Deprag 428001 A Operating Instruction Booklet Download

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013735en

Operating Instruction Booklet

- Translation of the original instruction -

Sequence Controller

AST6

428001 A

NOTICE ALL DOCUMENTATIONS !

Before beginning work

this operating instruction booklet and the enclosed

safety instructions

(no. 016000, pink-colored booklet) have to be read through

carefully. Always follow the instructions during operation. Give this operating in-
struction booklet and the appropriate safety instructions to the operator.

Summary of Contents for 428001 A

Page 1: ...LL DOCUMENTATIONS Before beginning work this operating instruction booklet and the enclosed safety instructions no 016000 pink colored booklet have to be read through carefully Always follow the instr...

Page 2: ...General 24 8 2 Operating via the Touch Display 24 8 2 1 Control Elements 24 8 2 2 Menu Structure 27 8 2 3 Description of the Menu Structure 28 8 3 Operation via the Web Interface 32 8 3 1 Requirements...

Page 3: ...DISPLAY AND TROUBLESHOOTING 72 14 1 System Errors 72 14 1 1 Screwdriver 72 14 1 2 Power Unit 72 14 1 3 Main Controller 73 14 1 4 Communication 73 14 1 5 I O Interface 74 14 2 Error in the Screwing Se...

Page 4: ...gure 18 Web Interface Menu Structure 33 Figure 19 The Home Page 34 Figure 20 Start page 35 Figure 21 Statistic 36 Figure 22 Downloading Curve Data 37 Figure 23 Screwdriver Results 38 Figure 24 Tool Da...

Page 5: ...us parameters 51 Table 10 Configurable Profinet parameters 51 Table 11 Configurable Ethernet IP parameters 51 Table 12 Default Values 52 Table 13 Default values for Profibus 52 Table 14 Default values...

Page 6: ...r which can cause serious injuries or even death if not avoided CAUTION Indicates a danger or unsafe procedure which can cause injuries to a per son or material damages if not avoided NOTICE Indicates...

Page 7: ...Use The sequence controller AST 6 is designed exclusively for fittings in industrial use And must only be operated with DEPRAG MICROMAT EC screwdrivers stationary of the series 320E12 and 320E19 The s...

Page 8: ...and 320E19 It has a E A interface and an Ethernet connection and as well as optional via one fieldbus interface The sequence controller AST6 can be operated via the web interface as well as via the to...

Page 9: ...Panel Figure 1 Front Panel of AST6 6 1 2 Connection Panel Main switch GX4 Screwdriver connection GX1 Power supply connection voltage supply GX3 Ethernet GX2 SFD connection clearance to start GX5 inte...

Page 10: ...tion GX4 Plug connector SUB D 15 pole bushing 6 2 2 Voltage Supply Designation GX1 Plug connector Circular plug in connector 3 pole Also see Required Accessories PIN Designation 1 24V 2 n c 3 GND 6 2...

Page 11: ...dule or component group of the AST6 must be fed with 24V DC to use the inputs outputs This is done by feeding 24V DC via the pins 23 and 25 6 2 5 Interface Fieldbus optional 6 2 5 1 Profibus Designati...

Page 12: ...12 7 Commissioning 7 1 Dimension Sheet Figure 3 Dimension Sheet...

Page 13: ...of the sequence controller AST6 with the in house power supply also refer to Technical Data Connect the screwdriver to the GX4 interface and screw on the retaining screw tightly Connect the plug of I...

Page 14: ...nal fieldbus module is installed control may be done via the fieldbus module or via the I O interface The choice is made in the menu Applying the start signal initiates the screwing in operation The p...

Page 15: ...ated 5 Wait for Ready output signal HIGH Controller is once again ready for screw fixing operation 6 Signal LOW at the program start input and if necessary change the bit pattern for program selection...

Page 16: ...16 7 5 2 2 Hardware configuration 7 5 2 2 1 Profibus DP Figure 5 Hardware configuration of Profibus DP 7 5 2 2 2 Profinet Figure 6 Hardware configuration of Profinet...

Page 17: ...with a new DB instance DB30 IDB_AST6DP DB instance for FB13 Example for Profibus DB31 AST6_Interface Data module for the interface parameters of FB13 DB32 IDB_AST6PN DB instance for FB13 Example for P...

