Bosch Rexroth Nexo Manual Download Page 3 | Manualshive

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Bosch Rexroth AG

| Tightening Technology

Nexo cordless Wi-Fi nutrunner

| 3 608 870 A47/2019-10

Title

Nexo cordless Wi-Fi nutrunner by Rexroth

Type of Documentation

Project planning

Document Typecode

DOK-NEXO-DOKU_V1.400-EN

Internal File Reference

3 608 870 A47_EN

Purpose of Documentation

This documentation describes the

Nexo cordless Wi-Fi nutrunner by Rexroth

.

Copyright

©

Bosch Rexroth AG, 2019

Copying this document, giving it to others and the use or communication of the contents thereof
without express authority, are forbidden. Offenders are liable for the payment of damages. All rights
are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN
34-1).

Validity

The specified data is for product description purposes only and may not be deemed to be guaran-
teed properties unless expressly confirmed in the contract. All rights are reserved with respect to
the content of this documentation and the availability of the products.

Published by

Bosch Rexroth AG

Postfach 1161
D-71534 Murrhardt, Germany

Fornsbacher Str. 92
D-71540 Murrhardt, Germany

Phone: +49 (0)71 92 22 208
Fax: +49 (0)71 92 22 181

www.boschrexroth.com

Note

Translation of the original documentation. This documentation is available as a PDF file.

Record of Revision

Version

Status

Comments

3 608 870 A47_AA/EN

07/2013

Edition for the Nexo cordless Wi-Fi nutrunner by Rexroth
and firmware V1000

3 608 870 A47_AB/EN

10/2013

Edition for the Nexo cordless Wi-Fi nutrunner by Rexroth
and firmware V1000
Editorial revision

3 608 870 A47_AC/EN

02/2015

Edition for the Nexo cordless Wi-Fi nutrunner by Rexroth
and firmware V1100

3 608 870 A47_AD/EN

11/2015

Edition for the Nexo cordless Wi-Fi nutrunner by Rexroth
and firmware V1200

3 608 870 A47_AE/EN

05/2017

Edition for the Nexo cordless Wi-Fi nutrunner by Rexroth
and firmware V1300

3 608 870 A47_AF/EN

09/2019

Version for the Nexo cordless Wi-Fi nutrunner by Rexroth
and firmware V1400

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Summary of Contents for Rexroth Nexo

Page 1: ...Nexo cordless Wi Fi nutrunner by Rexroth Version AF EN Project planning 3 608 870 A47 10 2019 Replace this image space with your product image ...

Page 2: ...n judgment and verification Our products are subject to a natural process of wear and aging This document as well as the data specifications and other information set forth in it are the exclusive property of Bosch Rexroth AG It may not be reproduced or given to third parties without its consent The title page shows an exemplary configuration The supplied product may therefore vary from the illust...

Page 3: ... rights are reserved with respect to the content of this documentation and the availability of the products Published by Bosch Rexroth AG Postfach 1161 D 71534 Murrhardt Germany Fornsbacher Str 92 D 71540 Murrhardt Germany Phone 49 0 71 92 22 208 Fax 49 0 71 92 22 181 www boschrexroth com Note Translation of the original documentation This documentation is available as a PDF file Record of Revisio...

Page 4: ...4 279 Bosch Rexroth AG Tightening Technology ...

Page 5: ...ner 34 3 3 1 Result storage without radio connection 34 3 3 2 Results storage via WLAN 35 3 3 3 Control and results storage via WLAN 36 3 3 4 PLC control and result storage via WLAN 38 3 3 5 Fieldbus control and result storage via WLAN 39 3 3 6 Process Quality Manager PQM 40 4 Assembly 41 4 1 Assembly notes 42 4 2 Adjusting the angle head 43 4 3 Attaching the torque support 45 4 4 Attaching the ac...

Page 6: ...ge job 194 9 7 Tightening programs 200 9 7 1 Definition Target monitoring additional function 200 9 7 2 Programs tab structure 201 9 7 3 Steps of tightening programs 202 9 7 4 Creating a new tightening program editing an existing tightening program 202 9 8 Settings 208 9 8 1 Time date 208 9 8 2 User accounts 209 9 8 3 Tool display 211 9 8 4 Data 214 9 8 5 Configuration 232 9 8 6 Firmware 235 9 8 7...

Page 7: ...tation This chapter contains general information on the present documentation Overview of this documentation page 8 Validity of the documentation page 8 Additional documentation page 8 Representation of information page 9 ...

Page 8: ...ons representations used glossary 2 Safety instructions Safety precautions on how to avoid hazardous situations when using Rexroth tightening systems Information on the intended use of Rexroth tightening systems 3 Introduction This chapter Definitions system structure components integration in an overall system 4 Assembly Assembly options for the Nexo cordless Wi Fi nutrunner 5 Construction guidel...

Page 9: ...not complied with Precautions states how the risk can be avoided Warning symbols e g dangerous electric voltage warn of dangers and consequential damages or denote prohibitions This documentation uses the following warning symbols The safety instructions describe the following types of risk The type of risk describes the risk if the corresponding safety instruction is not observed The signal words...

Page 10: ...tes an individual step 1 2 3 Sequence Take the steps specified while following the order specified Result This symbol indicates the result of a step Example Examples are in a gray field and illustrate the previously stated information A tip provides additional information that is not decisive for working with the tightening system but is important and useful Blue text References to other sections ...

Page 11: ...ing memory The oldest data will be overwritten with the latest data if more storage space is required Tightening process The tightening process describes the entire tightening procedure including the various individually parameterized tightening program steps such as finding driving in tightening etc until the target function is reached torque angle etc Tightening application Within a tightening a...

Page 12: ...ated Angle correction The angle correction is an additional parameter to measure the angle of turn Since the angle of turn is never measured directly on a bolt but above the output drive there is a small deviation between the measured angle and the angle on the bolt as a result of the torsion of the output drive due to the torque This deviation can be avoided with an angle correction at the end of...

Page 13: ...sed in this documentation Table 1 3 Abbreviations for the components of the Nexo cordless Wi Fi nutrunner Abbreviation Explanation DIN German Institute for Standardization EMC Electromagnetic Compatibility EN European standard HMI Human machine interface ISO International Organization for Standardization IP International Protection PLC Programmable logic controller ...

Page 14: ...14 279 Bosch Rexroth AG Tightening Technology 3 608 870 A47 Nexo cordless Wi Fi nutrunner 3 608 870 A47 2019 10 ...

Page 15: ... information that is necessary for the safe use of the Rexroth tightening system About this chapter page 16 General power tools safety warnings page 16 Work area safety page 16 Electrical safety page 17 Personal safety page 17 Power tool use and care page 18 Battery tool use and care page 18 Service page 19 Safety Instructions for nutrunners page 19 Intended use page 16 Improper use page 16 Person...

Page 16: ... are not complied with Read this documentation thoroughly and completely before commissioning and working with the product Follow all safety instructions referring to transport storage assembly commissioning and operation Keep this documentation in a location where it is accessible to all users at all times Always include the required documentation when you pass the product on to third parties 2 2...

Page 17: ... Nexo cordless Wi Fi nutrunner 3 608 870 A47 2019 10 2 4 Electrical safety 2 5 Personal safety M M M 3 M F G C C M 8 8 8 E E 3 M 8 M 8 8 t C 6 8 8 F 3G M t 3 4 M 8 M 3 M 8 C C C E E 7 E M M F C C p E B M 8 M E E M M E C E E 3 3 M 3 M M M E C 8 M p 3 M E M s M E ...

Page 18: ... 608 870 A47 2019 10 2 6 Power tool use and care 2 7 Battery tool use and care 3 7 M 3 E C 3 B M 8 8 M 8 8 E C E 4 F M 8 M M O 8 E E E C F E C E 7 8 8 C M8 E M M E E C E E 7 M M M E E C E E 6 M 8 M 8 8 8 M 8 8 8 E C C E 7 8 E M MP M 8 E M 8 M C E C E M C E C C E C E 3 M C C E 3 M t C C C E E ...

Page 19: ...the product documentation Only use apower tool ifthisuseisexpresslyspecifiedandpermitted in thedocumentation of the product If unsuitable electric tools are installed or used in safety relevant applications unintended operating states may occur in the application that may cause personal injuries and or damage to property WARNING M M E M E C M E E C E C M 8 sawing grinding drilling and other simila...

Page 20: ...vidual live cell modules of voltage class up to 800 V This electric tool is not suitable for tightening processes requiring stepwise tightening of the connection elements e g impact wrenches Never use this electric tool as a lever or hammer This electric tool is not suitable as a drill The electric tool is intended for industrial use and not for private use The electric tool may be commissioned on...

Page 21: ...isks caused by programming and configuring the tightening system 2 12 Personnel qualifications Assembly commissioning maintenance troubleshooting and disassembly of this Rexroth product and the handling of the product require basic electrical and mechanical knowledge as well as knowledge of the software and the appropriate technical terms In order to ensure the safe use the specified activities ma...

Page 22: ...ctions may cause electric shock fire and or serious injuries CAUTION Laser radiation Laser class 2 Light emission in the visible range Looking directly into the radiation source of the barcode scanner class 2 laser with low energy diode may result in damages to the eyes retina Do not look directly into the laser beam Do not manipulate the laser source as this may result in an uncontrolled emission...

Page 23: ... initial overview of the functions and application options of the Nexo cordless Wi Fi nutrunner Nexo cordless Wi Fi nutrunner page 24 WLAN Wireless Local Area Network page 32 Connection options of the Nexo cordless Wi Fi nutrunner page 34 ...

Page 24: ...nsmission of the results to the ex isting network In case of radio shadows the data are buffered Once the connection to the network is established the data are transferred The graphical display on the nutrunner directly shows the tightening results to the user irrespective of the their position and the radio connection The Nexo cordless Wi Fi nutrunner is supplied with energy by a slide in battery...

Page 25: ... interface The MicroUSB interface is intended for use with the programming adapter NX A from Rexroth 3 1 3 Safety lock interface The Nexo cordless Wi Fi nutrunner can be secured against theft via a security lock interface You can for example use a safety lock by Kensington NOTICE Format the mass storage device only with FAT32 If the memory module is formatted differently the system will return an ...

Page 26: ...he user interface with menus and clear icons can be operated intuitively Application options for the BSNEXO OS operating system Tightening system configuration Creating tightening programs by defining the tightening processes Tightening case analysis and diagnosis e g error diagnosis Creation of jobs Setting the operating mode 3 1 5 Tool display The tool display shows various information e g regar...

Page 27: ...data connection is displayed Activate the Display data connection status check box in menu Settings Tool display As of Nexo firmware version 1300 Display data connection status is activated by default Nutrunner is in automatic mode Green symbol All active data services are connected Red symbol At least one data service is not connected Gray symbol No data service active As of Nexo firmware version...

Page 28: ...elds for program selector in center position Main menu In the NEXO OS operating system use the menu to select Settings Nutrunner display Main menu to determine which views should be selectable in the main menu on the nutrunner display see page 213 If you leave the display of the PLC signals i e if the program selector is from the center position pushed to the left and or to the right the 0 3 0 4 a...

Page 29: ...tteries Independently from their charging con dition lithium ion batteries may be charged at any time without damaging the cells Lithium properties The properties of lithium the lightest solid substance in the element system enable the design of lighter means of energy storage However lithium is highly reactive with other substances A burning lithium ion cell is a metal fire As lithium leads to a ...

Page 30: ...harged using the CC CV process This means a constant current is applied to charge the battery until the charger switches to constant voltage near the charging end voltage Both parameters charging current and charging end voltage have a considerable effect on the service life of the battery The temperature of the battery is also a crucial charging parameter Batteries can often be discharged at high...

Page 31: ...le head Reduction ratio Efficiency NXA011S 36V B 3 608 870 AG2 1 40 0 94 NXA015S 36V B 3 608 870 AG2 1 40 0 94 NXA030S 36V B 3 608 870 BU0 5 25 0 94 NXA050S 36V B 3 608 870 BV1 6 3636 0 94 NXA065S 36V B 3 608 870 BV1 6 3636 0 94 Table 3 3 Nexo max output drive speed Nexo max output drive speed V1400 min 1 max output drive speed from V1400 min 1 NXA011S 36V B 850 1030 NXA015S 36V B 600 755 NXA030S ...

