Kolver K-DUCER Manuale utente

KDU1 / KDU1A

Torque range: 0.1 - 70 Nm

OPERATOR

MANUAL

Vers. 062721 2

IDENTIFICATION DATA OF THE MANUFACTURER

KOLVER S.r.l.

VIA M. CORNER, 19/21

36016 THIENE (VI) ITALIA

IDENTIFICATION DATA OF THE PRODUCT

MODEL:

KDU-1

KDU-1A

CODE:

035001

035001/A

TECHNICAL DATA OF THE PRODUCT

FUSE: 3,15 A

DIMENSIONS: 190 x 205 x h120 mm WEIGHT: 2,5 Kg

POWER SUPPLY: 90÷260 V AC 50÷60 Hz

TENSION: 40V DC

POWER: 600W

DECLARATION OF CONFORMITY

KOLVER S.r.l. declares that the new tool here described: control units model KDU-1, KDU-

1A are in conformity with the following standards and other normative documents:

2006/42/CE, LVD 2014/35/UE, EMCD 2014/30/UE, EN 62841-2-2:2014, EN 62841-1: 2015, EN

60204-1, EN 61000-6-2, EN 61000-6-4.

It is also in conformity with III normative (2011/65/UE and following 2015/863).

Name: Giovanni Colasante

Position: General Manager

Person authorized to compile the technical file in Kolver

Thiene, January 1st 2021 Giovanni Colasante

 
 
Vers. 062721 3
Table of Contents 
INTRODUCTION ...............................................................................................................................5
MODELS...............................................................................................................................................5
INSTALLATION .................................................................................................................................7
Installation of KDU unit.................................................................................................................7
Connectors .......................................................................................................................................8
Installation of KDS screwdriver....................................................................................................9
Installation of reaction arm......................................................................................................10 
QUICK START...................................................................................................................................13 
TERMINOLOGY ...............................................................................................................................16 
OPERATING THE KDS SCREWDRIVER .....................................................................................18 
OPERATING THE K-DUCER CONTROL UNIT.........................................................................20 
Main Screen – Program Mode.....................................................................................................20 
Main Screen – Program Mode – navigation tree ......................................................................22 
Main Screen – Sequence Mode....................................................................................................23 
Main Screen – Sequence Mode – navigation tree .....................................................................25 
Retrieving and storing the screwdriving results......................................................................26 
Connecting a barcode scanner ....................................................................................................28 
Connecting Kolver accessories SWBX88, CBS880 ....................................................................28 
CONFIGURING THE K-DUCER ...................................................................................................30 
MAIN MENU ................................................................................................................................30 
PROGRAMS menu .......................................................................................................................31 
PROGRAMS menu tree............................................................................................................32 
TORQUE & ANGLE menu ......................................................................................................35 
RAMP & TIME menu ...............................................................................................................37 
REV & PRE-REV menu ............................................................................................................39 
OTHER menu ............................................................................................................................40 
SEQUENCE SETTINGS menu ....................................................................................................43 
SEQUENCE SETTINGS menu tree.........................................................................................44 
CURRENT SEQ. menu .............................................................................................................45 
GENERAL SETTINGS menu.......................................................................................................47 
USB menu.......................................................................................................................................51 
USB menu tree...........................................................................................................................53 

 
 
