007 Angle2 HI No Check programming or the joint. HI°2

139
Trouble Shooting

Errcode Short description Ackowledge What to do? Help text

E100
E101 Pset invalid (Check Yes If Tools Talk DS/DL (TTDS/DL ) is
sum error) connected press read and change a
parameter in the programming
window and store it. After this
change the parameter back to what it
is supposed to be.
If no TT DS/DL is connected then
change Final target by the F2
function on the Drive Key Pad and
store it. Afterwards change it back
to it’s original value.
E102 Rundown prohibited No Give a signal on any input
due to Lock on programmed with Reset Lock On
Reject Reject or unmark Lock On Reject in
configuration in TTDS/DL .
E103 Clockwise direction No Deactivate the input programmed
prohibited via digital with “Clockwise disable”.
input
E104 Reverse direction No Deactivate the input programmed
prohibited via digital with “Counter Clockwise”.
input
E106 Rundown prohibited No Deactivate the input programmed
due to CycleHold with “Cycle Hold”.
active
E107 Rundown prohibited No Enable Line Control Start through
due to Line Control, any input programmed with Line
Line Control Start Control Start or unmark Line
not enabled. Control in TT DS/DL Configuration.
E108 Rundown prohibited No Press on the SET or ENTER button
due to keypad usage on the key pad until you see four
dashes or dots on the display.

140
 Trouble Shooting

Errcode Short description Ackowledge What to do? Help text

E109 Pset Revision not Yes Connect TT DS/DL version 2.20 or
supported by this higher. When connected a question
SW to update the p-set will come. Please
do this.
E110 Configuration Yes Connect TT DS/DL version 2.20 or
Revision not higher. When connected a question
supported by this to update the p-set will come. Please
SW do this.
E111 MC Rundown No Restart the tool.
timeout
E112 Rehit No You tried to tighten the fastener
when it was already tightened and
Alarm On Rehit was marked in
TTDS/DL /Configuration. Please
unmark Alarm On Rehit or retighten
the fastener.
E113 Current limit Yes Check the system why current limit
reached – rundown was reached.
aborted
E114 Open End Reference Yes You have tried to perform an Open
position not found End Tuning without success. Please
check the tool and/or the open end
gear.
E115 Direction uncertain Yes You have probably pressed the start
button to quick since last time.
Please allow more time between
releasing the start button and trying
to start the tool again.
E116 Self Tap Torque No Either the torque while tapping the
Max reached – hole is too great or Self Tap Torque
rundown aborted Max is set too low.
E120 Motortuning failure Yes Redo the Motortuning. If this does
not work, service the tool.

141
Trouble Shooting

Errcode Short description Ackowledge What to do? Help text

E121 OpenEnd tuning Yes Redo the Open End Tuning.
failure
E131 Tool Disconnected Yes Shut the drive off and connect the
tool. Start the drive.

E200
E201 First target > final No Lower First Target or increase Final
target Target.
E202 Final target > Tool No Lower Final Target.
max torque
E204 Final target < 10% No Increase First Target
of tool max torque
E205 Pset not open No Open the P-set in TTDS/DL .
E206 Pset nr invalid No Two or more sockets are lifted at the
same time or pset 9 or higher is
chosen.

E400
E403 IO device not No Check cables and restart drive.
responding
E408 Multiple devices of Yes You are only allowed to use one
same type on IO bus
E409 Multiple selectors on Yes
IO bus
E410 No selector found Yes Connect the Selector and restart the
and pset source is drive or chose none on Selector
IO bus Source in TT DS/DL /Configuration.
E412 IO expander has ID Yes
<> 2
E413 RE Alarm has ID Yes
<> 3

142
 Trouble Shooting

Errcode Short description Ackowledge What to do? Help text

E415 4socket selector has Yes
ID <> 5
E416 8socket selector has Yes
ID <> 6

E500
E501 Tool overheated No Let the tool cool down and restart.
E502 Service Indicator Yes Service the tool
E511 Tool-DC3000 size Yes Check that the tool and drive are of
mismatch the same “size”.
DS4 tool-DS4 drive
DS7 tool-DS7 drive
DS9 tool-DS9 drive
E512 Tool revision not Yes Verify that tool revision is correct.
supported by this
drive SW
E513 Tool EEPROM Yes Service Tool
error
E514 Tool EEPROM Yes Perform motor tuning
error
E515 Tool commutation Yes Restart drive. If error code still
sensor error remains then service tool.
E516 Rotor magnet Yes Restart drive. If error code still
remanens out of remains then service tool.
range
E517 Tool maxtorque or Yes Check tool memory.
Gear Ratio out of
range
E518 Tool normalisation Yes Perform normalisation.
out of range