Page 32: ...he required radio tech nology parameter options range and coverage It is also possible to use WLAN capable devices as access points that can be operated as hotspots such as industrial computers or laptops and are equipped with the required software e g Connectify The command prompt of Windows 7 and higher can also be used to start a hotspot using the command netshell netsh First enable the hotspot...

Page 33: ... software for Windows computers that offer these functions InSSIDer With this app a smartphone can be used as a simple WLAN measurement device It provides graphical representations of the available networks using the SSID in the range of 2 4 and 5 Ghz if sup ported by the smartphone This offers a clear overview of available stable networks and also indicates the reception quality The network condi...

Page 34: ...00 the results data can be stored in the standard Nexo format as a json file on the NX SD Micro SD card inserted in the nutrunner Using the NX A programming adapter the results data stored on the NX SD Micro SD card can be viewed The NX SD Micro SD card can also be accessed using a commercially available Micro SD card reader Settings in the NEXO OS operating system As of Nexo firmware version 1200...

Page 35: ...f the results data The data may be transmitted via WLAN using an IPC laptop or database server or via one or several external access points see figure 3 9 Settings in the NEXO OS operating system To configure the WLAN connection go to Settings WLAN page 240 As of Nexo firmware version 1200 To configure the connection FTP HTTP or File Share for results output go to Settings Data Standard Nexo page ...

Page 36: ...can be used for transmission of the results data The data may be transmitted via WLAN using an IPC laptop or database server or via one or several external access points see figure 3 10 Settings in the NEXO OS operating system To configure the WLAN connection go to Settings WLAN page 240 As of Nexo firmware version 1200 To configure the connection FTP HTTP or File Share for results output go to Se...

Page 37: ...age 240 To set the communication with VW XML go to Settings Data VW XML page 228 The PLC assignment table has to be applied as specified in chapter VW XML protocol To set the PLC assignment table go to Settings PLC signals page 236 The tag PI1 defined in the VW XML protocol can be applied as ID code in Nexo For this purpose the Selection of ID code source can be set to VW XML under mode in the sta...

Page 38: ...erver of the IPC or database server As of Nexo firmware version 1200 a HTTP or File Share server can be used for transmission of the results data The data may be transmitted via WLAN using one or several external access points see figure 3 12 Settings in the NEXO OS operating system To configure the access point go to Settings WLAN page 240 As of Nexo firmware version 1200 To configure the connect...

Page 39: ...de for communication with the Nexo cordless Wi Fi nutrunner via Rexroth Open Pro tocol The CS351 IL is equipped with two 24 V interfaces e g for the connection of socket trays If more socket trays are to be used they have to be connected directly to the PLC Furthermore the results data can be transmitted in the standard Nexo format as a json file via WLAN from the Nexo cordless Wi Fi nutrunner to ...

Page 40: ...sses and provides them in a screen on the tool display Various screens for analysis of tightening results are available to ensure quick reaction to errors in the production process If PQM is applied the HTTP connection can be used to transmit the results output data of the Nexo cordless Wi Fi nutrunner to the PQM Settings in the NEXO OS operating system As of Nexo firmware version 1200 To configur...

Page 41: ...y This chapter describes the assembly options for the Nexo cordless Wi Fi nutrunner Assembly notes page 42 Adjusting the angle head page 43 Attaching the torque support page 45 Attaching the accessories page 47 ...

Page 42: ... tightening operations with high torques the developing forces may cause injuries especially to joints see also EN 11148 and EN 1005 as currently applicable Recommendations Right angle nutrunners require the installation and use of a torque support when torques exceed 40 Nm Pistol grip nutrunners require the installation and use of a torque support when torques exceed 10 Nm Also observe country sp...

Page 43: ...d of the open end wrench Open end wrench wrench size 27 mm Fig 4 1 Loosening the angle head 1 Use open end wrench 3 to hold the hand held nutrunner at wrench face 4 of the angle head flange see figure 4 1 2 Use open end wrench 1 to loosen the union nut at wrench face 2 see figure 4 1 Fig 4 2 Adjusting the angle head and tightening the lock nut NOTICE Improper handling may cause damage Damage to th...

Page 44: ...ESWM 3608876473 Fig 4 3 Removing and adjusting the angle head 1 Clamp the mounting aid into a vise or similar 2 Mount the angle head into the mounting aid see the instruction leaflet for the mounting aid 3 Hook the hook spanner into an opening of the counter nut and rotate it in the direction of arrow A left hand thread to loosen the counter nut 3 see figure 4 3 4 Rotate the nutrunner 5 in the dir...

Page 45: ...S NXA050S and NXA065S Fig 4 5 Torque support clamping area NXA011S NXA015S Fig 4 6 Torque support clamping area NXA030S NXA050S NXA065S Torque and minimum clamping width for the torque support on right angle nutrunners Clamp the torque support to the right angle nutrunner inside the marked area making sure that it fits planar to the diameter of the nutrunner Minimum clamping width 12mm Tightening ...

Page 46: ... Technology 3 608 870 A47 Nexo cordless Wi Fi nutrunner 3 608 870 A47 2019 10 NXP Fig 4 7 Torque support clamping area Torque for the torque support on pistol grip nutrunners Fig 4 8 Clamping piece mounting position 15 19 mm A M 7 1 Nm ...

Page 47: ...4 55 0 2 Ø 9 M8 2 Ø43 H9 60 15 19 CAUTION Risk of injury Unintentional activation of the product during assembly disassembly may cause serious injuries Before working on the product put the program selector to its central position switch lock and remove the accumulator When attaching removing accessories be sure to observe the related instructions If flat output drives are to be installed observe ...

Page 48: ...48 279 Bosch Rexroth AG Tightening Technology 3 608 870 A47 Nexo cordless Wi Fi nutrunner 3 608 870 A47 2019 10 ...

Page 49: ... the extent to which they are relevant for the Nexo cordless Wi Fi nutrunner by Rexroth Additional information can be found online at www boschrexroth com tightening Design of a bolted connection page 50 Cycle times page 54 Compatibility with foreign substances page 55 Planning assistance page 55 ...

Page 50: ...tightened are pressed together compressed by fPM If operating forces act on the bolted connection the operating force FSA superimposes the mounting clamp force FM The bolt is additionally stretched by fSA while the compression on the material fPM is re duced by the amount fPA The deformed parts are relieved by the axial force fPA but the residual clamp force FKR acting on the parts remains Basics ...

Page 51: ...rs of the parts and bolts to be tightened Surface coating of bolts and components Thread form and pitch The friction consists of a combination of the thread friction and the underhead friction The actual friction itself does not make a calculation of the mounting clamp force from the tightening torque more difficult rather the distribution of the friction values from bolted connection to bolted co...

Page 52: ...on increases during tightening due to the plas tic insert in the nut 5 1 2 5 Tightening factor aA taking the tightening uncertainty into account The mounting clamp force of a bolted connection is influenced by numerous factors The spread of the friction actually occurring under the bolt head and at the thread only an assumed typical value can be used for calculation Differences depending on the se...

Page 53: ...2 31 8 36 1 40 1 43 8 50 3 55 8 12 9 33 6 32 8 32 0 31 1 30 2 28 4 26 6 31 8 37 2 42 2 46 9 51 2 58 9 65 3 M10 8 8 31 0 30 3 29 6 28 8 27 9 26 3 24 7 36 43 48 54 59 68 75 10 9 45 6 44 5 43 4 42 2 41 0 38 6 36 2 53 63 71 79 87 100 110 12 9 53 3 52 1 50 8 49 4 48 0 45 2 42 4 62 73 83 93 101 116 129 M12 8 8 45 2 44 1 43 0 41 9 40 7 38 3 35 9 63 73 84 93 102 117 130 10 9 66 3 64 8 63 2 61 5 59 8 56 3 ...

Page 54: ...ightening case determination according to VDI VDE 2647 The definition is set out in VDI VDE 2647 as follows Hard tightening case Increase in torque from 50 to 100 of the target torque within an angle of turn of 30 Soft tightening case Increase in torque from 50 to 100 of the target torque within an angle of turn of 360 The tightening case hardness is particularly relevant for selecting the speed i...

Page 55: ...th foreign substances All tightening system components from Rexroth are developed and tested in accordance with the latest state of the art As it is impossible to follow the continuous development of all the substances with which our tightening system components may come into contact e g lubricants for machine tools reactions to the materials used by us cannot be excluded in every case For this re...

Page 56: ...56 279 Bosch Rexroth AG Tightening Technology 3 608 870 A47 Nexo cordless Wi Fi nutrunner 3 608 870 A47 2019 10 ...

Page 57: ...gnals This chapter provides detailed information about the control signals of the tightening controller PLC of the Nexo cordless Wi Fi nutrunner by Rexroth PLC signals page 58 Description of all PLC signals page 58 ...

Page 58: ...Number Cancel current order ActEn Active Enable Enables a single tightening process ActScan 1 1 Supported as of Nexo firmware version 1100 Active Scanner Enables a single scan process AppIn0 15 Application In Bit 0 15 Application specific input signal Ccw Counterclockwise Loosen CcwIgnore Counter clock wise ignore Ignores the Ccw switch CwIgnore Clock wise ignore Ignores the Cw switch CcwLock Coun...

Page 59: ...y enables the scanner for a single scan process AppIn0 15 Application In Bit 0 15 Application specific input signal Application specific signals are used to make special adjustments for customer requirements Ccw Counter clock wise Loosen This signal starts the tightening program No 99 Loosen in a tightening channel The start signal must remain high while processing is in progress otherwise tighten...

Page 60: ... defined torque threshold 1 The controller then does not performs any evaluation OK NOK and results output CwLock Clock wise lock Disables the starting function This signal serves to lock the start of the selected tightening program CntRes Counter Reset Resets the counter value When this signal is set to high both counters of the OK NOK counter are reset to their programmed initial state Simultane...

Page 61: ...edgement signals correspond to the selected job The job number must be selected and acknowledged by the system before the job sequence is started ManOp Manual Operating Mode Activate manual mode This signal activates the manual mode for the nutrunner if in the start step at mode the PLC signal ManOp option has been activated under Trigger If the nutrunner changes into manual mode the signal is set...

Page 62: ... using the sequence number In order to delete the ID code after tightening has been started the Delete ID code after start option must be activated in the NEXO OS operating system in the ID input step mode WasByPass WAS Bypass Order nutrunner via PLC LisWAS is ignored With the signal WasByPass High the order nutrunner via PLC LisWAS is ignored The order is then only possible via scanner An active ...

Page 63: ...t CwLockAck Clock wise lock acknowledge Acknowledges that start is disabled CntNOK Counter NOK NOK counter has reached default value CntOK Counter OK OK counter has reached default value CyCmp Cycle Complete Process end CheckTool Check the tool Nutrunner test interval reached EnAck Enable acknowledge Acknowledges enabling EnScanAck 1 Enable scanner acknowledge Acknowledgement release scanner FtpF ...

Page 64: ...ing the controller BattOK Battery OK State of the battery pack slide in module This signal repors the state of the battery pack slide in module BattOK High The battery state is okay As soon as the battery charge condition does not allow tightening any longer or if the battery is defective the signal changes to low BattOff Battery Off Battery pack slide in module not inserted This signal reports wh...

Page 65: ...eached with the nutrunner EnAck Enable acknowledge Acknowledges enabling This signal serves to acknowledge the release for the start of the nutrunner EnScanAck Enable scanner acknowledge Acknowledges that the scanner is enabled This signal serves to acknowledge the release of the scan process EnScanAck 1 Scan process is enabled EnScanAck 0 Scan process is disabled FtpF Ftp Fault Results transfer e...

Page 66: ... the job selection Using this signal the PLC can determine whether the job was selected successfully The job number is only valid if the acknowledgement corresponds to the selection The controller always uses the acknowledged job number as a basis for a job sequence JobCyCmp Job Cycle Complete The job is finished Job CyCmp high signals the end of a tightening operation sequence and results process...

Page 67: ...en evaluated as NOK e g as a message on the display of the nutrunner These signals are set at the end of a tightening operation they change to low when tightening is started and when the Reset result signal is set RC0 4 Rework Code Bit 0 4 Rework code bit 0 4 These five output signals are used to output the binary encoded rework code A rework code can be used to inform the user on the steps requir...

Page 68: ...button on the nutrunner This signal shows the status of the tool button on the cordless Wi Fi nutrunner Holding down the tool button keeps the signal at high releasing it changes the signal to low TorqH Torque too high Torque too high Results description after a completed tightening sequence The torque is above the defined tolerance window TorqL Torque too low Torque too low Results description af...