Page 18: ...configuration e g 448 O_Addr1 INT Output address from the hardware configuration e g 256 O_Addr2 INT Output address from the hardware configuration e g 320 O_Addr3 INT Output address from the hardwar...

Page 19: ...der to stop or continue the screwdriver operation program ProgIn4 BOOL Input 4 for the screwdriver program This input can be sensed in the screwdriver program of the AST6 controller in order to stop o...

Page 20: ...6 controller if the DataSaved signal is set by the PLC program or a new screwdriver operation has been started Error BOOL Error This signal indicates that an error has occurred in the FB13 module The...

Page 21: ...ut module has been entered in the hardware configuration Input module 4 must be configured with 32 bytes in Incorrect start address of the input module 4 at the interface parameter I_Addr4 FF10 Error...

Page 22: ...The torque value of the data backup 2 is output here fd_Angle2 DINT Angle value of the Data backup 2 The angle value of the data backup 2 is output here fd_Step3 DINT Step number of the Data backup 3...

Page 23: ...the Save values command multiple times in the screwdriver program the previous values are shifted upwards fd_Step3 fd_Step2 fd_Step1 If an error occurs during the screwdriver operation the screw fixi...

Page 24: ...performed via the web interface since the movement of the EC screwdriver can only be started via the touch display 8 2 Operating via the Touch Display The sequence controller AST6 is equipped with a T...

Page 25: ...ting between several Options All options are displayed in their own buttons if several options are available for selection e g the language the torque unit The option that has been selected is highlig...

Page 26: ...e for the program name Tab the text input field and a keyboard will be displayed Here letters numbers hyphens and space characters can be entered A text that is already in the text input field can als...

Page 27: ...s Data Statistics Graphic System System Data Screwdriver Data Setup Screwdriving Sequence Test System Test Screwdriver Test Speed Test Angle Test Torque Test Sequence Test Interface I O Interface Fiel...

Page 28: ...sequence open without password a change is not possible only a display of the parameter is provided Test can not be opened without a password If the password is set to 0000 then all menus are released...

Page 29: ...eration see also Statistic First select the program number for which you would like to display the statistics To do this enter the program number directly or use the and keys Click on the Torque or An...

Page 30: ...controller AST6 can be set in the settings menu also refer to Settings If you did not enter a password then only the set values are displayed Changes are not possible 8 2 3 3 Screwing Sequence Menu Fi...

Page 31: ...equence controller AST6 as well as for the EC screwdriver also refer to Diagnosis The system test shows the current status of the sequence controller AST6 Different tests for the EC screwdriver an be...

Page 32: ...e the sequence controller AST6 as well as the browser must be set in a manner that a TCP Ip connection between both can be established and the data exchange released 8 3 2 1 Setting the Sequence Contr...

Page 33: ...ructure Startpage Prozess Data Statistics Graphic Final Values System Tool Data System Data Update Extensions Setup General Settings Time New Password Screwdriving Sequence Extras Manuals Additional P...

Page 34: ...25 108 The browser connects to the sequence controller AST6 and loads the home page Figure 19 The Home Page If you intend to perform changes enter the password The standard password at the time of de...

Page 35: ...dbus module installed Moreover the type of the screwdriver fitted and the version of the screwdriver logic is displayed On the left side is the main menu which is used to access the individual pages o...

Page 36: ...d This is done by clicking the respective button Also refer to Statistic IMPORTANT Statistic values are only saved and analyzed if the statistic command in the screwing sequence is open The upper and...

Page 37: ...he sequence controller AST6 is switched off or a new screw connection is established It is furthermore possible to download free of charge the viewing program GRAPH10 E for the binary curve data If yo...

Page 38: ...er Results The end values of the screwing of the last seven days can be downloaded as CSV data refer to Final Values Figure 23 Screwdriver Results The final values cannot be deleted if you have not en...

Page 39: ...tem menu is used to display data specific to the tool and the system 8 3 4 3 1 Tool Data On this page the important data of the connected screwdriver are displayed Figure 24 Tool Data Changes to the t...

Page 40: ...ge illustrates the invariant data as well as the network settings of the AST6 sequence controller Figure 25 System Data 8 3 4 3 3 Update New software may be copied to the controller in the Update menu...

Page 41: ...41 Figure 26 Update 8 3 4 3 4 Extensions On this page you are able to activate Extensions of the AST6 Figure 27 Activating Extensions...