143
Trouble Shooting

E600
E601 Dcbus LO Yes Restart drive. If problem still remains
check line voltage.
E602 Dcbus HI Yes Restart drive. If problem still remains
check line voltage.
E603 DC3000 overheated No Shut the drive off and let the drive
cool down. Restart drive.
E604 24V output error Yes 24 volt power supply overloaded.
Check current consumption and
restart drive. Read specifications for
maximum power consumption.
E605 Yes Contact Atlas Copco Service
personnel
E611 DC3000 EEPROM Yes Contact Atlas Copco service
corrupt (csum error) personnel.
E612 MC3000 EEPROM Yes Contact Atlas Copco service
corrupt (csum error) personnel.
E613 Config1 EEPROM Yes Connect TT DS/DL and check
corrupt (csum error) programming. Change parameters
and store.
E614 FirmWare corrupt Yes Reload drive soft ware.
(csum error etc)
E615 Option definition Yes Reload the drive software and make
HW/SW mismatch sure the right drive version (D302 /
D303 or D312 / D313) is chosen.
E616 Current Yes Contact Atlas Copco service
measurement offset personnel.
error
E617 Current Yes Contact Atlas Copco service
measurement gain personnel.
error

144
 Trouble Shooting

8.3 What might have happened…

Below we have described different scenarios that we know can disturb the functioning of the
DS/DL System. Mainly these disturbances are trigged by erroneous commands or actions when
communicating with the Drive through ToolsTalk DS/DL. However, it is not possible to harm the
system permanently no matter how wrong the programming is, the worst case possible is that you
might need to restart the Drive.
To restart the Drive just turn the power switch off and wait for ca 5-10 seconds and then turn it
back on again. When the Drive is powered on just click the Connect icon in ToolsTalk DS/DL and
you will be up programming again.

…if the tool does not run when I push the trigger?
First of all check that the power is on and that the tool cable is connected.
More:
Check for Error Codes on the display and read the error code list what might have prevent the tool
from running.
If a Store has just been made please wait up to 30 seconds and try to run the tool again.
If a selector is used an existing p-set has to be chosen. If a socket tray type selector is used only
one socket can be lifted (please check the LED’s on the socket tray to verify this, sometimes small
sockets do not trig the sensor if no positioning device is used).
Check the programming. Impossible programming (for example if First and Final Target are both
zero) will prevent the tool from running.
If the Store button is activated while the tool is running or if the Store button is activated while
ToolsTalk DS/DL is busy storing data into the Drive the P-set might not be correctly stored and
also impossible to run. This is easily solved by pressing Store again. This will be indicated with
E101 on the display.

…if the Drive does not start up?

Please check…
…that the power cable to the Drive and the cable to the tool are connected. Note that a tool of the
correct size is needed. In this case DS4, DS7 or DS9, depending on the Drive.
…that the fuses in the Drive are OK.
...that the Ground Fault Interrupter (GFI) is in its ”On”-position.

145
Trouble Shooting

…if the PC does not get contact with the Drive?

Please check…
…that the Drive is powered on.
…that you have the correct type of communication cable between the PC and the Drive, for
specification see chapter 9.
…that the communication cable between the PC and the Drive is connected to the RS 232 serial
communication port, COM port, on the PC.
… that the correct COM port is selected in ToolsTalk DS/DL.
If it doesn’t work, try to select another COM port in ToolsTalk DS/DL by choosing Options in
the pull down menu and then Settings and Communication.
If you click the arrow beside COM ports, ToolsTalk DS/DL will show you the available COM
ports.
…that the right Tools Talk DS/DL version in combination with the drive version is used.
All Tools Talk DS/DL versions are downward compatible.
For drive software versions 4.4 and higher it is necessary to use Tools Talk DS/DL 2.20 or higher
version.
If none of the COM ports work, and you have pin pointed the problem down to the COM
ports the COM ports in your computer are most likely configured in a special way. For example by
using another computer to verify that the Drive and cables are OK.
For more information about how to reset this configuration we refer to the manual for your PC.
…that only one ToolsTalk DS/DL is running in the computer. If by mistake ToolsTalk DS/DL has
been opened twice please close both sessions and restart one of them.