Page 69: ... used for data output or for data exchange with a partner controller Overview of tightening results communication page 70 Data output via FTP page 71 Data output via HTTP page 73 Data output via File Share page 74 Rexroth Open Protocol page 75 Rexroth IPM Protocol page 162 VW XML protocol page 165 BMW TPC service page 168 ...

Page 70: ...ngs on page 208 7 1 1 Identification code ID code The results data record of a tightening operation is uniquely identified by an identification code ID code for internal or external further processing and can therefore be assigned to the tightened component The ID code can comprise up to 100 ASCII characters e g parts of a workpiece number production number serial number chassis number or the like...

Page 71: ... RFC 959 File Transfer Protocol As of Nexo firmware version 1200 the data can be transmitted with SSL encoding For configuration of the filing process and contents of the results file various parameters are available 7 2 1 Opening and closing the FTP connections for results output Opening and closing the FTP connections is initiated by the tightening system The results data are always transferred ...

Page 72: ...points configured in the tightening program Value range of graph parameters Number of tightening steps Number of active target and monitoring functions of the particular step The biggest data volume is required saving the graph points The following coarse guide value applies At least 10 bytes are required for each graph point A maximum of 2000 graph points therefore results in 10 bytes x 2000 grap...

Page 73: ...he server is not maintained For transmission of additional results the tightening controller establishes a new connection Fig 7 1 Results data transfer via HTTP As of Nexo firmware version 1200 data output via HTTP is supported The settings for data output are made via the NEXO OS operating system in the Settings Data Standard Nexo HTTP menu see section Settings on page 208 Tightening controller R...

Page 74: ...ts data transfer via File Share Access to the File Share server is protected by the group ID and user ID As of Nexo firmware version 1200 data output via File Share is supported The settings for data output are made via the NEXO OS operating system in the Settings Data Standard Nexo File Share menu see section Settings on page 208 Tightening controller Results data record in configured Standard Ne...

Page 75: ...get information on events in the tightening controller via the client Example of a communication sequence The settings for the protocol are made via the NEXO OS operating system in the Settings Data Open Protocol menu see section Settings on page 208 Client connects to the tightening controller via MID 0001 Tightening controller sends an MID 0002 acknowledgement Tightening controller resets the ke...

Page 76: ...ID0061 Result ID 400 2 Result ID 401 3 Result ID 402 TCP connection establishment via port 4545 TCP connection establishment accepted MID 0001 MID 0042 MID 0064 Result ID 0 MID 0065 Result ID 402 MID 0065 Result ID 401 MID 0064 Result ID 401 Loss of radio communication Get last result Get result delta TCP connection establishment accepted Re establishing radio commu nication Tightening process is ...

Page 77: ...uperordinate system OP communication partner Scanner reads barcode Send barcode to OP communication partner Generate ID code Send ID code to nutrunner Echo ID code for confirmation Identify echo as new code and generate new ID code Send ID code to nutrunner Echo ID code for confirmation Identify echo as new code and generate new ID code ...

Page 78: ...tem KW ĐŽŵŵƵŶŝĐĂƟŽŶ ƉĂƌƚŶĞƌͿ MID 0005 MID 0504 MID 0005 MID 0501 MID 0150 MID 0005 ID code generation MID 0501 Job is selected and processed ƵďƐĐƌŝƉƟŽŶ ƚŽ ĐŚĂŶŐĞ ŝŶ ƚŚĞ W ŽƵƚƉƵƚ ƐŝŐŶĂůƐ Ŷ ĐĂƐĞ ŽĨ ĐŚĂŶŐĞ ŝŶ ƚŚĞ W ŽƵƚƉƵƚ ƐŝŐŶĂůƐ ƚŚĞ KW ĐŽŵŵƵŶŝĐĂƟŽŶ ƉĂƌƚŶĞƌ ŝƐ ŝŶĨŽƌŵĞĚ dŚĞ Žď ZĞƐĞƚ ZĞƐƵůƚ W ŽƵƚƉƵƚ ƐŝŐŶĂů ŝƐ ƐĞƚ W ŽƵƚƉƵƚ ƐŝŐŶĂů Žď Ǉ ŵƉ с Žǁ Send ID code to nutrunner Žď ĮŶŝƐŚĞĚ W ŽƵƚƉƵƚ ƐŝŐŶĂů Žď Ǉ ŵƉ ...

Page 79: ... Zählersatz wird nicht zurückgesetzt 1s Send keep alive confirmation Keep alive message received Send keep alive message Keep alive confirmation received Reset the counter value Reset the counter value 1s Message is missing Send keep alive confirmation Keep alive message received Send keep alive message Keep alive confirmation received Reset the counter value Reset the counter value Keep alive tim...

Page 80: ...tes Value 0057 MID message ID Describes how the sent message should be interpreted Each message ID is assigned to a specific message Value range 0000 9999 Example 4 Value 0002 Message Acknowledgement of communication start Revision Is required if different versions are available for the same MID Value range 000 999 Example 3 Revision 1 Value 001 No ack flag Only for subscription MIDs Presetting 0 ...

Page 81: ...2 Cell value 0001 0000 9999 4 Channel ID 02 2 Channel value 01 00 99 2 Tightening system ID 03 2 Tightening system name Controller 1 25 Value 010001020103Scontroller1 Data length 37 Table 7 3 Message structure in the Open Protocol data Numbers Data Bytes Example Cell ID value 1 Value 0001 4 Channel ID value 1 Value 01 2 Table 7 4 Message structure in the Open Protocol data ASCII characters Data By...

Page 82: ...70 A47 2019 10 Example The message in the above example would look as follows Header Data End characters 0057 0002 001 1 00000000 01 0001 02 01 03 controller1 NUL Name tightening system Tightening system ID Value channel Channel ID Value cell Cell ID Reserve No Ack Flag Revision MID Message length ...

Page 83: ...er x x MID 0021 Deactivating all OK NOK counters x MID 0030 OK counter upload request x MID 0031 OK counter upload response x MID 00324 Job data upload request x MID 00334 Job data upload response x MID 00344 Job info subscription x MID 00354 Upload job info x MID 00364 Upload job info acknowledgement x MID 00374 Cancel job info subscription x MID 00384 Select job number x MID 0040 Tool data uploa...

Page 84: ...Disable setting request x x MID 04112 AutoDisable setting response x x MID 0500 Subscription Output signal change x MID 0501 Upload Output signal change x MID 0502 Acknowledgement Upload output signal change x MID 0503 Cancel Output signal change x MID 0504 Change value of input signals x MID 05701 Activate job x MID 05711 Start job sequence x MID 05731 Select job number x MID 08001 Battery level ...

Page 85: ... message contains basic information on the tightening controller that has accepted the connection cell ID channel ID controller name Note Revision 001 002 003 Data field Data 37 bytes revision 001 42 bytes revision 002 105 bytes revision 003 Possible response none Table 7 7 MID 0002 revision 001 Parameter Comments Bytes Cell ID This is where the 7th level of the location name is returned The value...

Page 86: ... 9 MID 002 revision 003 Parameter Comments Bytes This revision includes the information from revision 002 and the following additional information Open Protocol version The Open Protocol version is transferred The value consists of 19 ASCII characters ID 05 2 Value range 0x20 0x7F Presetting Example Open Protocol version 7 0 version 34 Value 7 0 version 34 19 Software version The version transferr...

Page 87: ...Sent by superordinate computer Ends the command connection Note After this command has been received the tightening controller will only respond to the communication start command MID 0001 Revision 001 Data field is empty 0 bytes Possible response MID Error no Comment Command accepted 0005 Sent by Tightening controller The tightening controller uses this message if a request cannot be fulfilled fo...

Page 88: ...sion 1 Parameter Comments Bytes MID MID of the accepted request ID Value range 0000 9999 Presetting Example MID 18 Value 0018 4 Data length revision 001 4 Sent by superordinate computer Request for all available tightening program numbers Note Revision 001 Data field is empty 0 bytes Possible response MID Error no Comment Tightening program numbers upload response 0011 All valid tightening program...

Page 89: ...lue consists of three ASCII characters ID Value range 000 999 Presetting Example Tightening program number 2 Value 002 3 Data length revision 001 with one tightening program 6 Data field value 002005006 Sent by superordinate computer Request to upload the parameters from the last tightening step in a tightening program Note Revision 001 Data field Tightening program number 3 bytes Possible respons...

Page 90: ...ame prog1 Value prog1 25 Direction of rotation 1 Clockwise CW 2 Counterclockwise CCW The value consists of one ASCII character ID 03 2 Value range 0 9 Presetting Example Direction of rotation Clockwise CW Value 1 1 Placeholder value The value consists of two ASCII characters ID 04 2 Fixed value 00 2 Minimum torque The minimum torque limit is multiplied by 100 rounded and sent as a whole number The...

Page 91: ...e 45 Value 00045 5 Target angle The target angle is output in degrees The value consists of five ASCII characters ID 10 2 Value range 00000 99999 Presetting Example Target angle 40 Value 00040 5 Data length revision 001 84 Table 7 13 MID 0013 revision 001 Parameter Comments Bytes Sent by superordinate computer A message tightening program selected MID 0015 is sent to the superior computer each tim...

Page 92: ...le response MID Error no Comment Tightening program selected acknowledgement 0016 Table 7 14 MID 0015 revision 001 Parameter Comments Bytes Tightening program number The value consists of three ASCII characters ID Value range 000 999 Presetting Example Tightening program number 2 Value 002 3 Date of the last change Date output in the format YYYY MM DD HH MM SS The value consists of 19 ASCII charac...

Page 93: ...selected Sent by superordinate computer This message sets the presetting for the OK counter and the NOK counter of the Automatic operating mode parameter OK counter limit for the counter value specified in the command Tightening program number parameter Note Revision 001 002 Data field Data 7 bytes Possible responses MID Error no Comment Command accepted 0005 Command error 0004 01 Invalid data Tab...

Page 94: ...ogram number parameter Note If the Keep programmed counters option is enabled only the current actual values of the OK NOK counter values are reset Revision 001 Data field tightening program number three ASCII characters 000 999 3 bytes Possible responses MID Error no Comment Command accepted 0005 Command error 0004 01 04 Invalid data Tightening program not active Sent by superordinate computer Th...

Page 95: ... consists of two ASCII characters ID Value range 00 99 Presetting Example Two configured OK counters 2 Value 02 2 OK counter number The value consists of two ASCII characters ID Value range 00 99 Presetting Example Two OK counter numbers 25 36 Value 2536 4 Data length revision 001 with two configured OK counters 6 Table 7 18 MID 0031 revision 002 Parameter Comments Bytes Number of configured OK co...

Page 96: ...d Total data length 71 bytes 12 bytes x number tightening programs revision 001 73 bytes 12 bytes x number tightening programs revision 002 Possible response none Table 7 19 MID 0033 revision 001 Parameter Comments Bytes Job number Job number The value consists of two ASCII characters ID 01 2 Value range 00 99 Presetting Example Job number 01 Value 01 2 Job name The program name is output If the j...

Page 97: ...er processing Lock must be activated for all OK NOK counter values The value consists of one ASCII character ID 07 2 Fixed value 1 1 Line control Line control not supported The value consists of one ASCII character ID 08 2 Fixed value 0 1 Repeat job Repeat job not supported The value consists of one ASCII character ID 09 2 Fixed value 0 1 Loosen options 0 At least one of the loosen program lock op...

Page 98: ...acters value range 000 999 AutoValue one ASCII character value range 0 1 OKBatchSize two ASCII characters value range 00 99 ID 13 2 Value range Presetting Example List aa bbb c dd aa bbb c dd Value 01 005 0 03 12 Data length revision 001 71 N x 12 Table 7 20 MID 0033 Revision 002 Parameter Comments Bytes Job number The value consists of four ASCII characters ID 01 2 Value range 0000 9999 Presettin...

Page 99: ...me for processing the job The value consists of five ASCII characters 0000 is not supported ID 05 2 Value range 00000 99999 Value 5 Job counter value OK and NOK tightening counting procedure 0 only OK tightenings are counted 1 OK and NOK tightenings are counted If only the OK counter is assigned for all counter values a 0 is returned Otherwise 1 The value consists of one ASCII character ID 06 2 Va...

