Deprag AST11-1 Operating Instruction Booklet Download Page 1

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014091en

Operating instruction booklet

- Translation of the original instruction -

Sequence controller

AST11-1
AST11-1-S
AST11-2
AST11-2-S

390041 A
390041 B
390042 A
390042 B

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 AST11-1

Page 1: ...B 390042 A 390042 B 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 care...

Page 2: ...iver 23 7 6 2 Operation with a higher level controller 23 7 6 2 1 Operation with a handheld Screwdriver 23 7 6 2 2 Operation with a stationary Screwdriver 24 7 6 2 3 Selection and Start of a Screwdriv...

Page 3: ...Setup Serial Device 61 8 3 4 13 Setup Extensions 64 8 3 4 14 Screwdriving sequence 64 8 3 4 15 Tools Manuals 68 8 3 4 16 Tools Additional Programs 68 8 3 4 17 Tools Fieldbus 69 8 3 4 18 Tools Update...

Page 4: ...ng the software 98 13 1 1 Main control and touch display 98 13 1 2 Power element 98 13 2 Replace the filter mat of the sequence controller 98 13 3 Spare parts 100 14 ERROR DISPLAY AND TROUBLESHOOTING...

Page 5: ...3 DataLogger 112 17 10 4 TC30 PC Statistics 113 17 10 5 DEPRAG ASTxx Serial Remote 114 18 TECHNICAL DATA 115 19 GLOSSARY 116 20 EG CONFORMITY DECLARATION 120 21 SERVICE LOCATIONS AND AUTHORIZED PARTN...

Page 6: ...rinter settings 61 Figure 30 Selection of fieldbus 61 Figure 31 Settings for fieldbus EtherCAT example 62 Figure 32 Settings for fieldbus EtherNet IP example 62 Figure 33 Settings for fieldbus Profibu...

Page 7: ...Data structure of the screw data UDT33 34 Table 14 LEDs 36 Table 15 Menu and Cursor Keys 37 Table 16 Errors of F function 71 Table 17 Adjustable parameters 76 Table 18 Configurable Profibus parameters...

Page 8: ...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 9: ...s designed exclusively for fittings in industrial use And must only be operated with DEPRAG MICROMAT EC screwdrivers and DEPRAG MINIMAT EC screwdrivers stationary and handheld of the series 320Exx19 3...

Page 10: ...ctly altered to suit screwdriving tasks using the sequence controller s keypad The AST11 allows free programming of your screwdriving sequences for hand held or stationary screwdriving tools If requir...

Page 11: ...11 6 Hardware Description 6 1 Views of the AST11 6 1 1 Front Panel Figure 1 Front view AST11 Display Function display Operating elements...

Page 12: ...12 6 1 2 Rear View Figure 2 Rear view To ensure the air exchange the filter openings must not be covered up The inside filter can be replaced Attachment points Filter openings Attachment points...

Page 13: ...X10 for connection of printer barcode scanner or fieldbus 2 ethernet GX9 3 main switch 4 fuse 5 voltage supply GX2 6 F Controller port GX7 7 feeder port GX8 8 emergency stop port GX11 not shown only b...

Page 14: ...put GND internal 8 Input 8 Start Release 21 Output 24 V internal 9 Input 9 External Stop 22 10 Input 11 Reset Error 23 Input Release controller emergency stop 11 Input 12 Release Part 24 Input n c 12...

Page 15: ...ut Release controller emergency stop contact pins 21 and 23 6 2 6 Multifunctional Serial Interface Description GX10 Connector SUB D 9 pole socket This interface can be used in conjunction with a print...

Page 16: ...ble 3 Pin assignment feeder port Potential connected Potential free Figure 4 Connection of feeder port 6 2 8 Emergency Stop 2 Channel The emergency stop 2 channel module is integrated as standard in t...