Page 42: ...which contains the respective activation key The activation key can be entered directly on the bottom of the page or by clicking the button load key As an alternative the license data can be also dir...

Page 43: ...part of the page you can save your settings in order to transfer them to other sequence controllers Type AST6 or to reload later Figure 29 Default Settings Lower Part of the Page After clicking the Ba...

Page 44: ...troller AST6 Figure 30 Date Time 8 3 4 4 3 Password On this page you can set the password for the access to the sequence controller AST6 Figure 31 New Password The password is only valid for changes t...

Page 45: ...ard you can select program 1 to 20 For programs 21 to 100 click first on the matching registry card and subsequently select the desired program General parameter There are two parameters for each prog...

Page 46: ...Click the accept button which can be found below the last program step in order to save the program step and the parameter Copy program If you want to save an available program under another program...

Page 47: ...the screwdriver program If you would like to delete all screwdriver programs first click on the General tab and then on the Delete all programs button IMPORTANT A program step a complete program or al...

Page 48: ...in then you can read the manuals directly in the browser Figure 33 Manuals 8 3 4 6 2 Additional Programs On this page you may download all supplementary software available for the AST6 sequence contro...

Page 49: ...49 Figure 34 Additional Programs 8 3 4 6 3 Fieldbus On this page you may download all fieldbus drivers available for the AST6 sequence controller Figure 35 Fieldbus...

Page 50: ...screwing application The main direction right means that all screwing samples will operate rotating to the right all screw samples to release with rotate to the left Rotation speed decrease If the ro...

Page 51: ...ontroller lies Gateway The IP address of the gateway for the network segment in which the AST6 sequence controller lies Station name Station name of the AST6 in the Profinet Table 10 Configurable Prof...

Page 52: ...1 Efficiency 100 Direction change no Fieldbus Available no Control via I O interface inactive Statistic Limits for CP CPK value 15 Table 12 Default Values 9 2 2 Special parameters for fieldbus systems...

Page 53: ...he selected swell torque Switching off criteria The screwing process is ended once the cut out torque is reached the maximum screwing time monitoring time is expired the maximum angle of rotation is r...

Page 54: ...wing level the time monitoring is started At the start of the level screwing is done with rotation speed 1 Once the dwelling torque has been reached the rotation speed is changed to rotation speed 2 C...

Page 55: ...Maximum time until the cut out torque is reached monitoring time Cut out torque cut out torque min max Rotation speed 1 Swelling torque for rotation speed 2 Rotation speed 2 Torque holding time Angle...

Page 56: ...nd the value of the angle of rotation is in the set limits Furthermore the torque value must be within the set limits Not OK evaluation The screwing level is evaluated as Not OK faulty if the angle of...

Page 57: ...he measuring range is reached a monitoring criteria is reached the maximum screwing time monitoring time is expired Analysis OK evaluation The screwing level is considered OK fault free if the frictio...

Page 58: ...maximum torque that must not be exceeded by individual torque values during the friction monitoring Minimum friction value Input of the minimum torque that must not be undershot by the friction torque...

Page 59: ...ue of the previous level and the differential moment Minimum differential moment Lower limit of the differential end moment The actual torque lower limit results from the sum of the torque of the prev...

Page 60: ...gle Angle lower limit Lower limit of the end angle 10 1 4 3 Screwing Applications depending on Friction The screwing sample friction dependent screwing connects the screwing sample friction measuremen...

Page 61: ...angle range in which the friction monitoring should be active This range starts with the start angle of the friction measurement Friction value creation Selectively the maximum value or mean value of...

Page 62: ...e A holding time can be defined to keep the moment for this time End value creation Differential torque total torque Selectively the end torque can be displayed as difference between the total torque...

Page 63: ...like 10 2 5 Save Values Saves the values of the previous screwing level into the end value data set The command can be used as often as you like also see Screwdriver Results IMPORTANT As a maximum the...

Page 64: ...ates and the display field actual shows the present rotation speeds To stop the screwdriver tab the red stop symbol 11 2 2 Angle Test You are able to check the measured angles in the submenu angle tes...

Page 65: ...ng samples are displayed as program steps in the sequence test commands are skipped Please also be aware that the display of the program step must therefor not always match the number in the screwing...