Page 100: ...ID 10 2 Value range 0 2 Presetting Example Allow loosening Release Value 0 1 Reserved Reserved not supported The value consists of one ASCII character ID 11 2 Fixed value 0 1 Tightening programs number Number of tightening programs defined in the job The value consists of two ASCII characters ID 12 2 Value range 00 99 Presetting Example Number 3 Value 03 2 List of tightening programs List of N tig...

Page 101: ...on 002 003 supported by Rexroth OP Data field Data 45 bytes revision 002 59 bytes revision 003 Possible response MID Error no Comment Upload job info acknowledgement 0036 Table 7 21 MID 0035 revision 002 Parameter Comments Bytes Job number Number of the job The value consists of four ASCII characters ID 01 2 Value range 0000 9999 Presetting Example Job number 2 Value 0002 4 Job status Defines the ...

Page 102: ...tenings in the job The job is completed when the actual value counter for OK tightenings corresponds to the number of defined OK tightenings The value consists of four ASCII characters ID 05 2 Value range 0000 9999 Presetting Example Actual value counter 4 Value 0004 4 Time stamp Date and time of the job info message The value consists of 19 ASCII characters in the format YYYY MM DD HH MM SS ID 06...

Page 103: ...lue 005 3 Number of job steps Number of steps in the job The value consists of three ASCII characters ID 08 2 Value range 001 999 Presetting Example Number of steps 25 Value 025 3 Type of job step Type of job step 1 Job step 2 ID code of the step The value consists of two ASCII characters ID 09 2 Value range 01 02 Presetting Example Job step 1 Value 01 2 Data length revision 003 data length revisi...

Page 104: ...n be used to select the job number Note In the PLC assignment table the Job n signal must be applied to the OP module Revision 001 supported by Rexroth OP Data field Possible response MID Error no Comment Command accepted 0005 Command error 0004 20 Job cannot be specified Table 7 23 MID 0038 revision 001 Parameter Comments Bytes Job number The value consists of two ASCII characters ID Value range ...

Page 105: ...E factor via MID 0041 has an effect on the quality of the tool To ensure stable tool quality a machine capability test MCT should be carried out after a change in MCE factor via MID 0041 Sent by Tightening controller Tool data transmission Note Revision 001 002 1 Data field Data 101 bytes Possible response none Table 7 25 MID 0041 revision 001 Parameter Comments Bytes Tool number Serial number The...

Page 106: ...acters is not supported ID 03 2 Value range 0 9 and Presetting Example Date of the last maintenance 1 12 2009 2 43 57 PM Value 19 Serial number The value consists of ten ASCII characters is not supported ID 04 Value range 0000000000 9999999999 Presetting Example Serial number 476547 Value 10 Data length revision 001 61 Table 7 25 MID 0041 revision 001 Parameter Comments Bytes ...

Page 107: ...S The value consists of 19 ASCII characters ID 06 2 Value range 0 9 and Presetting Example Date of the last check 1 12 2009 2 43 57 PM Value 1 12 2009 2 43 57 PM 19 Cycles since maintenance Calculated from the cycles during the last maintenance and the current number of cycles The value consists of ten ASCII characters ID 07 2 Value range 0000000000 9999999999 Presetting Example Cycles since maint...

Page 108: ...dule see section PLC signals from page 58 In the PLC assignment table the Enable signal must be applied to bit 1 0 of the OP PLC module Revision 001 Data field is empty 0 bytes Possible response MID Error no Comment Command accepted 0005 Command error 0004 98 Request timeout in the control or PLC signal not assigned in the PLC assignment table Sent by superordinate computer This command can be use...

Page 109: ...ixed value 0 1 Calibration value The value is multiplied by 1000 and transferred as a whole number rounded to 3 decimals The value consists of six ASCII characters ID 02 2 Value range 500 2000 Presetting Example Calibration value 1 345 Value 001345 6 Data length revision 001 11 Is still supported but if a new version is implemented MID 0150 should be used Sent by superordinate computer Is used by ...

Page 110: ...e Note Revision see MID 0052 Data field is empty 0 bytes Possible responses MID Error no Comment Command accepted 0005 Command error 0004 06 Activation of ID code upload already available Sent by Tightening controller Transfer the current ID code Note If the option Transmit ID codes from non selected sources as well is activated new ID codes from an ID code source e g a scanner are transferred in ...

Page 111: ...ontains the characters 26 50 of the ID code The value consists of 25 ASCII characters ID 02 2 Value range 0x20 0x7F Presetting Example ID code part 2 5432154321543215432154321 Value 5432154321543215432154321 25 ID code part 3 Contains characters 51 64 of the ID code The rest of the characters are filled with space characters The value consists of 25 ASCII characters ID 03 2 Value range 0x20 0x7F P...

Page 112: ...value consists of 4 ASCII characters ID 05 2 Value range 0001 0006 Presetting Example ID code source Scanner Value 0003 4 Data length revision 999 data length revision 002 data length revision 999 114 Sent by superordinate computer Upload ID code acknowledgement Note Revision 001 Data field is empty 0 bytes Possible response none Sent by superordinate computer Reset the subscription for the ID cod...

Page 113: ...mit the size of the MID 0061 as much as possible the parameter IDs that would usually be sent in the message have been removed Revision 001 002 003 004 005 999 Data field Data 211 bytes revision 001 365 bytes revision 002 399 bytes revision 003 480 bytes revision 004 101 bytes revision 999 Possible response MID Error no Comment Last tightening results data acknowledgement 0062 Table 7 31 MID 0061 ...

Page 114: ...ber of the selected OK NOK counter The value consists of two ASCII characters ID 05 2 Value range 01 99 Presetting Example Job number 2 Value 02 2 Tightening program number Number of the current tightening program The value consists of three ASCII characters ID 06 2 Value range 000 999 Presetting Example Tightening program number 5 Value 005 3 OK counter limit OK counter presetting The value consi...

Page 115: ...ts of one ASCII character ID 11 2 Value range 0 2 Presetting Example Angle status OK Value 1 1 Minimum torque limit T The value is multiplied by 100 and transferred as a whole number rounded to 2 decimals The value consists of six ASCII characters ID 12 2 Value range 000000 999999 Presetting Example Minimum torque limit T 12 13 Value 001213 6 Maximum torque limit T The value is multiplied by 100 a...

Page 116: ...I characters ID 15 2 Value range 000000 999999 Presetting Example Torque T 20 50 Value 002050 6 Minimum angle A The value is output in degrees The value consists of five ASCII characters ID 16 2 Value range 00000 99999 Presetting Example Minimum angle A 5 Value 00005 5 Maximum angle A The value is output in degrees The value consists of five ASCII characters ID 17 2 Value range 00000 99999 Presett...

Page 117: ...ue consists of 19 ASCII characters in the format YYYY MM DD HH MM SS ID 21 2 Value range 0 9 and Presetting Example Date time of the change 1 12 2009 2 43 57 PM Value 1 12 2009 2 43 57 PM 19 OK NOK counter status Status of the OK NOK counter 0 if not 1 or 2 1 Ch x y CntOK 1 2 OK NOK counter not used not configured The value consists of one ASCII character ID 22 2 Value range 0 2 Presetting Example...

Page 118: ...h are separated by a space The value consists of two ASCII characters ID 02 2 Value range 01 20 Presetting 01 Example Channel ID 04 tightening channel Value 04 2 Controller name The second part of the channel name is used as the controller name The value consists of 25 ASCII characters ID 03 2 Value range 0x20 0x7F Presetting Example Controller name 04 tightening channel Value Tightening channel 2...

Page 119: ...ue The value consists of five ASCII characters ID 08 2 Fixed value 00000 5 OK counter limit OK counter presetting The value consists of four ASCII characters ID 09 2 Value range 0000 9999 Presetting Example OK counter limit 12 Value 0012 4 OK counter value Actual value of the OK counter The value consists of four ASCII characters ID 10 2 Value range 0000 9999 Presetting Example OK counter value 4 ...

Page 120: ...The value consists of one ASCII character ID 14 2 Value range 0 2 Presetting Example Angle status OK Value 1 1 Total angle status Total angle status not supported The value consists of one ASCII character ID 15 2 Fixed value 1 1 Power redundancy monitoring status Power redundancy monitoring status not supported The value consists of one ASCII character ID 16 2 Fixed value 1 1 Tapping status of sel...

Page 121: ...e range 0000000000 9999999999 Presetting Example Tightening error status AngTotH Value 0000000001 10 Minimum torque limit T The value is multiplied by 100 and transferred as a whole number rounded to 2 decimals The value consists of six ASCII characters ID 21 2 Value range 000000 999999 Presetting Example Minimum torque limit T 12 00 Value 001200 6 Maximum torque limit T The value is multiplied by...

Page 122: ...es The value consists of five ASCII characters ID 26 2 Value range 00000 99999 Presetting Example Maximum angle A 45 Value 00045 5 Target angle AP The value is output in degrees The value consists of five ASCII characters ID 27 2 Value range 00000 99999 Presetting Example Target angle AP 90 Value 00090 5 Angle A The value is output in degrees The value consists of five ASCII characters ID 28 2 Val...

Page 123: ...pping Self tapping bolts Not supported The value consists of six ASCII characters ID 36 2 Fixed value 000000 6 Self tapping torque Self tapping bolts Not supported The value consists of six ASCII characters ID 37 2 Fixed value 000000 6 Minimum friction torque Friction torque of self tapping bolts is not supported The value consists of six ASCII characters ID 38 2 Fixed value 000000 6 Maximum frict...

Page 124: ...lue range 0x20 0x7F Presetting Example Serial number A36363 Value A36363 14 Time stamp Date and time of the tightening The value consists of 19 ASCII characters in the format YYYY MM DD HH MM SS ID 45 2 Value range 0 9 and Presetting Example Time stamp 1 12 2009 2 43 57 PM Value 1 12 2009 2 43 57 PM 19 Date time of the last change Date and time of the last change in the tightening program settings...

Page 125: ... 5 Kgfm 6 Kgm 0 All other units The value consists of one ASCII character ID 48 2 Value range 0 4 Presetting Example Torque value units Nm Value 1 1 Result type 1 Tighten programs 0 to 98 2 Loosen program 99 The value consists of two ASCII characters ID 49 2 Value range 01 02 Presetting Example Result type Program 99 Value 02 2 Data length revision 003 data length revision 003 data length revision...

Page 126: ...2334455 25 Data length revision 004 data length revision 004 data length revision 003 480 Table 7 35 MID 0061 revision 005 Parameter Comments Bytes This revision includes the information from revision 004 and the following additional information Tightening error code customer Contains the error code that occurred at the customer during the tightening The value consists of four ASCII characters alw...

Page 127: ...counter presetting The value consists of four ASCII characters ID Value range 0000 9999 Presetting Example OK counter limit 12 Value 0012 4 OK counter value Start as a single channel Actual value of the OK counter Start in an application Fixed value 1 The value consists of four ASCII characters ID Value range 0000 9999 Presetting Example OK counter value 4 Value 0004 4 OK NOK counter status Status...

Page 128: ...High Value 2 1 Angle status 0 Low 1 OK 2 High The value consists of one ASCII character ID Value range 0 2 Presetting Example Angle status OK Value 1 1 Torque T The value is multiplied by 100 and transferred as a whole number rounded to 2 decimals The value consists of six ASCII characters ID Value range 000000 999999 Presetting Example Torque T 20 00 Value 002000 6 Angle A The value is output in ...

Page 129: ...Example Date time of the change 1 12 2009 2 43 57 PM Value 1 12 2009 2 43 57 PM 19 Tightening ID With an activated OP consecutive number for each tightening result for further information see MID 0064 The value consists of ten ASCII characters ID Value range 0000000000 9999999999 Presetting Example Tightening ID 123456 Value 0000123456 10 Data length revision 999 101 Table 7 36 MID 0061 revision 9...

Page 130: ...ID not found Sent by Tightening controller Upload the archived tightening Note Revision 001 002 003 004 Data field Data 98 bytes revision 001 206 bytes revision 002 213 bytes revision 003 294 bytes revision 004 Possible response none Table 7 37 MID 0065 revision 001 Parameter Comments Bytes Tightening ID With an activated OP consecutive number for each tightening result The value consists of ten A...

Page 131: ...e Tightening status OK Value 0 1 Torque status 0 Low 1 OK 2 High The value consists of one ASCII character ID 06 2 Value range 0 2 Presetting Example Torque status High Value 2 1 Angle status 0 Low 1 OK 2 High The value consists of one ASCII character ID 07 2 Value range 0 2 Presetting Example Angle status OK Value 1 1 Torque T The value is multiplied by 100 and transferred as a whole number round...