Page 17: ...IMPORTANT The relay must only be switched on without any load Pay attention to the signal sequence see 7 6 2 5 Standard Communica tion higher level controller Emergency Stop 2 Channel 6 2 9 F Control...

Page 18: ...18 7 Commissioning 7 1 Dimension Sheet Figure 5 Dimension sheet...

Page 19: ...tions for the Operation of the Sequence Controller AST11 with 320E EC screwdriver CAUTION Injuries from electricity or damages on the device Prior to connecting to the power compare the layout design...

Page 20: ...erface ATTENTION Sequence controller not function ing The interface GX6 must always be occupied When the I O interface is not in use plug in the connector 385476 A Optional Multifunctional serial prin...

Page 21: ...on the sequence controller AST11 using the main switch More information about the interface assignment can be found under 6 1 3 Connection panel and 6 2 Interface Description Read the Operating Instr...

Page 22: ...22 7 3 Example for screwdriving systems Figure 6 Screwdriving system handheld screwdriver power supply cable AST11...

Page 23: ...new screw assembly programs refer to 8 3 4 14 Screwdriving sequence 7 6 Functioning of the Sequence Controller AST11 7 6 1 Operation as Stand Alone unit with a handheld Screwdriver When manually scre...

Page 24: ...0 7 0 1 1 1 8 1 0 0 0 9 1 0 0 1 10 1 0 1 0 11 1 0 1 1 12 1 1 0 0 13 1 1 0 1 14 1 1 1 0 15 1 1 1 1 Table 6 Program choice 7 6 2 4 Standard Communication higher level controller AST11 Signal sequence of...

Page 25: ...must be set Communication Screwdriving cycle without Emergency Stop Situation 1 Request a Ready Signal Pin 15 high and Normally Closed Contact low 2 Signal high to input Program Start Pin 1 3 Request...

Page 26: ...a master controller via the Fieldbus optional 7 6 3 1 Profibus DP Profinet The device files for the Profibus and Profinet can be downloaded through the AST40 se quence controller s web interface see 8...

Page 27: ...s Fieldbus 7 7 1 1 General Information All the program modules necessary for Profibus or Profinet connection to a Siemens S7 controller are available in the DEPRAG_AST11PNDP zip software package IMPOR...

Page 28: ...must be loaded for each AST11 sequence controller with each new instance data block respectively DB50 IDB_AST11DP DB instance for FB15 e g Profibus DB51 AST11_Interface Data module for the interface...

Page 29: ...256 O_Addr2 INT Output address from the hardware configuration e g 320 O_Addr3 INT Output address from the hardware configuration e g 384 O_Addr4 INT Output address from the hardware configuration e...

Page 30: ...e AST11 sequence controller in order to stop or continue the screwdriver operation program FC_PART_ SENSOR BOOL F Function Input part sensor When the part sensor is connected the status of the signal...

Page 31: ...screwdriving program of the AST11 sequence controller this output can be set or reset and read on the PLC DataAvailable BOOL Data available This signal indicates that there is new screwdriving data av...

Page 32: ...start address of the input module 4 at the interface parameter I_Addr4 FF10 Error in the output address range Cause The interface parameter O_AddrX X 1 4 does not have a value or has one that is 0 FF...

Page 33: ...que value of the Data backup 2 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 St...

Page 34: ...es 0 OK 1 too short 2 too long 3 part missing 4 change part FC_COUNTER _TARGET INT F Function Target screw assemblies Number of OK screw assemblies until the component is finished FC_COUNTER _CURRENT...

Page 35: ...fd_Step3 fd_Torque3 fd_Angle3 When using 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...

Page 36: ...or it can be operated by a PLC 8 2 Operating Elements Figure 11 Operating Elements 8 2 1 Functional Display LEDs The LED s located below the display notify the user about the operating status of the s...

Page 37: ...r values such as nominal speed to set a pa rameter or to perform a test Always confirm any numerical input with RETURN key Use the ESC key to interrupt your input the original value remains intact 8 2...