…if I do not succeed with my installation of Tools Talk DS / DL?

Please check…
…that the PC fulfils the requirements stated in chapter 10 on page 10 – 2.
Be sure to write A:\setup in the installation procedure. Sometimes A:\install is used, but not for
ToolsTalk DS/DL.
For Windows NT special routines may be required.

146
 Trouble Shooting

…if I do not succeed with my installation of drive soft ware

If you can not down load the drive sw please check so that the FIFO-buffers are enabled. Below is
described where you find the FIFO-buffer.
Windows 95 and Windows 98
Go to: Control Panel
System
Device Manager
Ports (COM & LPT)
Port Settings
Advanced
Mark ”Use FIFO-buffers” and click on defaults.
Windows NT
Go to: Control Panel
Ports (COM & LPT)
Settings
Advanced
Mark ”FIFO enabled”.

147
Trouble Shooting

148
 Part List

9. Part List
9.1 DS Drive, Part List
4 2

7 1

No.Part Description Ordering No Info.

1 Fuse Holder 4220-0412-00
Fuse 4220-0413-15 15 A (S4)
Fuse 4220-0413-20 20 A (S7)
Fuse 4220-0413-25 25 A (S9)
2 Connector Card 4222-0400-80
3 Drive Card 4222-0385-80 Tensor DS-4
4222-0386-80 Tensor DS-7
4222-0387-80 Tensor DS-9
4 Motor Card 4222-0389-80 D 301
Motor Card 4222-0390-80 D 311
4 Motor Card 4222-0389-82 D 302
Motor Card 4222-0390-82 D 312
5 Display Card 4222-0410-80 For three button membrane panel
4222-0603-81 For six button membrane panel
6 Ground Fault Interrupter 4222-0020-00 10 mA (Special Appl.)
4222-0020-01 30 mA (DS4, DS7, DS9)
7 Turn Switch (Complete) 4222-0362-90

150
 Part list

No.Part Description Ordering No Info.

8 Back Panel Lock 4222-0363-01
9 Three button Membrane 4222-0355-82 Tensor DS 4
Switch Panel 4222-0355-83 Tensor DS 7
4222-0355-84 Tensor DS 9
Six button Membrane 4222-0605-81 Tensor DS 4
Swith Panel 4222-0605-82 Tensor DS 7
4222-0605-83 Tensor DS9
10 Front Panel (Complete) 4222-0347-90
11 Back Panel 4222-0323-82

151
Part List

9.2 DL Drive, Part List

No.Part Description Ordering No Info.

1 Back panel 4222 0854 00 Wall mount
2 Main switch 4222 0839 00
3 DL- Cable connector 4222 0857 96
4 MC- Card 4222 0392 80 D303-DL
4 MC- Card 4222 0393 80 D313-DL
5 Drive card 4222 0847 80
6 Front 4222 0834 80
7 Cover 4222 0873 80
8 Lock screw 4222 0878 00
9 Membrane panel 4222 0837 00
10 Display card 4222 0603 80
11 Connector card 4222 0849 80

152
 Part list

9.3 Tensor DS, Tool List

Model Square Torque Speed Weight Lengh CS dist Ordering No.
drive
in Nm/ft lb r/min kg lb mm mm

ETV DS4
3
DS4-10-10S / 8” 4.5-15 3.5-11 585 1.3 2.9 365 13.5 8433 0706 14
3
DS4-20-10S / 8” 6-20 4.4-14.5 400 1.3 2.9 365 13.5 8433 0706 49

ETP DS4
DS4-05-I06S ¼” (1) 2-5 1.5-3.6 1310 1.1 2.5 195 21 8433 0708 61
DS4-05-06S ¼” 2-5 1.5-3.6 310 1.1 2.5 190 21 8433 0708 76
DS4-07-I06S ¼”(1) 2.1-7 1.5-5.1 900 1.1 2.5 195 21 8433 0708 80
DS4-10-I06S ¼” 3.5-12 2.5-8.8 60 1.1 2.5 195 21 8433 0708 83
DS4-10-06S ¼” 3.5-12 2.5-8.8 660 1.1 2.5 190 21 8433 0708 92
3
DS4-10-10S / 8” 3.5-12 2.5-8.8 660 1.1 2.5 190 21 8433 0709 06