Page 132: ... counter 0 if not 1 or 2 1 Ch x y CntOK 1 2 OK NOK counter not used not configured The value consists of one ASCII character ID 11 2 Value range 0 2 Presetting Example OK NOK counter status OK NOK counter not used Value 2 1 Data length revision 001 98 Table 7 38 MID 0065 revision 002 Parameter Comments Bytes Tightening ID With an activated OP consecutive number for each tightening result The value...

Page 133: ...rent strategy of the tightening controller The value consists of two ASCII characters ID 05 2 Fixed value 99 2 Placeholder value The value consists of five ASCII characters ID 06 2 Fixed value 00000 5 OK counter limit Start as a single channel OK counter presetting The value consists of four ASCII characters ID 07 2 Value range 0000 9999 Presetting No presetting for single channels Fixed value 000...

Page 134: ...ample OK NOK counter status OK NOK counter not used Value 2 1 Torque status 0 Low 1 OK 2 High The value consists of one ASCII character ID 11 2 Value range 0 2 Presetting Example Torque status High Value 2 1 Angle status 0 Low 1 OK 2 High The value consists of one ASCII character ID 12 2 Value range 0 2 Presetting Example Angle status OK Value 1 1 Total angle status Total angle status not supporte...

Page 135: ...e defined tolerance window Bit 14 C Cw 0 CCw or Cw deactivated during the tightening bit 15 TorqL The torque is below the defined tolerance window bit 18 Start up test Start up test NOK bit 21 TimeH The time is above the defined tolerance window bit 23 En 0 Enable during tightening deactivated The value consists of ten ASCII characters ID 18 2 Value range 0000000000 9999999999 Presetting Example T...

Page 136: ...ence number Job sequence number is not supported ID 25 2 Fixed value 00000 5 Sync tightening ID Cycle counter The value consists of five ASCII characters maximum value 65535 ID 26 2 Value range 00000 99999 Presetting Example Sync tightening ID 3232 Value 03232 5 Serial number Nutrunner The value consists of 14 ASCII characters ID 27 2 Value range 0x20 0x7F Presetting Example Serial number A36363 V...

Page 137: ...ers ID 30 2 Value range 01 02 Presetting Example Result type Program 99 Value 02 2 Data length revision 003 data length revision 003 data length revision 002 213 Table 7 40 MID 0065 revision 004 Parameter Comments Bytes This revision includes the information from revision 003 and the following additional information ID code part 2 Contains the characters 26 50 of the ID code The value consists of ...

Page 138: ...er successful subscription a status message MID 0076 will be sent to the superordinate computer for each active error in the controller Revision 001 Data field is empty 0 bytes Possible responses MID Error no Comment Command accepted 0005 Command error 0004 11 Activation of system errors already available Sent by Tightening controller If a system error occurs in the tightening controller it will b...

Page 139: ...me 1 12 2009 11 54 29 AM Value 1 12 2009 11 54 29 AM 19 Data length revision 001 33 Table 7 41 MID 0071 revision 001 Parameter Comments Bytes Sent by superordinate computer Acknowledgement for MID 0071 Note Revision 001 Data field is empty 0 bytes Possible response none Sent by superordinate computer Cancel system errors subscription Note Revision 001 Data field is empty 0 bytes Possible responses...

Page 140: ...he connected controller Exactly one system error status message is sent for each active system error in the connected controller Revision 001 Data field Data 36 bytes Possible response MID Error no Comment System error status acknowledgement 0077 Table 7 42 MID 0076 revision 001 Parameter Comments Bytes System error status 0 No system error active 1 A system error is currently active The value con...

Page 141: ...H MM SS ID 05 2 Value range 0 9 and Presetting Example Time 1 12 2009 11 54 29 AM Value 1 12 2009 11 54 29 AM 19 Data length revision 001 36 Table 7 42 MID 0076 revision 001 Parameter Comments Bytes Sent by superordinate computer Acknowledgement for MID 0076 Note Revision 001 Data field is empty 0 bytes Possible response none Sent by superordinate computer Class 3 errors can be acknowledged by the...

Page 142: ...xt to be displayed and whether the text has to be confirmed by the operator Note Revision 001 Data field data 117 bytes Divided into four lines each with 25 ASCII characters Lines with less than 25 characters must be filled with space characters 0x20 The tool display can represent up to 15 characters per line Possible responses MID Error no Comment Command accepted 0005 Command error 0004 01 Inval...

Page 143: ... maximum of 25 ASCII characters The tool display can represent up to 15 characters per line ID 5 2 Value range 0x20 0x7F Presetting Example Line 3 Line 3 Value Line 3 25 Line 4 Fill in with empty spaces if 25 characters The value consists of a maximum of 25 ASCII characters The tool display can represent up to 15 characters per line ID 6 2 Value range 0x20 0x7F Presetting Example Line 4 Line 4 Val...

Page 144: ...ption of the tag ID Note Revision 001 Data field is empty 0 bytes Possible response MID Error no Comment Command accepted 0005 Command error 0004 98 Tag ID unknown tag ID subscription already exists or MID revision is not supported Sent by Tightening controller Upload of the tag ID Note Revision 001 Data field Data 10 bytes Possible response MID Error no Comment Command accepted 0263 Table 7 44 MI...

Page 145: ...ID 0401 After confirmed logon command accepted MID 0005 the tightening controller moreover sends a message upload automatic manual mode MID 0401 with the current operating mode to the superior computer Note Revision 001 Data field is empty 0 bytes Possible response MID Error no Comment Command accepted 0005 Command error 0004 82 Activation for automatic manual mode already available Sent by Tighte...

Page 146: ...computer The operating mode is changed Note Revision 001 supported by Rexroth OP Data field Operating mode 1 byte The operating mode is identified by one ASCII character and can be as follows 0 automatic mode 1 manual mode Possible response MID Error no Comment Command accepted 0005 Sent by superordinate computer Requests the setting Disable tool of the active OK NOK counter It is set in the NEXO ...

Page 147: ...rordinate computer As a consequence of this message the superior computer is informed about every change in the configurable output signals at the OP PLC module by means of a message upload change in output signals MID 0501 After confirmed logon command accepted MID 0005 the tightening controller moreover sends a message upload change in the output signals MID 0501 with the current assignment of t...

Page 148: ...of the oprtcl PLC module Data length revision 001 8 Table 7 47 MID 0501 revision 002 Parameter Comments Bytes This revision outputs the values of the first 16 assignable output signals of the OP PLC module The output is effected in the order in which the signals have been stored by the user The signals can be applied to the OP PLC module from 0 0 1 7 Signals Every signal is represented by a byte T...

Page 149: ...es of the 16 configurable input signals of the PLC module OpenProtocol may be changed Note Revision 001 Data field Number of signals 16 bytes Possible response MID Error no Comment Command accepted 0005 Table 7 48 MID 0504 revision 001 Parameter Comments Bytes Signals Every signal is represented by a byte The meaning of each signal e g position recognition results from the special case ID none Val...

Page 150: ... Bytes Job status Defines the status of the job The value consists of one ASCII character ID 01 2 Value range 0 deactivated 1 activated Presetting Example Job status deactivated Value 0 1 Data length revision 001 3 Sent by superordinate computer This command can be used to start the job function of the tightening channel Note In the PLC assignment table the JobStart signal must be applied to the O...

Page 151: ...Possible response MID Error no Comment Command accepted 0005 Command error 0004 98 Request timeout in the control or PLC signal not assigned in the PLC assignment table Table 7 51 MID 0573 revision 001 Parameter Comments Bytes Job number Number of the job The value consists of three ASCII characters ID Value range 000 999 Presetting Example Job number 001 Value 001 3 Data length revision 001 3 Sen...

Page 152: ...module was reinserted the state if charge of the battery is being checked 5 The battery level warning level is reached The value consists of one ASCII character ID 02 2 Value range 0 5 Presetting Example State of the battery pack slide in module The battery level is okay Value 3 1 Data length revision 001 8 Sent by superordinate computer Subscription for changes in the battery level As a consequen...

Page 153: ...ters ID Value range 00 99 Presetting Example Change in the battery level Entered value 25 25 Battery level 100 A message will be sent when the battery level is at 75 The next messages will be sent when the battery level is at 50 and 25 Value 25 2 Data length revision 001 2 Sent by Tightening controller If the battery level changes it will be reported to the superior computer Note Revision 001 Data...

Page 154: ...II character ID 02 2 Value range 0 5 Presetting Example State of the battery pack slide in module The battery level is okay Value 3 1 Data length revision 001 8 Table 7 54 MID 0803 revision 001 Parameter Comments Bytes Sent by superordinate computer Cancels the battery level changes subscription Note Revision 001 Data field is empty 0 bytes Possible response MID Error no Comment Command accepted 0...

Page 155: ...o Comment Command accepted 0005 Command error 0004 37 There is already a subscription for changes in the reception quality Table 7 56 MID 0807 revision 001 Parameter Comments Bytes Change of reception quality Selection of the value for the change in the reception quality as integer If the reception quality changes the superior computer is informed about the change in the reception quality by means...

Page 156: ...mple the min value of the angle monitoring function is smaller than the associated max value stored in the program If necessary the sequence of the PIDs within the telegram must be observed here i e an existing max value must first be increased so that a new min value which is greater than equal to the original max value is accepted Table 7 57 MID 0806 revision 001 Parameter Comments Bytes Recepti...

Page 157: ...vision 001 Data field variable length Possible response MID Error no Comment Command accepted 0005 Command error 0004 3 Example 1 In the tightening program no 34 the speed in the 1 tightening step is set to 160 1 min Table 7 58 MID 2505 revision 001 Parameter Comments Bytes Tightening program number The value consists of three ASCII characters ID Value range 000 255 Presetting Example 1 Program no...

Page 158: ...G ID Value range 02052 05102 05105 05110 05113 05115 Presetting Example 1 Speed Value 02052 5 Length Length of the data value The value consists of three ASCII characters ID Value range 001 999 Presetting Example 1 Length of the data value 4 Value 004 3 Data type The value consists of two ASCII characters 01 UI unsigned integer The data value is an integer without a negative sign 02 I signed integ...

Page 159: ... to start step 1A corresponds to end step 12A with max 10 tightening steps Presetting Example 1 1 tightening step 2 corresponds to 1 Tightening step 2A Value 0002 4 Data value The number of ASCII characters is defined by the parameter Length The data value must correspond to the data type Parameter Data type 01 UI Admissible characters are 0 9 and Parameter Data type 02 I Admissible characters are...

Page 160: ...Sent by superordinate computer The superior computer sends a keep alive message to the tightening controller The tightening controller returns the received message to the superior computer A communication timeout of 15 s can be parameterized by the BS applies to the tightening controller i e if no message is exchanged between the superior computer and the tightening controller within 15 s the tigh...

Page 161: ... already available 14 Subscription for tightening program selection is not available 15 Requested tightening ID not found 16 Connection rejected max number of connections exceeded 20 Job cannot be specified 35 There is already a subscription for changes in the battery level 36 There is no subscription for changes in the battery level 37 There is already a subscription for changes in the reception ...

Page 162: ...eway server database and web interface for visualization analysis and archiving The application package consists of the following components see Fig 7 3 IPM gateway and IPM server The IPM gateway receives the measurement data telegrams of the Nexo cordless Wi Fi nutrunner and checks it for correctness and then sends it to the IPM server The IPM server sends the data to the database There are 1 n I...

Page 163: ...ram and AFO the physical process information and process data is then assigned to the logical features This assignment is defined and managed by configuring it in the NEXO OX operating system The number of data records is also configured via the NEXO OS operating system using the Settings Data Results storage menu see page 214 7 6 1 Message structure Table 7 60 shows the basic structure of a messa...

Page 164: ...g program Graphs Graphs Filtered tightening result graphs graph filter with and without tightening steps 1 If there is no actual value for a characteristic e g as the corresponding monitoring function in the tightening program is not activated a so called actual dummy value with the value 9999999 will be transferred In the subsequent evaluation on the IPM web interface this pseudo measurement valu...

Page 165: ... the number of OK NOK check box for nutrunner and Prg99 If the OK or NOK counter is reached the nutrunner and Prg99 are disabled After the first tightening process the Nexo cordless Wi Fi nutrunner is neither disabled in case of OK nor NOK result 7 7 1 Assignment of PLC signals To ensure proper function of the VW XML protocol the vwXml PLC module has to be activated in menu Settings PLC signals Ex...