Page 38: ...ast Start Release Speed Reduction Beeper Default Values Maintenance Interval F Control Settings Activate Resetbutton Part Clearance Programs Diagnostics Program Choice Number Screwjoints PG Setting Ti...

Page 39: ...wdriver The data can be displayed during equipment operation without interrupting the automatic sequence 8 2 5 1 1 Tool Data The tool data include all important information about the connected driver...

Page 40: ...ics for individual programs right cursor key 8 2 5 3 Menu Setup Use the setup menu to input general sequence controller adjustments 8 2 5 3 1 Date Time The current system time as well as system date w...

Page 41: ...the menu without making any changes 8 2 5 3 5 Startmode Handtool It can be selected to use external start start and program choice by e g PLC with the handtool 8 2 5 3 6 Optional Parameters 8 2 5 3 6...

Page 42: ...ooted and the display shows AST11 Reboot System Gateway When the gateway is changed the system starts up new To change the gateway use the function key Modify input the four numerical blocks individua...

Page 43: ...the sequence controller is not ready The enable start may be activated or deactivated The basic setting is deactivated Make a selection with the cursor keys and use the ENTER key to confirm your selec...

Page 44: ...separate chapter 9 F Function 8 2 5 3 6 12 Program Choice Here you can set the mode for program choice see also 10 1 1 Parameters of the System Settings If fixed setting is selected then in the follow...

Page 45: ...in use the ENTER key to confirm the change Use the ESC key to interrupt an input the previous valid values remain Again use the ESC key to exit the menu Now use the two function keys to save or not sa...

Page 46: ...is dis played Use the right function key RESET to reset the angle value to 0 Exit the menu item Angle Test with the ESC key 8 2 5 5 1 3 Torque Test The menu item Torque Test allows the verification of...

Page 47: ...ntroller The status of the parameters is updated only when calling the menu Use the cursor keys to switch between the individual values 8 2 5 5 3 Process Test Use the Sequence Test to check the functi...

Page 48: ...the display Inputs 000000000000 Input 1 Start Input 2 Input 3 Program Selection Input 4 Program Selection Input 5 Program Selection Input 6 Program Selection Input 7 Reload Input 8 Start Release Inpu...

Page 49: ...ll keys are te sted in regard to their functionality To exit the key test menu at any time simply press the ESC key 8 2 5 5 7 LED Test Use this LED Test function to verify that all LED s on the sequen...

Page 50: ...er that a TCP IP connection between both can be established and the data exchange released 8 3 2 1 Setting the sequence controller AST11 A set IP address must be set at the sequence controller AST11 a...

Page 51: ...nfo Tool Data System Data Process Data Screwdriving Sequence Statistics Graphic Final Values Setup General Settings Time F Control New Password Serial Device Extensions Screwdriving Sequence Tools Man...

Page 52: ...he home page If you intend to perform changes enter the password The standard password at the time of delivery is 0000 If you only want to view data without changing them you will not need a password...

Page 53: ...to special cases Minimum torque smallest possible torque Maximum torque largest possible torque Minimum rotation speed smallest possible rotation speed Maximum rotation speed largest possible rotation...

Page 54: ...IP Address IP address of the sequence controller Netmask bitmask of the sequence controller network element Gateway IP address of the gateway set in the sequence controller MAC Address hardware addres...

Page 55: ...ue o Direction change this option indicates whether the offset gear reverses the turn direction of the screwdriver Handheld with External Start displays if handheld screwdriver will be started by a hi...

Page 56: ...istics for all programs are displayed You can select the program for which the statistic should be displayed This is done by clicking the respective button Also refer to 12 3 Statistic Click on the de...

Page 57: ...tion as a da ta from the sequence controller AST11 In principle all screwing applications are recorded The record will be available until the sequence controller AST11 is switched off or a new screw c...