Vers. 062721 4
K-EXPAND software ....................................................................................................................54 
Interface Selection .....................................................................................................................54 
Screwdriver................................................................................................................................55 
Settings .......................................................................................................................................55 
General Settings.........................................................................................................................56 
Sequence Settings......................................................................................................................57 
Programs ....................................................................................................................................58 
Actions........................................................................................................................................60 
REMOTE CONTROL INTERFACES..............................................................................................64 
24V I/O............................................................................................................................................64 
Introduction ...............................................................................................................................64 
Pinout (CN3)..............................................................................................................................65 
Wiring diagrams........................................................................................................................69 
Binary tables for sequence and program selection ..............................................................71 
MODBUS TCP ...............................................................................................................................73 
Introduction ...............................................................................................................................73 
Usage...........................................................................................................................................73 
K-DUCER MODBUS map........................................................................................................74 
MODBUS TCP code examples and literature .......................................................................75 
OPEN PROTOCOL.......................................................................................................................76 
Introduction ...............................................................................................................................76 
Terminology...............................................................................................................................76 
Supported MIDs........................................................................................................................76 
MAINTENANCE AND CARE........................................................................................................78 
INTRODUCTION .........................................................................................................................78 
CALIBRATION..............................................................................................................................78 
MAINTENANCE..........................................................................................................................79 
EXPLODED VIEWS AND SPARE PARTS.....................................................................................80 
GUARANTEE....................................................................................................................................82 
 
 

Vers. 062721 5

INTRODUCTION

K-DUCER is the new class A intelligent transducerized assembly system from Kolver.

Thanks to a sophisticated control system, the electronic circuit communicates with KDS

series screwdriver equipped with integrated torque/angle transducer and allows to stop the

screwdriver instantly when reaching the preset torque or angle.

The AC 90÷260V - 50÷60Hz power supply is converted into 40VDC required by the KDS

series screwdrivers through a switching board.

IMPORTANT: K-DUCER is a highly accurate unit but it is critically important to select the

appropriate settings to ensure that the desired and proper torque is being applied and that

the screwdriver motor works efficiently. Read the menu description carefully and if unsure

please contact Kolver for support.

MODELS

K-DUCER power supply and control units are available in two versions:

Code

Model

Features

035001

KDU-1

035001/A

KDU-1A

as KDU-1 + RJ45 connector, provoding

Modbus TCP (server) communication

protocol and Open Protocol v1.6rev3

K-DUCER units are compatible with any of the KDS electric screwdrivers with transducer,

available in straight, pistol and fixture configuration.

Code

Model

Torque

(Nm)

Speed (rpm)