Page 166: ... have special characteristics Tightening process torque AD process Table 7 62 shows how the AD tightening process has to be parameterized in the Nexo cordless Wi Fi nutrunner Table 7 61 Assignment of the tightening step categories for VW XML in the Nexo firmware VW corporate requirement specifications Nexo category of the tightening step Start up step AS 0 None 1 Tightening 11 Start Pre tightening...

Page 167: ...dly assigned the value 0 Lower tolerance time t Table 7 63 Parameterization of the AW process top torque Function in NEXO OS Parameter in NEXO OS Parameter in VW corporate requirement specifications Comments 1 Target function Angle Angle set value AA 2 Target function Torque Torque upper limit switching TO Torque lower limit Always fixedly assigned the value 0 Torque lower limit switching TU Speed...

Page 168: ...C module has to be activated in menu Settings PLC signals Except for the Cw and Ccw signals all control signals have to be applied under Inputs to the BmwTpc module according to the designation highlighted in gray The Cw and Ccw signals are applied on the tool PLC module All control signals have to be applied under Outputs to the BmwTpc module according to the designation highlighted in gray As of...

Page 169: ...ibes the commissioning and necessary configuration of the Nexo cordless Wi Fi nutrunner by Rexroth Overview page 170 NEXO OS operating system page 172 Configuration page 173 Special features of nutrunners with angle compensation page 173 ...

Page 170: ...chrexroth com tightening There you can also find further information on Service packs for older versions if available Current firmware updates Further information on upgrading downgrading different versions releases NOTICE Danger to system safety System safety is put at risk when firmware is downloaded during ongoing operation Before downloading firmware ensure that the tightening system is not in...

Page 171: ...ng the slide in battery pack activate push the red button at the battery Shortly press the start button at the hand held nutrunner Calling the NEXO OS operating system see page 177 Optional Updating the firmware version see page 177 Configuring the cordless Wi Fi nutrunner using the NEXO OS operating system see page 172 Fig 8 1 Overview of commissioning steps To prevent data loss switch off the Ne...

Page 172: ...he same subnet Confirm your settings with OK 7 Now open your web browser and enter the default IP address of the Nexo cordless Wi Fi nutrunner 192 168 1 10 8 Then enter the default user data on the login page User Bosch Password Robert Configuring the NEXO OS operating system Configuring the WLAN see page 240 Defining the tightening programs see page 214 Defining the PLC assignment table see page ...

Page 173: ...O OS operating system all settings of the Nexo cordless Wi Fi nutrunner can be reset to default 8 4 Special features of nutrunners with angle compensation An IP address may be assigned only once For detailed information about troubleshooting of configuration conflicts refer to chapter Troubleshooting from page 265 The angle compensation function is available from version 1400 of the Nexo firmware ...

Page 174: ...tening program with a speed of 0 angle of turn tolerance window for the output drive of 88 92 and a tightening time of approx 5 seconds After start up of the tightening program the nutrunner is moved by 90 in the direction of the tightening axis The test result is illustrated in the graph display see page 185 8 4 2 Error messages The following system errors may occur FC 116 117 Tightening directio...

Page 175: ...ess Wi Fi nutrunner with its menus and functions General information about the NEXO OS operating system page 176 Starting the program page 177 Function overview page 182 Analysis page 184 Mode page 187 Job page 193 Tightening programs page 200 Settings page 208 Diagnosis page 251 Help menu page 255 ...

Page 176: ...ents for the software and firmware versions are currently stored on the Internet at http www schraubtechnik com You can also find instructions for upgrades downgrades there Service packs are provided on the Internet at http www schraubtechnik com If you use the components in an existing system as a replacement or an extension you must install the firmware that is used in the system NOTICE Incompat...

Page 177: ...applied To an older version that was not installed on the nutrunner When updating to an older firmware version the configurations are not converted default configurations are applied 9 2 Starting the program The browser based NEXO OS operating system allows configuring and controlling the Nexo cordless Wi Fi nutrunner on any computer desired The user can simultaneously connect to several operating...

Page 178: ...display of the current actual values ActualGraph for display of the actual graph Example 192 168 1 10 ActualValues Separators for floating decimal numbers Login page Fig 9 1 Login As a rule the separators for floating decimal numbers in the language of the user login to the NEXO OS operating system are used see figure 9 1 The default language shown on the login page is the language used to configu...

Page 179: ...o display the corresponding menu in the foreground This allows quick access to the different menus To close the menu click the tab once again 3 Work space After the NEXO OS operating system has been started the work space is blank Once you have opened a menu a separate window will be opened for it in the work space Table 9 2 Elements in the navigation panel Element Description Displays the menus a...

Page 180: ...attery pack Indicates radio communication As of Nexo firmware version 1300 Display of the data connection status Automatic mode or manual mode Green symbol All active data services are connected Red symbol At least one data service is not connected Gray symbol No data service active Nutrunner operating state Left hand LED Yellow steady light Enable signal present Enable or Active Enable PLC signal...

Page 181: ...tting configurations or tightening programs to the hardware You are reading available tightening programs from the hardware Query of diagnosis data You have opened one of the menus in the operating system Analysis Actual values Analysis Stored values Analysis Actual graph Analysis Stored graphs 9 2 2 Exiting the program Click the following icon in the status bar to log off from the NEXO OS operati...

Page 182: ...issions Can be used to add edit or delete group rights page 210 My account Displays the user s own profile and allows changing the password page 211 Tool display Setting for the graphical display on the Nexo cordless Wi Fi nutrunner and for the operating system page 211 Data Result storage Settings for the internal result storage page 214 Standard Nexo FTP Settings for FTP output NX SD card 2 Sett...

Page 183: ... and loading of stored data page 250 Diagnosis System information Displays information about hardware and software page 251 Log book Displays the logs of previous actions in the operating system page 251 Open Protocol 4 Protocol display for Rexroth Open Protocol page 252 BMW TPC 4 Protocol display for BMW TPC service page 252 Status Status display page 252 System errors Error messages and statisti...

Page 184: ... an internally stored tightening job Result display Torque T Angle A Time t The measured value recording ends when the specified target value is reached as soon as the torque value is below 5 of the spindle overload After 200 ms at the latest Table 9 4 Actual values tab Element Description Previous step Displays the actual values of the previous step Next step Displays the actual values of the nex...

Page 185: ...y requests the next graph Table 9 6 Actual graph tab Element Description Min Lower zoom area limit Max Upper zoom area limit 100 Shows the complete graph Points Number of graph points contained in the zoom area and total number of graph points display only If Internet Explorer version 8 is used as browser a problem may arise in connection with curves that are represented with a great number of poi...

Page 186: ...dd Via the button Add you can add a new filter for Job Result Program Step Quality code ID code Date time Rework code Rework instructions and System failures Edit Click the button Edit to edit an existing filter entry Activate Click the button Activate to activate the selected filter Deactivate Click the button Deactivate to deactivate the selected filter Remove Click the button Remove to remove t...

Page 187: ...er is reached 9 5 1 Structure of the Mode tab The header of the Mode tab features the following buttons On its left it shows icons to start various functions As of Nexo firmware version 1100 the mode function is supported As of Nexo firmware version 1100 the mode function is used to set up the ID code to identify a set of results data Selection of the ID code source via the start step As of Nexo f...

Page 188: ...ng mode In this step define the settings for the operating modes and for the ID code which identifies a result data record of the Nexo cordless Wi Fi nutrunner Table 9 11 Available mode steps Element Designation Explanation See page Operating mode step As of Nexo firmware version 1300 Determination which operating mode will be active after restart or mode storage page 188 Start step Start of the m...

Page 189: ...D code Multiple ID inputs The ID input made available via the ID input step s in the job and or mode is used to generate the ID code VW XML As of Nexo firmware version 1200 The tag set by the VW XML master PC PI1 is used for generating the ID code BMW TPC As of Nexo firmware version 1400 Delete ID code after start Display only for Open Protocol Scanner VW XML and BMW TPC Enable the check box to de...

Page 190: ...clicking the ID input step or the respective icon opens the corresponding dialog for entering the parameters Table 9 16 ID input step dialog timeout options panel Element Description Name Step name Admissible characters are ASCII characters numbers spaces hyphens dashes and underscore Comments Enter a comment for the step Admissible characters are ASCII characters numbers spaces hyphens dashes and...

Page 191: ...nd Job0 7 must not be applied in the PLC assignment table ID code ID assignment The ID input is used to create an ID code and to select a program or job using the ID assignment table When using this option in the Automatic operating mode the PLC signals JobEn JobStart and Job0 7 must not be applied in the PLC assignment table Masking ID code Masking ID assignment Depending on the selection made in...

Page 192: ... step The tool is disabled in this step Table 9 19 ID input step dialog scan options panel Element Description Trigger scan process The scan process can be selected using the following option Play at start switch Center function key Function key Left Function key Right PLC signal Laser on time Maximum time that the laser is turned on Acoustic signal If the check box is activated an acoustic signal...

Page 193: ...he job function is supported Table 9 20 Job tab Element Description Up to 256 jobs can be programmed Saves the current job Opens the Job information dialog There you can save a comment on the current job max 1000 characters Admissible characters are ASCII characters numbers spaces hyphens dashes and underscore Deletes the current job This displays a prompt asking whether the user really wishes to ...

Page 194: ... closed in either case Click Save to apply the tightening program 9 6 3 1 Start step Every job has exactly one start step The properties of the start step apply to the complete job sequence General Table 9 22 Available job steps Element Designation Explanation See page Start step Starts the job page 194 ID input Step for the treatment of an ID input page 195 Single program Step for basic processin...

Page 195: ...nding dialog for entering the parameters Table 9 25 ID input step dialog general panel Element Description Identifier Name for the clear identification of the step Name Step name Admissible characters are ASCII characters numbers spaces hyphens dashes and underscore Comments Description of the step Admissible characters are ASCII characters numbers spaces hyphens dashes and underscore Table 9 26 I...

Page 196: ... displayed on the nutrunner display after the timeout Table 9 28 ID input step dialog scan options panel Element Description Trigger scan process The scan process can be selected using the following option Start switch Center function key Function key Left Function key Right PLC signal Laser on time Maximum time span that the laser is turned on Acoustic signal If the check box is activated an acou...

Page 197: ...ew ID code you can define a prefix and a postfix as well as a max of 10 more components You can select the following values Mode Result of the mode Userdefined Text User defined text IDInput xx Result of a scan step of the respective job Example ID Input1 A2 is the result in the step column A line 2 The ID code will be displayed on the nutrunner display Mode Æ ID input step Æ dĂƌŐĞƚ ƐĞůĞĐƟŽŶ ĐŽĚĞ ...

Page 198: ... for this tightening program Integer values between 0 and 255 are valid characters Max NOK Defines the maximum number of NOK tightening operations for this tightening program Integer values between 0 and 255 are valid characters Conditional blocking of the loosen program after OK result Blocks the loosen program no 99 after an OK tightening after NOK result Blocks the loosen program no 99 after a ...

Page 199: ...ng the parameters Table 9 33 End step dialog General panel Element Description Name End step name Admissible characters are ASCII characters numbers spaces hyphens dashes and underscore Comments Description of the job step Admissible characters are ASCII characters numbers spaces hyphens dashes and underscore Table 9 34 End step dialog options panel Element Description Enable nutrunner Enable nutr...

Page 200: ...ers with an upper and a lower limit value e g M and M but also with only one limit value e g time A distinction is made between evaluating and switching monitoring functions Evaluating monitoring functions With evaluating monitoring functions achieved tightening results e g torque angle of turn are compared to all monitoring functions assigned to the tightening step at the end of the tightening st...

Page 201: ...es hyphens dashes and underscore Deletes the current tightening program This displays a prompt asking whether the user really wishes to remove the program Opens the Name dialog There you can enter a new program name for the tightening program Table 9 36 Programs functions Element Description Inserts a new tightening step Opens the dialog for editing the selected step Deletes a selected tightening ...

Page 202: ...lable in a tightening program 9 7 4 Creating a new tightening program editing an existing tightening program A tightening program contains the following information Type and order of tightening steps Target and monitoring parameters of each tightening step Accept values Click OK to apply the edited values to the tightening program Click Cancel to discard your changes The dialog window will be clos...