ETD DS4
DS4-05-I06S ¼” (1) 2-5 1.5-3.6 1310 1.2 2.7 375 28 8433 0710 26
3
DS4-05-10S / 8” 2-5 1.5-3.6 620 1.2 2.7 370 28 8433 0710 29
3
DS4-05-10ST / 8” 2-5 1.5-3.6 620 1.3 2.9 420 28 8433 0710 37
3
DS4-10 10S / 8” 4-14 3-10 620 1.2 2.7 370 28 8433 0710 52
3
DS4-10-10ST / 8” 4-14 3-10 620 1.3 2.9 420 28 8433 0710 73

ETF DS4
3
DS4-05-10ST / 8” 2-5 1.5-3.6 1310 1.1 2.5 390 21.5 8433 0450 08
3
DS4-10-10ST / 8” 4-14 4.4-10 620 1.2 2.7 390 21.5 8433 0450 31

153
Part List

9.4 Tensor DS, Tool List

Model Square Torque Speed Weight Lengh CS dist Ordering No.
drive
in Nm/ft lb r/min kg lb mm mm

ETV DS7
3
DS7-15-10S / 8” 5-17 3.6-12.4 1160 1.4 3.1 400 13.5 8433 0720 10
3
DS7-30-10S / 8” 10-35 7.3-25 800 1.4 3.1 400 13.5 8433 0721 42
DS7-30-10S-HAD 10-35 7.3-25 800 1.6 3.4 400 14 8433 0721 59
3
DS7-40-10S / 8” 12-40 9-29 800 1.6 3.6 420 18 8433 0721 94
DS7-40-10S-HAD 12-40 9-29 800 1.8 4.0 420 18.5 8433 0722 15
DS7-40-10S-FS 12-40 9-29 800 1.8 4.0 420 18.5 8433 0722 03
3
DS7-50-10S / 8” 17-55 12-40 480 1.6 3.6 420 18 8433 0722 58
3
DS7-50-10ST / 8” 17-55 12-40 480 1.7 3.8 470 18 8433 0722 67
DS7-50-10S-HAD 17-55 12-40 480 1.8 4.0 420 18.5 8433 0722 65
DS7-70-13S ½” 24-80 18-58 345 2.1 4.7 445 20 8433 0723 16
DS7-70-13S-FS 24-80 18-58 345 2.3 5.1 445 20.5 8433 0723 26
DS7-100-13S ½” 33-110 24-80 240 2.3 5.1 465 20 8433 0723 70
DS7-100-13S-HAD 33-110 24-80 240 2.5 5.6 465 20.5 8433 0723 73
DS7-100-13S-FS 33-110 24-80 240 2.5 5.6 465 20.5 8433 0723 86
DS7-160-13S ½” 45-150 33-110 150 2.8 6.3 508 25 8433 0723 98
DS7-160-13S-FS 45-150 33-110 150 3.0 6.7 508 25.5 8433 0724 00
DS7-200-13S ½” 60-200 44-146 120 2.8 6.3 508 25 8433 0724 15
DS7-200-13S-FS 60-200 44-146 120 3.0 6.7 508 25.5 8433 0725 01

ETP DS7
3
DS7-30-10S / 8” 10-35 7.3-25 750 1.6 3.6 262 18 8433 0726 36
DS7-50-13S ½” 17-55 12-40 535 1.9 4.2 306 23 8433 0726 87
DS7-70-13S ½” 21-70 15-51 370 2.1 4.7 327 23 8433 0727 01
DS7-70-13ST ½” 21-70 15-51 370 2.2 4.9 377 23 8433 0727 05
DS7-70-13SSW ½” 21-70 15-51 370 2.2 4.9 327 23 8433 0727 09
DS7-90-13S ½” 28-95 21-69 275 2.1 4.7 327 23 8433 0727 19
DS7-90-13SSW ½” 28-95 21-69 275 2.2 4.9 327 23 8433 0727 28
DS7-120-13S ½” 38-125 28-91 220 2.1 4.7 327 23 8433 0727 47
DS7-120-13SSW ½” 38-125 28-91 220 2.2 4.9 327 23 8433 0727 84