Page 58: ...ure 23 Screwdriver results The files have the same limits for CSV data as described in 12 2 Curve Representation The final values which are older than seven days will be replaced by new final values A...

Page 59: ...the lower part of the page you can save your settings in order to transfer them to other sequence controllers Type AST11 or to reload later Figure 25 General settings lower part of the page After cli...

Page 60: ...o do the appropriate adjustments Figure 27 Setup F Control More information on the F Control function you find in chapter 9 F Function 8 3 4 11 Setup Password On this page you can set the password for...

Page 61: ...e printed text is printed as entered whereby the variables are replaced by the relevant values Variables always begin with the symbol and must end with a space character A detailed description of the...

Page 62: ...eldbus EtherCAT example Figure 32 Settings for fieldbus EtherNet IP example Figure 33 Settings for fieldbus Profibus example Figure 34 Settings for fieldbus ProfiNet example Click on Submit to transfe...

Page 63: ...marker for barcode end marker which the barcode scanner sends once a bar code has been read Any character within the range 0x0A 0x0F if a barcode is selected for Program Choice in the Basic Settings...

Page 64: ...ctive option The key can either be directly copied and inserted in an email or saved by clicking the file You will receive a license file for the activation which contains the respective activation ke...

Page 65: ...ier labelling of the program and has no effect on the screwdriving sequence The program name must not contain any special characters Direction change Determines if another main rotational direction ap...

Page 66: ...found below the last program step in order to save the program step and the parameters Copy program If you want to save an available program under another program number select the new program number...

Page 67: ...s saved programs can be restored and all programs can be deleted After clicking the Create Backup of all Programs button a window is opened in which you can set the name and location of the back up fi...

Page 68: ...then you can read the manuals directly in the browser Figure 39 Manuals 8 3 4 16 Tools Additional Programs On this page you can download all programs which are available for the controller AST11 Usage...

Page 69: ...ay download all fieldbus drivers available for the AST11 sequence controller Figure 41 Fieldbus 8 3 4 18 Tools Update New software can be loaded onto the sequence controller in the Update menu also se...

Page 70: ...LED glows and the se quence controller doesn t release the screwdriver no Ready Signal i e no green LED After resetting the error either with the reset button on the sequence controller or through th...

Page 71: ...an error Part Missing is displayed If the correct number of O K screw joints is reached the controller will give an acoustical signal and the display indicates Change Part If the screwdriver is used...

Page 72: ...ice between Part Clearance by Button yes or no Make your selection with the cursor keys Confirm your selection with the ENTER key and exit this menu with the ESC key If the part clearance by button is...

Page 73: ...e analysis acquires values from 5 screw joints Proceed as follows First input the program number which is used for the analysis Thereafter process the first screw joint the actual screwdriving time is...

Page 74: ...s what direction is defined as 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 Spe...

Page 75: ...Setting will always be started keys the number keys on the keyboard are used to select program number This function is not available if F Function is activated Barcode selection of program depends on...

Page 76: ...via Profinet Net mask It designates the network segment in which the AST11 sequence controller lies Gateway The IP address of the gateway for the network seg ment in which the AST11 sequence controll...

Page 77: ...int options always Gear transmission ratio 1 Efficiency 100 Offset gear Direction change no Type of program choice fixed setting Program 1 Password 0000 Delay interrupt 3 active no Reset by Button ina...

Page 78: ...78 Ethernet IP Parameter Value IP address 10 10 24 11 Net mask 255 255 0 0 Gateway 10 10 20 9 DHCP inactive BOOTP inactive Table 24 Default values for Ethernet IP Ethercat No settings are necessary...

Page 79: ...hreshold Shut off criteria The screwdriving process is ended once the Target torque is achieved the maximum screwdriving time monitoring time is exceeded the maximum angle of rotation is reached only...

Page 80: ...option Strategy Description Figure 44 Expanded screwdriving to Torque Strategy description At the start of the first screwdriving sequence step time monitoring is started and the screwdriving process...

