FEC AFC3000 Hardware Operation Manual Download

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AFC3000E-HW-1

Summary of Contents for AFC3000

Page 2: ...ument or any related matter should be directed to FEC INC at 586 580 2622 faxed to 586 580 2620 or emailed to support fec usa com The information set forth in the following document is the property of FEC INC This document shall not be released to or copied for any person and or organization With out the expressed prior consent of FEC INC Unauthorized reproduction or distribution of this manual is...

Page 3: ...ner and correctly use this machine Always keep this instruction manual with the equipment Wirings and parameter settings shall only be conducted by a qualified professional Indicate the following on all instruction manuals that use this equipment This equipment is capable of high voltages hazardous to human life Never conduct a withstand voltage test or insulation resistance test on this equipment...

Page 4: ...urer DAI ICHI DENTSU LTD Directives Machinery Directive 2006 42 EC EMC Directive 2004 108 EC The above product has been evaluated for conformity with above directives using the following European standards The technical construction file TCF for this product is retained at the above manufacturer s location and it is complied according to ANNEX Ⅶ part B Machinery Directive EN ISO12100 2010 EN 60204...

Page 5: ...bligation shall be to correct in the manner and for a period of time provided above THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER EXPRESSED OR IMPLIED EXCEPT THAT OF TITLE AND ALL IMPLIED WARRANTIES INCLUDING ANY WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED Correction by the company of nonconformity s whether patent or latent...

Page 6: ... instructions that are marked with may result in severe damage if they are not observed according to conditions Contents marked with the above symbols are very important instructions For your safety follow all instructions and especially those marked with these symbols This instruction manual uses the following additional symbols for instructions that shall be observed Warning Caution This symbol ...

Page 7: ...jury Turn OFF the power when conducting wiring operation and maintenance Failure to observe this instruction may cause electric shock and injury Never damage the cables apply excess stress to cables or squeeze the cables Never use damaged cables Failure to observe this instruction may cause electric shock and fire Conduct type 3 grounding of FG terminals Failure to observe this instruction may cau...

Page 8: ...ion may cause injury and malfunction Do not hold the indictor on the front panel when transporting the Controller MFC Unit The indicator may come off and drop from the front panel Failure to observe this instruction may cause injury and malfunction The equipment shall be stored under the following conditions Ambient temperature 5 C 55 C Avoid freezing Ambient humidity 85 RH or lower Avoid moisture...

Page 9: ...lfunction Do not use tools or Controller MFC Units that are damaged or missing parts Failure to observe this instruction may cause fire injury and malfunction Do not get on the top of equipment or do not place heavy objects on the top of equipment Failure to observe this instruction may cause injury and malfunction Do not subject the equipment to excess shock and impact Failure to observe this ins...

Page 10: ...rve this instruction may cause injury false operation and malfunction The equipment may restart suddenly when the equipment is reset with the start signal ON Always ensure that the start signal is OFF before resetting the equipment Failure to observe this instruction may cause injury Do not turn ON and OFF the equipment repeatedly Failure to observe this instruction may cause malfunction Do not us...

Page 11: ...ixed added controller and cable info 2017 9 6 AFC3000E HW 1 Updated Chapter 4 RS232C info Chapter 10 added Abn 8_21 Abn10_10 2018 3 16 AFC3000E HW 1 Added CE Declaration to Introduction Manual Numbering Convention AFC3000E HW 1 DSP1500 Servo Press AFC1500 Nutrunner FUSION DC Hand Tool HW Hardware Operation Manual SW Software Manual DSP1500 Servo Press AFC3000 Nutrunner FUSION DC Hand Tool E Englis...

Page 12: ...es 2 7 Chapter 3 System Description 3 1 System Structure 3 2 3 1 1 Single System Diagrams 3 2 3 1 2 Multi System Diagrams 3 5 3 2 Controller Description 3 7 3 2 1 Front Panel Switches and Connectors 3 7 3 2 2 Controller Front Panel LED 3 9 3 2 3 Controller Top Bottom Panel Switches and Connectors 3 10 3 2 4 Controller Side Panel Connector 3 11 3 2 5 Front Display Unit 3 12 3 2 6 Expansion Unit 3 1...

Page 13: ...nal Multi System Slave 4 29 4 6 5 I O Hardware Specifications and Recommended Connection Circuit 4 33 4 6 6 Description of I O Signals 4 34 4 6 7 Fastening Timing Chart 4 39 4 7 External Monitoring Interface 4 41 4 7 1 Output Signal Specifications 4 41 4 7 2 How to Calibrate the External Monitoring Device 4 42 4 7 3 Output Circuit 4 42 4 8 RS 232C Interface 4 43 4 8 1 RS 232C Communication Specifi...