Page 203: ...use e g M M Possible categories include e g Start Tightening Pre tightening Final tightening Loosen Rework Table 9 39 Start step dialog graph properties panel Element Description Graph resolution Is used to select the graph resolution in angular degrees The smallest value 0 25 results in the highest resolution and the highest value 50 in the lowest resolution Default setting 1 The resolution selec...

Page 204: ...ed The start up test reduces the possibility of bolt heads and output drives being torn off if an already tightened bolt is re tightened Speed Is used to select the value for the speed in of the nominal speed of the configured nutrunner at which the start up test is to be conducted Default setting 5 Start up suppression Selection of the time span during which after start of the tightening step the...

Page 205: ... a tightening job was evaluated as OK or NOK With an NOK evaluation the cause will also be described In NOK cases the category is used as a detailed distinction so that a different quality code can be output in different tightening steps for the same NOK cause e g M M Possible categories include e g Tightening Pre tightening Final tightening Loosen Rework Graph resolution Is used to select the gra...

Page 206: ...ning step may be terminated Table 9 45 Tightening step dialog target panel Element Description Speed Is used to select the speed set speed to be used for tightening in this tightening step A negative speed means counterclockwise rotation a positive speed means clockwise rotation Start up suppression Selection of the time span during which after start of the tightening step the tightening process i...

Page 207: ...e min value angle max value These monitoring functions can also be selected Each of the monitoring limits can be marked as switching If a limit is switching the tightening process will be stopped with an NOK result when it exceeds or falls below its limit If it is not switching the tightening process will be completed as usual however the result will be NOK Time This monitoring function is always ...

Page 208: ...ystem All tightening system outputs use the local time of the nutrunner This also applies to outputs in the operating system like actual values or graphs If the slide in battery pack is not inserted the local time of the nutrunner is supplied for one week Thereafter the local time must be reconfigured Table 9 49 Time date tab Element Description System time Displays the current date and time setti...

Page 209: ...Use this menu item to show add or delete users with their user names and data Users must be activated to be able to log in on the login page of the NEXO OS operating system Table 9 50 Users tab Element Description Add Click Add to add a new user 1 Click the button A new line will appear at the end of the list 2 Click Edit to define the data for the new user entry Remove Click Remove to remove a us...

Page 210: ...rights in the form of a matrix 1 Activate the corresponding right for the group Read and write access rights are identified by icons 2 Click Save to save the edited data Click Discard to discard the edited data Adding read and write access rights If no group is selected for a user the user does not have any rights Table 9 51 Groups tab Element Description Add Click Add to add a new group 1 Click t...

Page 211: ...ions panel Element Description Allow acknowledgement of system errors Enable Allow acknowledgement of system errors to acknowledge system errors using the nutrunner display Enforce acknowledgement of NOK results As of Nexo firmware version 1200 Enable Allow acknowledgement of NOK results to acknowledge NOK results using the nutrunner display Note Activation does not become active before the first ...

Page 212: ...ed Activate Force read to be able to confirm the reading of the warning on the nutrunner display only at the end of the warning text Table 9 56 Tool display index card Main menu panel Element Description Entries Under Entries select the views to be displayed in the main menu on the display of the portable Nexo cordless Wi Fi nutrunner and define their order If the check box is activated the view i...

Page 213: ... the nutrunner display language Chinese German English Spanish French Italian Hungarian Polish Portuguese Slovak Czech Russian Date time System time settings date and time Design Selection of day or night design for the screen display Backup Restore 1 1 As of Nexo firmware version 1200 the Backup Restore option is activated by default in the main menu on delivery of the Nexo cordless Wi Fi nutrunn...

Page 214: ... As of Nexo firmware version 1100 the results are stored in the internal memory of the nutrunner In addition the results can be stored in the json format on the Micro SD card inserted into the nutrunner Table 9 59 Result storage tab Element Description Max results Selects a maximum number of results to be saved The storage comprises up to 5 000 results with actual values and graph Use ring buffer ...

Page 215: ...FTP server or the DNS entry of the FTP server Port Selection of the TCP IP port for data transfer value range 0 65535 Default setting 21 Users Enter the user name for FTP connection The user name has to be valid on the FTP server and has to have write access to the target directory and authorization to create directories If necessary ask your system administrator whether the user has write access ...

Page 216: ...e results files will be generated Results files which have already been generated and still exist will not be output before HTTP output has been reactivated IP address DNS Either directly enter the IP address of the HTTP server or the DNS entry of the HTTP server Port Selection of the TCP IP port for data transfer value range 0 65535 Default setting 8080 Page Under Page enter the target page of th...

Page 217: ...ories If necessary ask your system administrator whether the user has write access User ID Enter the user ID for File Share connection The user ID has to be valid on the File Share server and has to have write access to the target directory and authorization to create directories If necessary ask your system administrator whether the user has write access Directory Enter the directory1 for the tig...

Page 218: ...or NOK tightening output are defined To do so activate the respective check box For an overview of parameters see on page 219 Add Click Add to add a new user defined parameter Click Save to save the changes or Cancel to discard the changed data Edit Click Edit to edit a user defined parameter Change the presettings and click Save to save the changes or Cancel to discard the changed data Remove Cli...

Page 219: ... parameters graph see page 222 In addition the associated graph points are returned under each step Table 9 65 General tightening result parameters and their meaning Parameter Meaning format Default setting for data output via HTTP The format identifier enables recognition of the type of the transmitted file by the communication partner channel The received file contains the tightening results of ...

Page 220: ...or MCE factor of the nutrunner total angle threshold nom Set value of the total angle counting torque threshold total angle threshold act Actual value of the total angle counting torque threshold total angle Total angle sum batch nr OK NOK counter number batch valid Value of the OK NOK counter batch canceled Shows whether the OK NOK counter value was changed while it was being processed 0 counter ...

Page 221: ...LC Signal Ccw removal En 0 PLC Signal En removal SysFault System errors rdy 0 Ready for operation during tightening removed torque Step final torque angle Step final angle duration Step duration in seconds quality code Quality code speed Set speed angle threshold nom Set value of angle counting torque threshold angle threshold act Actual value of angle counting torque threshold Table 9 67 Tighteni...

Page 222: ...y acknowledgement node id see table 9 65 General tightening result parameters and their meaning no see table 9 65 General tightening result parameters and their meaning hardware see table 9 65 General tightening result parameters and their meaning mac0 see table 9 65 General tightening result parameters and their meaning ip0 see table 9 65 General tightening result parameters and their meaning sw ...

Page 223: ...ectory a sub directory is created The file name of the sub directory can be composed of different parameters Activate the respective parameters Number of files Display on selection of NX SD card On the applied file system of the NX SD card sub directories can only contain a defined number of files Due to this restriction an additional sub directory with the current time stamp YYYY MM DD_hh mm ss i...

Page 224: ...menu and Suppress echo from ID codes is enabled this will result in the following ID codes that are received via Open Protocol MID 0050 or MID 0150 are then not transmitted to the respective subscribers of the ID codes via Open Protocol MID 0052 This means that this option default setting disabled prevents a situation where new ID codes are constantly generated but the actual tightening job is nev...

Page 225: ...er character at this position is ignored New placeholder character to provide a clearer view I Character at the position marked by I is taken over in IPM ID code IP code data The IPM data set has different text data fields to which flexible parts of the ID code can be mapped The maximum number of characters that can be entered is 255 This element can be used for this purpose with the following cha...

Page 226: ...228 menu Prg Selects the program number for this work sequence AFO Name of the work sequence no more than 30 characters Allowed character set 7 bit US ASCII no umlauts Description Allowed character set 7 bit US ASCII no umlauts no more than 30 characters This field may remain empty so that the description can later be assigned to this AFO at the server In this case you can then e g create country ...

Page 227: ...p category Defines the step category for IPM data output End final tightening mode Possible output values are either unknown or end tightening End tightening is only output if the step number is identical with the buffered end tightening step number of an OK tightening of this AFO completed in advance Step type The number of the step type of the tightening step of the tightening system is accepted...

Page 228: ... for the removal of the release after loss of connection never after connection lost after keep alive timeout System data Under System data the corresponding parameters for VM XML tightening results output can be configured Tag default setting empty System name ABZ In the ABZ tag 32 characters are available e g wheel assembly Plant WRK In the WRK tag 16 characters are available Production segment ...

Page 229: ...ed If no confirmation is received within this time at the port the connection will be disconnected default setting 3 seconds Options Selection of the default transmission class that is to be used by default for the transmission of the tightening results data The transmission class must be set independently for OK tightening jobs and NOK tightening jobs Class 1 All values of the final tightening st...

Page 230: ...g Specification of the max time span until the start of the order processing Default setting 20 seconds Time for processing Specification of the time span during which an order has to be processed Default setting 100 seconds Number of scan tries Defines the maximum number of scan attempts for the item and serial number scan Scan serial no If the check box is enabled the serial number will moreover...

Page 231: ...Selection of the connection protocol RFC1006 TCP IP native S5 Header Source TSAP Indication of RFC1006 ISO DP 8073 source TSAP Target TSAP Indication of RFC1006 ISO DP 8073 target TSAP Acknowledge If the check box is selected an acknowledgement from Plc LisWas is expected Acknowledge timeout Specification of the time span how long an answer from Plc LisWas is awaited with active acknowledgement De...

Page 232: ...ll ID Cell ID of the nutrunner Torque unit Selection of the torque unit As of Nexo firmware version 1200 the units Ftlb Inlb Kpm Kgfm and Kgm are available for selection The torque unit defined in the tightening programs is independent from this setting ID number Number used to identify the nutrunner Comments Enter a comment MCE MCE factor The MCE factor serves to adjust the Nexo measuring system ...

Page 233: ...If in active monitoring the set limits are reached in the next check the controller sends the PLC output signal CheckTool see page 65 and enters a class 0 system error The PLC signal is reset if one of the following events occurs Cycle Enter the cycle during which the check is to be carried out Date Date for the next check Last check Date Enter exactly when the check was carried out Cycle Enter ex...

Page 234: ... torque of the encoder and the output drive data Min speed Programmed minimum speed Max speed Programmed maximum speed Min torque Programmed minimum torque with torque target function Max torque Programmed maximum torque with torque target function Save Click Save to save the edited data Discard Click Discard to discard the edited data Table 9 80 Configuration tab Element Description Special compo...

Page 235: ...lement Description Refresh Click Update to load a new firmware version 1 The Update nutrunner firmware dialog is opened 2 Select the file nxfw for updating the firmware 3 Click Update to start the update Click Cancel to stop the update Firmware update was not carried out or canceled In this case restart the firmware update via the NEXO OS If the firmware update fails again remove the battery pack ...

Page 236: ...put signal can be assigned up to a maximum of four times Inserts a signal highlighted in the signal list in the selected insert position of the assignment table Removes the highlighted signal from the assignment list PLC signals from BMW TPC PLC module BmwTpc PLC signals from Rexroth Open Protocol PLC module oprtcl PLC signals of the nutrunner PLC module tool As of Nexo firmware version 1300 If th...

Page 237: ...ounter value option allows setting a total of 255 OK NOK counters A maximum value for OK tightenings and a maximum value for NOK tightenings is defined for each counter Click Add or Remove button to add or delete a counter value respectively OK NOK Set the counting direction i e whether counting is to be ascending or descending Disable when OK NOK number is reached The appropriate control signal i...

Page 238: ...tightening program is regarded as OK on assignment of the quality code Table 9 85 Quality code basic settings Quality code Rework codes TJ NOK TJ OK all other TJ Category 1 0 All OK System 130 0 Cw 0 OK NOK System 131 0 Ccw 0 OK NOK System 132 0 En 0 OK NOK System 139 0 StartUp OK NOK System 129 0 Fault OK NOK System 2 0 A OK NOK All 4 0 A OK All 8 0 T OK All 10 0 T A OK All 12 0 T A OK All 16 0 T...

Page 239: ...Description Add Opens a dialog to add a quality code Edit Opens a dialog to edit the selected quality code Remove Deletes an entry from the quality code assignment table Move up Move down The table is searched from top to bottom when selecting the quality code Thus the order of the entries may be decisive for the selection of the quality code Use Move up or Move down to move the selected entry up ...

Page 240: ...n the country Select the target country using the country code Check with Rexroth if there is a radio certification for the target country Europe ETSI 1 European Telecommunications Standards Institute USA FCC Federal Communications Commission Australia ACMA Argentina CNC Brazil Canada IC Industry Canada China SRRC Cert State Radio Regulatory Commission India WPC Cert Wireless Planning and Coordina...