Page 81: ...OK if the angle value is outside the preset limits Parameters The following parameters are used in the screwdriving sequence Supervision time Maximum time until the shut off torque is reached shut of...

Page 82: ...st be within the preset limits Not OK evaluation The screwdriving sequence is evaluated as Not OK faulty if the angle of rotation is outside the preset limits or the screwdriving time has been exceede...

Page 83: ...ia The screwdriving sequence is completed when an external Stop Signal is received the maximum angle is exceeded the maximum torque is exceeded the maximum allowable screwdriving time time supervision...

Page 84: ...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 85: ...maximum torque that must not be exceeded by individual torque values during the friction monitoring Friction value lower limit Input of the minimum torque that must not be undershot by the friction t...

Page 86: ...f the torque of the previous level and the differential moment Differential torque lower limit Lower limit of the differential end moment The actual torque lower limit results from the sum of the torq...

Page 87: ...t of the end angle Angle lower limit Lower limit of the end angle 11 1 5 3 Fasten dependent on friction value The screwing sample friction dependent screwing connects the screwing sample friction meas...

Page 88: ...angle range in which the friction monitoring should be active This range starts with the start angle of the friction measurement Friction value type Selectively the maximum value or mean value of the...

Page 89: ...A holding time can be defined to keep the moment for this time Final values type Differential torque total torque Selectively the end torque can be displayed as difference between the total torque and...

Page 90: ...crewing level per program If the statistic command is entered more than once into the program then only the statistic for the last screwing level is calculated for which the statistic command has been...

Page 91: ...occur as soon as the input is set Parameters maximum waiting time Input number 11 2 8 Set output Sets an output Only available for output number 8 Parameters output number time supervision yes no o t...

Page 92: ...files are subject to the same limitations as described in chapter 12 2 Curve Represen tation for the curve data The CSV file is structured as follows First line Title bar with caption of the values F...

Page 93: ...5536 rows the curve data however frequently contain more data sets Microsoft Excel Version 2007 and newer as well as OpenOf fice org LibreOffice org Calc Version 3 3 and newer can contain 1 048 576 ro...

Page 94: ...nds whereby texts can be output directly to the printer and commands can be replaced by the respective valid value see following table A command consisting of characters and ending with a blank charac...

Page 95: ...atistics Torque Stan dard Deviation Value 1 7 StatTorqueStddevAbs Statistics Torque Stan dard Deviation abs Value unit 0 020 Nm StatTorqueCPK Statistics Torque CPK Value 1 77 StatTorqueCP Statistics T...

Page 96: ...rortext Issue 2013 04 24 07 13 37 PG 12 ST 3 TQ 2 15 Nm AN 1080 OK The amended format string date_euro time Program prog step step fault error runtime runtime torque torque angle angle delivers follow...

Page 97: ...tics Do not keep the device in cold conditions 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 de...

Page 98: ...and click Load Alternatively you can select the file by clicking the Search button next to the input field After you clicked the Load button the inscription the update is being uploaded to the control...

Page 99: ...on the rear housing wall 5 Remove the power unit at the rear housing wall 6 Pull out the filter mat from the rear wall in the direction marked in the illustration Figure 52 Filter mat on the housing r...

Page 100: ...100 Caution Prior to the re start perform the operating media test acc to the valid regulations e g BGV A3 13 3Spare parts Designation Part no Filter mat 826057...

Page 101: ...or 2 in EEPROM not re pairable 006 Test sum error in RAM 007 Test sum error in flash 008 EEPROM error Maximum amount of screwing cycles reached Troubleshooting not possible 009 next maintenance is due...

Page 102: ...iver and power unit do not match Ensure that you have installed the correct screwdriver model to the AST11 The AST11 1 S can be operated with screw drivers of the series 320Exx19 and 320Exx22 and 320E...