154
 Part list

Model Square Torque Speed Weight Lengh CS dist Ordering No.

drive
in Nm/ft lb r/min kg lb mm mm

ETD DS7
3
DS7-20-10S / 8” 6-20 4.4-14.5 750 1.4 3.1 438 28 8433 0730 23
3
DS7-20-10ST / 8” 6-20 4.4-14.5 750 1.5 3.3 438 28 8433 0730 44
3
DS7-30-10S / 8” 10-35 7.3-25 750 1.4 3.1 438 28 8433 0730 88
3
DS7-30-10ST / 8” 10-35 7.3-25 750 1.5 3.3 488 28 8433 0731 05
DS7-50-13S ½” 17-55 12-40 535 1.9 4.2 447 28 8433 0731 12
DS7-50-13ST ½” 17-55 12-40 535 2.1 4.7 486 28 8433 0731 24
DS7-70-13S ½” 21-70 15-51 370 2.2 4.9 468 28 8433 0731 31
DS7-70-13ST ½” 21-70 15-51 370 2.4 5.4 507 28 8433 0731 40
DS7-90-13S ½” 28-95 21-69 275 2.2 4.9 468 28 8433 0731 45
DS7-90-13ST ½” 28-95 21-69 275 2.4 5.4 507 28 8433 0731 52
DS7-120-13S ½” 38-125 28-91 220 2.2 4.9 468 28 8433 0731 84
DS7-120-13ST ½” 38-125 28-91 220 2.4 5.4 507 28 8433 0731 96

ETF DS7
3
DS7-15-10ST / 8” 5-15 3.6-11 990 1.3 2.9 457 21.5 8433 0455 44
3
DS7-25-10ST / 8” 8-25 6-18 595 1.3 2.9 457 21.5 8433 0455 59
DS7-40-13ST ½” 12-40 9-29 430 2.0 4.4 455 26.8 8433 0455 78
DS7-50-13ST ½” 15-50 11-36 290 2.3 5.1 476 29.5 8433 0456 05
DS7-70-13ST ½” 21-70 15-51 220 2.3 5.1 476 29.5 8433 0456 42
DS7-100-13ST ½” 30-100 22-73 175 2.3 5.1 476 29.5 8433 0456 82

ETV DS9
DS9-100-13S ½” 40-100 29-73 685 3.3 7.4 575 20 8433 0750 21
DS9-180-13S ½” 72-180 53-131 385 3.8 8.5 585 25 8433 0750 68
DS9-180-FS 72-180 53-131 385 4.0 8.9 585 25 8433 0750 73
DS9-270-20S ¾” 108-270 79-197 235 7.0 15.6 665 34 8433 0751 38
DS9-270-FS 108-270 79-197 235 7.2 16.0 665 34 8433 0751 44
DS9-370-20S ¾” 148-370 108-270 150 7.1 15.8 665 34 8433 0751 86
DS9-450-20S ¾” 180-450 131-328 145 11.6 25.8 702 54 8433 0752 04
DS9-600-25S ¾” 240-600 175-438 145 11.6 25.8 702 54 8433 0752 63

155
Part List

Model Square Torque Speed Weight Lengh CS dist Ordering No.

drive
in Nm/ft lb r/min kg lb mm mm

ETP DS9
DS9-100-13S ½” 40-100 29-73 715 3.8 8.5 412 29 8433 0765 39
DS9-100-13SSW ½” 40-100 29-73 3.9 8.7 412 29 8433 0765 41
DS9-150-13S ½” 60-150 44-110 455 3.8 8.5 412 29 8433 0765 58
DS9-200-13S ½” 80-200 58-146 330 3.8 8.5 412 29 8433 0766 05
DS9-200-13S ½” 80-200 58-146 330 3.8 8.5 412 29 8433 0766 12
DS9-270-20S ¾” 108-270 131-328 225 5.8 12.9 466 36 8433 0766 49
DS9-270-20SSW ¾” 108-270 131-328 225 5.9 13.1 466 36 8433 0766 54
DS9-450-20S ¾” 180-450 131-328 125 7.4 16.5 502 36 8433 0767 52
DS9-450-20SSW ¾” 180-450 131-328 125 7.5 16.7 502 36 8433 0767 61
DS9-600-20S ¾” 240-600 175-438 110 7.4 16.5 502 36 8433 0768 08
DS9-600-20SSW ¾” 240-600 175-438 110 7.5 16.7 502 36 8433 0768 20
DS9-1000-25S 1” 400-1000 292-730 70 12.0 27 630 52 8433 0768 66
DS9-2000-25S 1” 800-2000 584-1460 40 22 48.9 630 68 8433 0769 20