Page 14: ... 28 5 5 1 ID Data Input Setting 5 29 Chapter 6 Operational Tests 6 1 Power Activation Operational Test 6 2 6 1 1 Before Powering On 6 2 6 1 2 Items to be checked when the power is turned on 6 3 6 1 3 Initial Data Setting 6 4 Chapter 7 Fastening Instructions 7 1 Fastening Settings Outline 7 2 7 2 Fastening Methods 7 3 7 2 1 Torque Control Method Angle Monitoring 7 3 7 2 2 Angle Control Medhod Torqu...

Page 15: ...tem 8 22 8 5 1 Multi System Single System 8 22 8 5 2 Single System Multi System 8 23 8 6 Parameter Copy Erase the Fastening Results History 8 24 8 7 Parameter Structure 8 27 8 7 1 Parameter Lists 8 28 8 7 2 System Parameter 8 32 8 7 3 Fastening Parameter Fastening Setting 8 39 8 7 4 Fastening Parameter Torque 8 42 8 7 5 Fastening Parameter Angle 8 46 8 7 6 Fastening Parameter Rate Time 8 47 8 7 7 ...

Page 16: ...Amplifier Reply Errors 10 9 10 6 A 06 Servo Amplifier Type Errors 10 10 10 7 A 08 Servo Amplifier Errors 10 11 10 8 A 09 Parameter Errors 10 15 10 9 A 10 Multi Signal Errors 10 16 10 10 Spindle Judgment Checking The Reason For a Reject 10 19 10 11 Ethernet Communication 10 21 10 11 1 Check Windows Firewall 10 22 10 11 2 Confirmation Connection by Using the Command Prompt 10 24 10 12 RTC Real Time ...

Page 17: ......

Page 18: ...Chapter 1 Outline PAGE 1 1 Chapter 1 Outline 1 ...

Page 19: ...f AFC3000 expansion units Chapter 5 System Setup and Wiring Equipment installation procedures dimensions Input and Output signal descriptions and requirements for PLC programming Chapter 6 Power Up and Initial Checks Preliminary power up and operational tests Chapter 7 Fastening Instructions Basic fastening operations and presetting procedures Chapter 8 System Operation Instructions for the input ...

Page 20: ...control signals Ex STOP START REVERSE BYPASS etc to all of the Controllers connected to it up to 32 spindles via the high speed communication port thus eliminating direct connection control to the individual spindles saving costly I O connection E E E External control interfaces Fieldbus By using a Fieldbus expansion unit a variety of Fieldbus interfaces are available for I O as well as fastening ...

Page 21: ...f for an emergency stop Additionally a hardwired auxiliary STOP input connector has been added to provide a hardwired STOP signal when Fieldbus interfaces are used The independent emergency stop signal can be used to cease a fastening operation via a hardwired method allowing the system to meet safety requirements of a hardwired STOP Reduced space requirements The installation space has been reduc...

Page 22: ...ED on the front panel of the bypassed unit will light In a mutli spindle configuration the bypassed spindle is ignored as if it doesn t exist This allows a spindle to be bypassed while all other connected spindles continue to operate 3 Abnormal Signal Output Function Any system fault Abnormal state code numbers are displayed on the Controller MFC Unit front panel If a system error occurs during a ...

Page 23: ...ower of the Unit is turned OFF 9 Fastening Result Storage Function Up to 12 000 of the most recent fastening cycles of data can be stored in the controller The AFC3000 User Console is required for retrieving reading the fastening result stored data In the case of a multi system the fastening results of the entire multi system connected spindles are stored in the MASTER Axis together with the resul...

Page 24: ... could be transmitted directly to a MFC Unit Static Electricity The AFC3000 MFC Unit incorporates many electronic Surface Mounted Devices SMD It is advisable to strictly adhere to practices for safe electrostatic discharge in order to prevent damage to the system components when handling them Cleaning Do not use any organic solvents such as thinner to clean a MFC Unit The solvent could melt the su...

Page 25: ......

Page 26: ...Chapter 2 Specifications PAGE 2 1 Chapter 2 Specifications 2 ...

Page 27: ...r lower Avoid condensation Max Motor Case Temp 70 C 158 F Outer Motor Case Storage conditions Ambient Temperature 5 C to 55 C 23 F to 131 F Avoid freezing Ambient Humidity 90 Rh or lower Avoid condensation Shipping Conditions Ambient Temperature 5 C to 55 C 23 F to 131 F Avoid freezing Ambient Humidity 50 Rh or lower Avoid condensation Package Tight seal Do NOT use in an airtight environment The t...