Page 103: ...l has not been reached 4 TORQUE LOW The indicated minimum torque of the screwing level was not reached 5 TORQUE HIGH The set maximum torque of the screwing level has been ex ceeded Check the screw pro...

Page 104: ...ing position hold posi tion could not be loaded 16 FRICT LOW Friction torque in monitored window too small 17 FRICT HIGH Friction torque in monitored window too large Check the screw process and adapt...

Page 105: ...ST 11 does not start no power supply Switch the AST11 on at the main switch see 7 2 Assembly Instructions A connection to the se quence controller is not pos sible Check if the IP address set at the A...

Page 106: ...42 A Length 5 m 16 4 ft straight connection 385442 B Length 8 m 26 2 ft straight connection 385442 C Length 12 m 39 4 ft straight connection 385442 D Length 2 5 m 8 2 ft angle connection 90 385442 A L...

Page 107: ...U 207725 A Connection cable FBC4 AST11 US 207725 B 17 4 2 Profinet Designation Part no Interface fieldbus external ProfiNet 428010 B Connection cable FBC4 AST11 EU 207725 A Connection cable FBC4 AST11...

Page 108: ...bletop unit Designation Part no Base 405278 A 17 7Barcode scanners The barcode scanner cannot be used in conjunction with the printer or with the fieldbus module All barcode scanners which process up...

Page 109: ...109 Example slide door...

Page 110: ...wing samples Friction value measurement Screwing on differential torque Screwing applications depending on friction For detailed description also refer to 11 1 5 Friction value package optional The so...

Page 111: ...gure 54 GRAPH10E The GRAPH10 E program can be downloaded free of charge via the web interface How ever the use of the superimposed graph display feature is subject to cost Designation Product Code Gra...

Page 112: ...ord the end value data sets from up to ten sequence controllers AST or ComCenter 10 and to archive them The DataLogger program can be downloaded free of charge via the web interface How ever the use o...

Page 113: ...for evaluation of the screwdriving data and calculation of av erage value standard deviation and cmk value For the graphic display several alterna tives may be selected The programme TC30 PC Statisti...

Page 114: ...graphs and end value data sets from a sequence controller to a computer The supervision when and which data should be saved is done by a PLC The ASTxx Serial Remote program can be downloaded free of...

Page 115: ...A Protection class IP 54 Dimensions WxHxD 160 mm x 295 mm x 200 mm Weight kg lbs 6 0 13 23 Temperature Ambient conditions MIL PRF 28800F class 2 During operation 0 to 40 C 32 to 104 F During storage 2...

Page 116: ...networks to exchange data between all devices connected in a network computer printer etc EtherNet IP Ethernet based fieldbus for the control and data exchange with sequence control resp the base stat...

Page 117: ...Sigma s Cp Cpk Limit values within limit values Error contri bution 0 30 s 68 3 30 0 70 2s 95 4 5 1 00 3s 99 7 3 1 33 4s 99 994 60 ppm 1 63 4 891s 99 9999 1 ppm 1 66 5s 99 99994 0 6 ppm 2 00 6s 99 999...

Page 118: ...gnal indicates that the control is ready for the start of a screw assembly If the ready signal is not available then either a screw assembly is active or a state is present that prevents the screw ass...

Page 119: ...ich the screw assembly should be done e g torque angle etc Toolbox Accessories for the automatic selection of a certain screwdriv ing program based on the used tool Web interface Software interface fo...

Page 120: ...SEQUENCE CONTROLLER Machine Type _________________________________________________________ Serial Number _________________________________________________________ Year of Manufacture _________________...

Page 121: ...ite 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 00 37...

Page 122: ...92203 Amberg Germany Carl Schulz Platz 1 92224 Amberg Germany Service Hotline 49 0 0700 00 371 371 49 0 9621 371 0 Fax 49 0 9621 371 120 Internet http www deprag com e mail info deprag de Jan 15 Techn...

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