ETD DS9
DS9-100-13S ½” 40-100 29-73 15 3.0 6.7 536 32 8433 0756 42
DS9-100-13ST ½” 40-100 29-73 715 3.2 7.1 575 32 8433 0756 92
DS9-150-13S ½” 60-150 44-110 455 3.2 7.1 536 32 8433 0757 54
DS9-150-13ST ½” 60-150 44-110 455 3.4 7.6 575 32 8433 0758 03
DS9-200-13S ½” 80-200 58-146 330 3.2 7.1 536 32 8433 0758 71
DS9-200-13ST ½” 80-200 58-146 330 3.4 7.6 575 32 8433 0759 11
DS9-270-20ST ¾” 108-270 79-197 225 6.0 13.4 660 36 8433 0760 55
DS9-450-20ST ¾” 180-450 131-328 125 7.6 17 695 36 8433 0760 88
DS9-450-20SSW ¾” 180-450 131-328 125 7.8 17.4 695 36 8433 0760 94
DS9-600-20ST ¾” 240-600 175-438 110 7.6 17 695 36 8433 0761 35
DS9-600-20SSW ¾” 240-600 175-438 110 7.8 17.4 695 36 8433 0761 59
DS9-1000-25ST 1” 400-1000 292-730 70 12.5 28 826 52 8433 0763 63

Drive units
D302 / D303-S4 8433 0820 48
D312 / D313-S4 8433 0820 33
D302 / D303-S7 8433 0822 48
D312 / D313-S7 8433 0822 33
D302 / D303-S9 8433 0824 48
D312 / D313-S9 8433 0824 33

156
 Part list

9.5 Tensor DL, Tool List

Inline tools
Model Square Torque Speed Weight Lengh CS dist Ordering No.
drive
in Nm/ft lb r/min kg lb mm mm

Lever start
ETD DL21-04-I061,2 - 4 0,9 - 3 1 600 0,6 1,3 236 16,5 8433 4014 25
ETD DL21-07-I062,2 - 7 1,6 - 5,2 970 0,6 1,3 236 16,5 8433 4017 31
ETD DL21-10-I06 3 - 10 2,2 - 7,4 720 0,6 1,3 236 16,5 8433 4019 10
All models:
- Are reversible
- Female hexagon drive for bits: 1/4"
- Have quick change chuck

Right angle tools

Model Square Torque Speed Weight Lengh CS dist Ordering No.
drive
in Nm/ft lb r/min kg lb mm mm

Lever start
ETV DL21-04-I06 1,2 - 4 0,9 - 3 1 600 0,6 1,3 tbd 18,5 (?) 8433 4004 47
ETV DL21-04-I06-QC1,2 - 4 0,9 - 3 1 600 0,6 1,3 tbd 18,5 (?) 8433 4004 73
ETV DL21-04-10 1,2 - 4 0,9 - 3 1 600 0,6 1,3 tbd 18,5 (?) 8433 4004 91
ETV DL21-07-I06 2,2 - 7 1,6 - 5,2 970 0,6 1,3 tbd 18,5 (?) 8433 4007 66
ETV DL21-07-I06-QC2,2 - 7 1,6 - 5,2 970 0,6 1,3 tbd 18,5 (?) 8433 4007 79
ETV DL21-07-10 2,2 - 7 1,6 - 5,2 970 0,6 1,3 tbd 18,5 (?) 8433 4007 94
ETV DL21-10-I06 3 - 10 2,2 - 7,4 720 0,6 1,3 tbd 18,5 (?) 8433 4009 34
ETV DL21-10-I06-QC3 - 10 2,2 - 7,4 720 0,6 1,3 tbd 18,5 (?) 8433 4009 61
ETV DL21-10-10 3 - 10 2,2 - 7,4 720 0,6 1,3 tbd 18,5 (?) 8433 4009 77

Tool cables
Model Ordering No.
3 meter 4220 2604 03
5 meter 4220 2604 05
10 meter 4220 2604 10
15 meter 4220 2604 15
Drive units
Model Ordering No.
Basic DL – D303 8433 4850 48
Advanced DL – D313 8433 4850 33

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 Technical Specifications

10. Technical Specifications

10.1 DS Drive

Enclosure
The Drive is enclosed in a steel box. The drive consists of two parts, back
panel and drive. The connectors are located on the backside of the drive and
display/buttons/power switch on the front part.