Page 241: ...C DFS TPC 104 1 5520 DFS TPC DFS TPC 108 1 5540 DFS TPC DFS TPC 112 1 5560 DFS TPC DFS TPC 116 1 5580 DFS TPC DFS TPC 120 1 5600 DFS TPC DFS TPC 124 1 5620 DFS TPC DFS TPC 128 1 5640 DFS TPC DFS TPC 132 1 5660 DFS TPC 136 1 5680 DFS TPC 140 1 5700 DFS TPC 149 1 5745 153 1 5765 157 1 5785 161 1 5805 165 1 5825 Supported Not supported DFS Dynamic Frequency Selection dynamic selection of channels due...

Page 242: ... of 32 characters BSSID Activate BSSID to enter the BSSID Basic Service Set Identification of the access point Table 9 92 WLAN tab address Element Description Host name Supported as of Nexo firmware version 1100 Assignment of a permanent network name maximum of 63 characters The network name is used to address the nutrunner For example when the NEXO OS operating system is started enter the network...

Page 243: ...in this case the same passphrase is assigned to each user WPA2 has a higher safety level than WPA Authentification Is displayed with Method WPA WPA2 enterprise Select the authentification PEAP EAP TLS EAP TTLS User name Is displayed with Method WPA WPA2 enterprise Enter the user name Password Is displayed with Method WPA WPA2 Personal WPA WPA2 Enterprise Enter the WPA passphrase in Password 32 cha...

Page 244: ...si threshold The difference between the two thresholds then indicates the required improvement in the received signal of the new access point compared to the existing access point Low snr threshold Minimum signal to noise ratio dBm that triggers roaming Data retry threshold Consecutive number pcs of lost data packets that triggers roaming Num expected tbtt for bss loss Consecutive number pcs of lo...

Page 245: ...ted data Discard Click Discard to discard the edited data Restart Press this button to restart the NEXO OS A restart may be required in case of WLAN problems for example Import Opens the Import dialog Select the file to be imported Export Exports the current settings to the download area Restore defaults All settings in this tab are reset to the factory setting Table 9 96 Security tab Element Desc...

Page 246: ... mode Start switch The tightening position illumination is turned on by pressing the start switch During tightening Activate this check box in order to enable the tightening position illumination during the tightening process Illumination LED Intensity Use the slider control to define the brightness of the illumination LED Signal LED RGB Use the slider to define the color of the signal LED in the ...

Page 247: ...ing off the tightening position illumination Values from 0 to 30 seconds are valid Flashing cycle Sets the flashing cycle of the tightening position illumination System errors Activate this check box in order to enable the tightening position illumination in case of a system error Illumination LED Intensity Use the slider control to define the brightness of the illumination LED Signal LED RGB Use ...

Page 248: ...ogram Activate this check box to activate the tightening program Job Activate this check box to activate the job No Enter the number of the tightening program or job Integer values between 0 and 255 are valid characters Comments Enter a comment Add Adds a new entry in the assignment table Remove Deletes an entry from the assignment table Save Click Save to save the edited data Discard Click Discar...

Page 249: ...Convert to Code 32 Italian Pharma Code Code 32 Prefix Check Digit Verification Transmit Digit Verification Full ASCII Code 93 L1 L1 L2 L1 L2 Any Code 11 L1 L1 L2 L1 L2 Any Check Digit Verification Transmit Digit Verification Interleaved 2 of 5 L1 L1 L2 L1 L2 Any Check Digit Verification Check Digit 2 of 5 to EAN 13 Codebar L1 L1 L2 L1 L2 Any CLSI Editing NOTIS Editing MSI L1 L1 L2 L1 L2 Any Check ...

Page 250: ...from a backup copy Table 9 101 Defaults index card Element Description Basic settings Click Basic settings button to reset all settings to default Discard Click Discard to discard the edited data Table 9 102 Backup Restore tab export Element Description Export to file Save data to a data carrier The cfg filename extension cannot be changed Assign a unique file name to be able to distinguish the fi...

Page 251: ...ordless Wi Fi nutrunner Hardware Information about the hardware Name platform and IP address Software Information about the operating system version 9 9 2 Log book Diagnosis Log book With this menu item the latest changes to the operating system can be displayed This display is limited to 500 entries The log book is set up as a ring memory a new entry always overwrites the oldest one By default so...

Page 252: ...item to display the error list Error list tab List of errors that occurred Statistics tab List of all errors of the error list concerned sorted by their frequency The Error list tab provides the following information Table 9 106 Open Protocol tab Element Description Refresh Updates the display of the entries Connection Selection of all 1 2 3 4 or 5 Export Exports the entries to a nxlgx file Table ...

Page 253: ...her an error was confirmed acknowledged 1 acknowledged 0 not acknowledged Refresh Click Request to update the error list which requires a connection to the operating system there is no permanent automatic update function Clear all Click Delete to delete the error list Acknowledge Click Acknowledge to confirm that you have noted an error of error class 3 Table 9 110 Statistics tab Element Descripti...

Page 254: ...ailability of which is to be checked Display output Enable the check box to display the data packages transmitted between the target address and the sender Start Click Start to start the test Stop Click Stop to stop the test Delete Click Delete button to delete the test Table 9 115 TCP data index card Element Description TCP data Under TCP data select the entry Open Protocol Recording time Select ...

Page 255: ...port tab Element Description Export to file Use this button to save data to a data carrier The zip file extension cannot be changed Assign a unique file name to be able to distinguish the files Export to NX SD card Save data to the NX SD Micro SD card inserted in the nutrunner Only possible if an NX SD Micro SD card is inserted in the nutrunner Table 9 118 Help menu access to NX SD card Element De...

Page 256: ...256 279 Bosch Rexroth AG Tightening Technology 3 608 870 A47 Nexo cordless Wi Fi nutrunner 3 608 870 A47 2019 ...

Page 257: ...ibes the tightening processes for the Nexo cordless Wi Fi nutrun ner that are the most essential ones in tightening technology Overview page 258 Torque controlled tightening process page 259 Angle of turn controlled tightening process page 260 ...

Page 258: ...s special tightening processes Standard processes include Torque controlled tightening process see page 259 Angle of turn controlled tightening process see page 260 Besides standard processes special processes can also be programmed They are characterized by a combination of various standard processes Execution of defined tightening cycles multi step tightening processes to adjust the tightening p...

Page 259: ... controlled angle of turn monitored tightening process The torque increases from positioning of the bolt head exceeds the torque threshold Ts starting angle counting and reaches the target parameter TP after which the tightening process is ended The torque threshold TT should be at the beginning of the linear increase of the tightening graph as the joining pro cesses of the tightening parts are al...

Page 260: ...spersion of the mounting clamp force i e the tightening factor1 is close to 1 a particularly high bolted connection strength can be attained The angle of turn is registered in the measurement transducer Function Fig 10 2 T f A angle of turn controlled torque monitored tightening process The torque increases from positioning of the bolt head until it reaches the torque threshold Ts torque controlle...

Page 261: ...deforms Re usability of the bolt is limited due to lasting cross section constriction This is why special bolts with sufficient deforma tion characteristics e g stretch shank bolts should be used in this process As the result value for all data outputs the maximum angle that occurred after the switch off is output via the target function 1 Limit values T T should be defined via statistical evaluat...

Page 262: ...262 279 Bosch Rexroth AG Tightening Technology 3 608 870 A47 Nexo cordless Wi Fi nutrunner 3 608 870 A47 2019 10 ...

Page 263: ...3 608 870 A47 Tightening Technology Bosch Rexroth AG 263 279 Nexo cordless Wi Fi nutrunner 3 608 870 A47 2019 10 ...

Page 264: ...264 279 Bosch Rexroth AG Tightening Technology 3 608 870 A47 Nexo cordless Wi Fi nutrunner 3 608 870 A47 2019 10 ...

Page 265: ...cordless Wi Fi nutrunner and provides troubleshooting advice Error codes and classes page 266 Detecting and acknowledging errors with the NEXO OS operating system page 267 Complete error list page 268 Replacing defective components page 273 Shortening of power supply on battery change page 273 ...

Page 266: ...stem see page 267 Switching the nutrunner off on note after having removed the slide in battery pack wait for approx 20 seconds before reinserting the pack Control signals Self acknowledgement applies only to error class 4 11 1 2 Error code assignment table A list with error codes and the relevant error texts are supplied in PDF format All error codes can also be found in the error list see Comple...

Page 267: ...he access point Please also note the LEDs at the access point see operating instructions Table 11 2 Error classes Error class Error type Remedy 0 Errors of class 0 are not displayed by the communication partner for the Open Protocol see Rexroth Open Protocol from page 75 which is called Open Interface System message no error e g test interval reached Remedy not required 1 This error class signals ...

Page 268: ... Check ambient temperature 13 4 Servo amplifier communication error Reboot nutrunner 14 4 Servo amplifier service error Start and R L switch state cannot be read Reboot nutrunner 15 4 Servo amplifier incorrect input voltage Slide in battery pack defective Replace slide in battery pack 100 0 Tightening program not available A tightening program selected for execu tion cannot be found in the nutrunn...

Page 269: ...ter nal memory Reboot nutrunner Update firmware 300 4 NX SD card was removed The NX SD card was removed while data output configured to NX SD card or is not available Insert the NX SD card again or deactivate the function accessing it e g results output Reboot nutrunner 301 1 Initialization of results data failed The results database in the internal memo ry could not be initialized Reboot nutrunne...

Page 270: ...iguration cannot be read by the internal memory Reboot nutrunner Repeat Open Protocol configuration in NEXO OS Reset the Open Protocol settings to default in NEXO OS Update firmware 702 0 Open Protocol Blocking failed 800 1 Job Initialization error The mode file read by the internal memory cannot be read Create or import the mode again Use backup 801 3 Job Job number not available A job selected f...

Page 271: ... XML Timeout Port B for the answer from Master PC Master PC has not responded to port B within the expected time acknowledge timeout Inform the manufacturer operator of the master PC Adjust VW XML configuration 918 0 VW XML Connection error on port B The connection on port B was terminated by the master PC Inform the manufacturer operator of the master PC 919 0 VW XML Timeout KeepAlive port B Nexo...

Page 272: ...DAT received is in process Duplicate order data 1003 3 SOLLDAT received has unsent LSA results Reboot nutrunner Delete BMW database 1004 3 SOLLDAT received has unsent WAS results Reboot nutrunner Delete BMW database Table 11 3 Error description Error code Error class Description Possible cause consequence Suggested solution ...

Page 273: ...ttery pack has been disconnected several times in succession Increased operating time of integrated power supply Defective internal power supply WARNING Improper execution of service work Improper performance of service work may result in personal injury damage to components and jeop ardization of the tightening system Ensure that service work is always carried out by qualified personnel having th...

Page 274: ...274 279 Bosch Rexroth AG Tightening Technology 3 608 870 A47 Nexo cordless Wi Fi nutrunner 3 608 870 A47 2019 10 ...

Page 275: ...s not covered by any liability or warranty on the part of Bosch Rexroth AG For the license conditions of the used software click on the symbol in the navi gation panel of the NEXO OS Use the Access to NX SD card menu item to open an Explorer window The licenses can be found in the directories licenses and sourcecode ...

Page 276: ...276 279 Bosch Rexroth AG Tightening Technology 3 608 870 A47 Nexo cordless Wi Fi nutrunner 3 608 870 A47 2019 10 ...

Page 277: ...s and email address where we can reach you if we have any questions For additional information on service repairs and training as well as the current addresses of our sales offices please refer to www boschrexroth com If you are located outside of Germany please contact your nearest Rexroth partner Service Germany Phone 49 9352 40 50 60 E mail service svc boschrexroth de Sales Germany Bosch Rexrot...

Page 278: ...ightening Technology 3 608 870 A47 Nexo cordless Wi Fi nutrunner 3 608 870 A47 2019 10 Bosch Rexroth AG Training Center Erbach Berliner Straße 25 64711 Erbach Odenwald Phone 49 6062 78 600 E mail training erbach boschrexroth de ...

Page 279: ...tfach 1161 71534 Murrhardt Germany Fornsbacher Str 92 71540 Murrhardt Germany Phone 49 71 92 22 208 Fax 49 71 92 22 181 www boschrexroth com tightening 3 608 870 A47 EN 2019 10 AF Bosch Rexroth AG 2019 Subject to revisions ...

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