Page 28: ... Switches Bypass slide switch For changing between RUN and BYPASS Setting switch For user setting Unit front panel Axis setting switch Maximum of 32 spindles can be set 1 spdl to 32 spdl Internal setting switch 8 bits for setting by FEC Unit bottom panel LED MULTI LED STATUS LED JUDGE LED COM LED BYPASS LED CONTROL POWER LED Ethernet LED CPU SH 2A RS232C Communication 38400bps factory setting 1920...

Page 29: ...42 4 Arms 84 8Arms Avg Power Consumption 4 Heat Output 32Watt 15Watt Idle 41Watt 15Watt Idle 137Watt 15Watt Idle Allowable Number of Times of Drive Power ON OFF 2 10 million times 3 million times 2 5 million times Allowable Drive Power ON OFF Cycle 3 10 seconds 10 seconds 15 seconds Heat Radiation Fan None None 2 Internal Rear Panel Heat Sink None Provided Provided Weight kg 1 60 1 96 4 92 1 The a...

Page 30: ...Outer Motor Case Contact FEC regarding a specified cycle time more than 60 Duty 2 2 Unit Identification 2 2 1 MFC Unit Type Unit Type Name Description Part No Controller AFC3000 24A Controller For Tool Type CFT RS1 MFC S024 AFC3000 60A Controller For Tool Type CFT RS3 MFC S060 AFC3000 120A Controller For RM4 RM5 Motors MFC S120 Expansion Unit AFC3000 D I O Expansion Unit 1 with discrete I O MFC DT...

Page 31: ...y above modules 2 2 2 Fieldbus Specifications Fieldbus Name I O Input Output Message Input Output MASTER Axis PLC PLC MASTER Axis MASTER Axis PLC PLC MASTER Axis CC Link V1 10 14 bytes 112 points 14 bytes 112 points 32 bytes 16 words 30 bytes 15 words CC Link V2 00 110 bytes 880 points 110 bytes 880 points 144 bytes 72 words 142 bytes 71 words DeviceNet 32 bytes 256 points 12 bytes 96 points 2048 ...

Page 32: ...99 999 MFC S060 6 CFT 202RS3 S 200 00 387 1 99 999 MFC S060 7 CFT 302RS3 S 300 0 260 1 999 99 MFC S060 NFT Type Tools Added 9 2017 Tool No Tool Type Max Torque N m Max RPM rpm Min RPM rpm Compatible Unit Type 100 NFT 502RM4 S 490 0 155 1 MFC S120 101 NFT 802RM4 S 785 0 100 1 MFC S120 125 NFT 051RM1 S1 4 90 500 1 MFC S024 126 NFT 010RM1 S 0 98Nm 1100 1 MFC S024 127 NFT 051RM1 S 4 90 1100 1 MFC S024...

Page 33: ...quare Drive Tool Size SA 3S1 2 38 38 2 3 8 CFT 101RS1 S CFT 201RS1 S CFT 401RS1 S SA 3S3 2 50 50 2 1 2 CFT 801RS3 S CFT 132RS3 S SA 3S3 2 62 62 2 5 8 CFT 202RS3 S SA 3S3 2 75 75 2 3 4 CFT 302RS3 S Offset Tools Spindle Unit Type Standard Stroke Square Drive Tool Size OA 3S1 2 38 38 2 3 8 CFT 101RS1 O CFT 201RS1 O CFT 401RS1 O OA 3S3 2 50 50 2 1 2 CFT 801RS3 O OA 3S3 2 62 62 132 2 5 8 CFT 132RS3 O O...

Page 34: ...Chapter 3 System Description PAGE 3 1 Chapter 3 System Description 3 ...

Page 35: ...single spindle Configured as MASTER The MASTER spindle has a dedicated Ethernet port and communicates to all connected spindles configured as SLAVES via the AXIS LINK ports Fastening operation is according to SEQUENCE control from the MASTER The MASTER Spindle or SLAVE Spindle setting for communication with the AFC3000 User Console PC and for I O PLC control is set with the special function SW1 sw...

Page 36: ...s suitable for a small number of spindles and robot equipped systems The LAN cables circuit protectors and noise filters are not included with the equipment Noise Filters are required where input power source is known to have electrical Noise Tool Tool Tool Tool External Emergency Stop Tool Tool Tool Tool Axis Link Terminator LAN Connector Noise Filter 3 phase Power Source 200 to 230V AC 50 60Hz N...

Page 37: ...lease note that multiple MASTER Units cannot be accessed from a single PC if a hub is not provided To access multiple MASTER Units from a single PC multiple AFC3000 User Consoles must be started up Tool Tool Hub User Console MASTER Spindle Unit No 1 MASTER Spdl Unit No 2 Control Power Source 24V DC Circuit Protector Circuit Protector Noise Filter Noise Filter External Emergency Stop 3 phase Power ...