Over all dimensions

Width 174 mm
Height 399 mm
Depth 321 mm

Weight DS4/DS7 9.7 kg

DS9 10.2 kg

Input voltage 100-120, 200-240 VAC, 50 -60 Hz

GFI ∆I max 30 mA
Ground Fault Interrupter

Operating conditions
Temperature 0 to +50°C, 32 to 122°)
Humidity 5 to 95% non -condensing

Power consumption
Stand by Normal 20 W, Max 100 W
During Tightening DS4 < 0.8 kW
DS7 < 1.1kW
DS9 < 2kW
Continuously ≈200W

Connectors
24 VDC supply Max current 800 mA isolated
Inputs 17-50 VDC
5 mA at 24 VDC
Relays Max 50 V DC/AC
Min switching load 1 mA
500 mA max capacity resistive load

158
 Technical Specifications

10.2 DL Drive

Enclosure
The DL Drive is enclosed in a steel box. The drive consists of two parts, back panel and drive. The
connectors are located on the backside of the drive and display/buttons/power switch on the front
part.
Over all dimensions
Width 340 mm
Height 225 mm
Depth 116 mm

Weight 6kg

Input voltage 100-120, 200-240 VAC, 50 -60 Hz

Main fuse 5X20 mm – Slow blow 6.3A

Operating conditions
Temperature 0 to +50°C, 32 to 122°)
Humidity 5 to 95% non -condensing

Power consumption
Stand by Normal 80 W, Max 150 W
During Tightening DS2 < 250W

Continuously ≈80W

Connectors
24 VDC supply Max current 800 mA isolated
Inputs 17-50 VDC
5 mA at 24 VDC
Relays Max 50 V DC/AC
Min switching load 1 mA
500 mA max capacity resistive load

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Technical Specifications

10.3 Tools Talk DS/DL

The following concerns the equipment you need to run ToolsTalk DS/DL and to communicate
with the DL Drive. The equipment needed, besides the Drive, is a Computer and a cable.
ToolsTalk DS/DL runs on an IBM compatible PC or a Lap Top under Windows 95, 98, 2000 or
NT. For example 32 bit Windows which includes Windows 95 and Windows NT but not Windows
3.X.
To install ToolsTalk DS/DL the PC has to have a diskette or CD drive.
A serial RS 232 COM port to communicate with the Drive.
The best is if you have a Super VGA screen. It will work fine with only a VGA screen also, but
then you might need to adjust the size of the ToolsTalk DS/DL application windows manually.
You need to have at least 25 MB free disk space on your PC to install and run ToolsTalk DS/DL.
The PC has to have a RAM of at least 8 Mb.
It is not necessary to have a mouse to run ToolsTalk DS/DL.

Cable
The cable between the PC and the Drive is a standard Zero Modem computer cable, see below.
The cable has part no. 4222 0255 xx or 4222 0546 xx. xx is the length in meters.
On the Drive side it should have a 9 pin DSub male and on the PC side whatever fits in the serial
RS 232 COM port on your computer. Normally 9 pin DSub female.

PC Drive
1 not used 1
RXD 2 2 RXD
TXD 3 3 TXD
4 not used 4
GN 5 5 GN
6 not used 6
7 not used 7
8 not used 8
9 not used 9

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 Abbreviations

11. Abbreviations
CAN Controller Area Network
CCW Counter-clockwise
CW Clockwise
Digin Digital input
GFI Ground Fault Interrupter
HW Hardware, (data)
I/O (Digital) inputs/outputs
IR Infra red light
n x OK Number OK. Number of tightenings in an operation is completed
NOK Not OK, result not approved.
PLC Programmable Logic Controller
Pset Parameter set
PVT Prevailing torque
Qprog Quick programming, fast way of programming
RS232 Field bus, serial communications link
RE-Alarm A portable device to give signals for OK, NOK and nxOK
SW Software, (data) programs, etc
TTDS/DL Tools Talk DS / DL
VAC Volt Alternative Current
VDC Volt Direct Current

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