Page 66: ...csv The files are subject to the same limitations as described in chapter Curve Representation for the curve data The CSV file is structured as follows First line Title bar with caption of the values...

Page 67: ...ce Calc can not process more than 65536 lines that contain curve data but often more datasets 2 Both table processes interpret the decimal number depending on language German version expects a decimal...

Page 68: ...CPK value The limits for the Cp CPK value calculation can be entered If no limits are set then the calculation is done automatically with 15 of the mean value The limits entered are maintained even af...

Page 69: ...s Internal dampness can build up and damage the electric circuitry when the device then is moved to normal temperature conditions Do not try to open the device in any other way than in the instruction...

Page 70: ...ion is done as described in section Start Click on settings and then update In order to update the Power unit enter the file name and path in the input field and click load Alternatively you can selec...

Page 71: ...switch and disconnect the power plug 2 Remove the six pan head screws Allen screw SW 2 5 at the back of the sequence controller AST6 and open the housing IMPORTANT Ensure polarity when inserting the b...

Page 72: ...act the DEPRAG Service Department 101 Position indicator index signal not found 102 QEP position indicator signal missing or wrong 103 Initialization error spindle free Please ensure that the drive of...

Page 73: ...st them if necessary 205 Error in the data storage 206 Error in the communication with power unit Please contact DEPRAG Service 207 not used 208 No connection to fieldbus Switch off the AST6 and then...

Page 74: ...s input 412 READY output used as input 413 OUT1 output used as input 414 OUT2 output used as input 415 OUT3 output used as input 416 OUT4 output used as input 417 Supply voltage of I O interface beyon...

Page 75: ...The start signal has been reset prior to the normal end of the screwing application The start signal must be present until the end of the screwdriver operation 11 Over current Current exceeds maximum...

Page 76: ...and Troubleshooting A connection to the controller is not possible Check if the IP address set at the AST6 is correct Display does not react to touch Press a bit harder onto the touch display Ensure t...

Page 77: ...of the PC It is required to access the controller Designation Part no Patch cable 831902 17 2 Fieldbus Module 17 2 1 Profibus Designation Part no Expansion Kit AST6 Profibus 385816 A 17 2 2 Profinet D...

Page 78: ...pole 832625 17 5 Plug Connector Voltage Supply Plug connector to connect the sequence controller AST6 to the available 25V supply Designation Part no Cable socket 810122 17 6 Touch Pen Special pen fo...

Page 79: ...pending on friction For detailed description also refer to Friction Value Package optional The software package must be released as described under Extensions Designation Part no Software release key...

Page 80: ...PH10E The GRAPH10 E program can be downloaded free of charge via the web interface of the sequence controller AST6 However the use of the curve overlapping is subject to cost Designation Part no Graph...

Page 81: ...gulations 016000 see Chapter Environmental protection regulations Storage and Disposal page 18 Decommissioning is to be done using the following steps No Activity 1 De energize the electrical equipmen...

Page 82: ...mum input power W 150 Display and operation TFT Graphic display 4 3 480x272 Pixel with Touchscreen Storage temperature C 20 60 Humidity 25 75 Vibrations g 3 Impact load g 30 Type Part no Mains unit AS...

Page 83: ...on of a motor shaft or an drive unit End value dataset The dataset in which all result data for the screwing application is stored Ethernet Data network technology for local data networks to exchange...

Page 84: ...t is possible to check if the requirements are met with sufficient safety It is the objective of the process capability examination to verify that the a processes to be examined is processing with the...

Page 85: ...ectronic where all data of the screwdriver is stored If the screwdriver is connected to the controller then it recognizes all data of the screwdriver No settings have to be performed manually Screwing...

Page 86: ...86 Web interface Software interface for the programming of the sequence control that are actuated via a standard Internet browser...

Page 87: ...e Type _________________________________________________________ Serial Number _________________________________________________________ Year of Manufacture ___________________________________________...

Page 88: ...eb site www deprag com If you need any further information then please either contact your representative or us directly at DEPRAG SCHULZ GMBH u CO During business hours our Service Hotline 49 0 700 0...

Page 89: ...Germany 92203 Amberg Carl Schulz Platz 1 Germany 92224 Amberg Service hotline 49 0 0700 00 371 371 49 0 9621 371 0 Fax 49 0 9621 371 120 Internet http www deprag de e mail info deprag de Jan 13 Techn...

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