Min

Max

175015

KDS-MT1.5

0,1-1,5

850

175015/ESD

KDS-MT1.5/ESD

0,1-1,5

850

175016/ESD

KDS-MT1.5P

0,1-1,5

850

175016/U/ESD

KDS-MT1.5P/U

0,1-1,5

850

175115

KDS-MT1.5CA

0,1-1,5

850

175115/FN

KDS-MT1.5CA/FN

0,1-1,5

850

175015/A

KDS-MT1.5ANG

0,1-1,5

850

135006

KDS-PL6

0,5-6

850

135006/ESD

KDS-PL6

0,5-6

850

Vers. 062721 6

135007/ESD

KDS-PL6P

0,5-6

850

135007/U/ESD

KDS-PL6P/U

0,5-6

850

135106

KDS-PL6CA

0,5-6

850

135106/FN

KDS-PL6CA/FN

0,5-6

850

135006/A/ESD

KDS-PL6ANG

0,5-5,5

850

135010

KDS-PL10

0,8-10

600

135010/ESD

KDS-PL10

0,8-10

600

135011/ESD

KDS-PL10P

0,8-10

600

135011/U/ESD

KDS-PL10P/U

0,8-10

600

135110

KDS-PL10CA

0,8-10

600

135110/FN

KDS-PL10CA/FN

0,8-10

600

135010/A/ESD

KDS-PL10ANG

0,8-9

600

135015

KDS-PL15

0,5-15

320

135015/ESD

KDS-PL15

0,5-15

320

135016/ESD

KDS-PL15P

0,5-15

320

135016/U/ESD

KDS-PL15P/U

0,5-15

320

135115

KDS-PL15CA

0,5-15

320

135115/FN

KDS-PL15CA/FN

0,5-15

320

135015/A/ESD

KDS-PL15ANG

0,5-12

320

135020

KDS-PL20

2-20

210

135120

KDS-PL20CA

2-20

210

135120/FN

KDS-PL20CA/FN

2-20

210

135030/ANG

KDS-PL30ANG

3-30

140

135035

KDS-PL35

3-35

140

135135

KDS-PL35CA

3-35

140

135135/FN

KDS-PL35CA/FN

3-35

140

135045/ANG

KDS-PL45ANG

4-45

135050

KDS-PL50

5-50

135150

KDS-PL50CA

5-50

135150/FN

KDS-PL50CA/FN

5-50

135070/ANG

KDS-PL70ANG

7-70

Vers. 062721 7

INSTALLATION

Installation of KDU unit

The K-DUCER is supplied with the following mounting bracket (all dimensions reported in

mm):

Vers. 062721 8

The bracket should be fixed to the four provided 8mm depth female threads on the back

panel using the provided M4x8 screws.

Also available separately:

•table stand (part number 010400)

•vertically and horizontally adjustable bracket (part number 010401).

Connectors

Vers. 062721 9

TOOL connector

To connect a KDS series screwdriver. Take care to respect the alignment tabs on the

connector. See “Installation of KDS screwdriver” section for instructions on connecting the

screwdriver.

CN1 connector

Reserved for servicing the unit and upgrading the firmware.

CN2 male serial connector

To connect with a compatible barcode scanner, such as Kolver Barcode P/N 020050, serial

printers such as Kolver PRNTR1, or serial terminals (PC/PLCs).

CN4 female serial connector

To connect with Kolver accessories SWBX88/CBX880, serial printers such as Kolver

PRNTR1, or serial terminals (PC/PLCs).

CN3 I/O connector

To connect with 24V I/O functionality such as PLCs, pedals/buttons, LEDS, etc. Refer to

REMOTE CONTROL INTERFACES chapter.

CN5 ethernet connector RJ45

To connect using MODBUS TCP, Open Protocol, or K-Expand on any compatible device or

software (PLCs, PCs, etc). Refer to REMOTE CONTROL INTERFACES chapter.

USB mini B

To connect using K-Expand software. Refer to K-EXPAND software chapter.

USB A

Plug in a FAT32 formatted flash drive to automatically save screwdriving results and backup

all settings. Refer to the “Retrieving and storing the screwdriving results” and “USB menu”

sections.

Installation of KDS screwdriver

Cable connection and part numbers

The KDS screwdriver series require one of the following cables:

-2.5m male/female cable (code 250064)

-2.5m male/female cable with strain relief (code 250064/H)

-5.0m male/female cable (code 250564)

-5.0m male/female cable with strain relief (code 250564/H)

Vers. 062721 10

To connect the screwdriver to the unit:

1. insert the male connector into the appropriate TOOL connector on the bottom of the

unit, taking care to respect the alignment tabs. Push the connector into its position

and turn the OPEN/CLOSE nut clockwise until it clicks*

2. insert the female connector into the appropriate connector at the top of the

screwdriver, taking care to respect the alignment tabs. Push the connector into its

position and turn the OPEN/CLOSE nut clockwise until it clicks*

To disconnect the cable:

1. push the connector in lightly towards the screwdriver or the unit

2. turn the OPEN/CLOSE nut counterclockwise*

3. pull the connector out

*note: some models use a threaded nut instead of an OPEN/CLOSE nut. In this case, tighten

the nut all the way until it stops, without overtightening with excessive force.

Installation of reaction arm

Note: a reaction arm is ALWAYS required for KDS screwdrivers size 20Nm and above.

Kolver recommends always using a reaction arm for operator comfort, especially for

applications with torques above 5 Nm.

Fix the reaction arm to the indicated areas only.

KDS series screwdrivers sizes 15Nm and below have two positions designed for connecting

to the reaction arm:

1. The naked metal cylinder near the head of the screwdriver

2. The reinforced plastic section at the very top of the screwdriver (not present on the

pistol-shaped version)

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