Page 38: ... ON OFF System Parameter D No SYS 003 System Indication Multi Multi The LAN cables circuit protectors and noise filters are not included with the equipment Noise Filters are required where input power source is known to have electrical Noise Tool Tool 3 phase Power Source 200 to 230V AC 50 60Hz User Console MASTER Spdl Unit No 1 SLAVE Spdl Unit No 2 Axis Link Terminator Axis Link Terminator Contro...

Page 39: ... No 1 SLAVE Spdl No 2 Unit Front Panel SW1 No 8 Communication axis setting ON OFF System Parameter D No SYS 003 System Indication Multi Multi Tool Printer output RS232C Barcode reader ID system RS232C Expansion I O PLC Expansion I O Connector Input 32ch Output 32ch Fieldbus Connector CC Link Ver2 00 Ver1 10 DeviceNet ErherNet IP PROFIBUS DP V1 PROFINET IO Tool Compact Flash Control Power Source 24...

Page 40: ...SS BYPASS Mode AXIS Link Connector IN OUT Standard I O Connector Input 12 Output 12 Sensor Connector Motor Connector AC Power Input Connector Display unit Installation Connector ETHERNET Connector for PC communication Display Unit MFC DP01 Plug in connector on the back side of the display unit MFC S024 MFC S060 RS232C Connector Control Power Connector AXIS No Address Switch Special Function SW1Swi...

Page 41: ... Allows setting of spindle number See 4 12 for setup AXIS Link Connector IN OUT Communication ports for AXIS LINK between spindles RUN BYPASS Switch RUN Operation Mode BYPASS Spinlde BYPASS Mode ETHERNET Connector for PC communication Communication port for AFC3000 user console software Control Power Connector Control power connector DC 24V RS232C Connector Fastening data output port Sensor Connec...

Page 42: ... ACCEPT within acceptable limits this spindle Red Fastening or CAL Zero Level check judgment REJECT outside of acceptable limits this spindle COM LED Orange PC Communication in process AFC3000 User Console Software CONTROL POWER LED Green Control power on 24VDC Red Unit operation error CPU Error MULTI LED Green Fastening or CAL Zero Level check overall judgment ACCEPT all spindles Orange Fastening...

Page 43: ...ormally disabled Must be enabled using SW2 switch Provides hardwired STOP signal in the case where Fieldbus is used for I O interface Or a redundant STOP signal if discrete I O is used STOP signal must be ON to Enable System Polarity of wiring must be followed as shown in cable specifications 3 2 8 External sensor input connector For Factory use Boot connector For Factory use Bottom panel SW2 Swit...

Page 44: ...Panel Connectors Unit Side Panel Connector List Item Description Fieldbus expansion I O connector Connection for expansion unit 1 CFCard RS232C expansion connector Connection for expansion unit 2 Fieldbus expansion I O connector CFcard RS232C expansion connector ...

Page 45: ... here when an abnormal occurs D No Display LED 3 digits The Parameter DATA number is displayed here Abnormal sub code is displayed when an abnormal occurs The speed mode during fastening is displayed here START Pushbutton The fastening starts after pushing this pushbutton REV Pushbutton Tool rotates in the opposite direction of fastening while pushing this pushbutton CAL Pushbutton Full Scale CAL ...

Page 46: ...n this slot CF ACCESS LED Display LED for CF card mode Expansion RS232 connectors RS232C 2 Data Input Connector ID Data RS232C 3 Output Fastening Results Data Programmable output format from AFC3000 Software FIELDBUS connector installation slot CC Link Ver2 00 Ver1 10 DeviceNet ErherNet IP PROFIBUS DP V1 PROFINET IO CF card slot CF ACCESS LED Expansion RS232 connectors Expansion Unit 1 MFC DT MFC ...

Page 47: ...ign minimizes space requirements Preamp built into the torque transducer o Intelligent transducer design accomplished through the use of an ID Chip o ID Chip used to verify integrity of fastening operations Connector o Single connection point for Motor Resolver and Transducer o Compact quarter turn connector design Tool and Spindle Assembly Spindle Assemblies are used to take up the travel of a th...

Page 48: ... Server AFC3000 User Console Software Control Power Source 24V DC Noise Filter 3 phase Power Source 200 to 230V AC 50 60Hz Must be grounded CP Circuit Protector Noise Filter External PLC Tool Unit 1 CFT RS Tool Unit 2 CFT RS I O Connector Drive Power Cable Axis Link terminator Axis Link terminator SLAVE Spdl No 2 Single Control MASTER Spdl No 1 Single Control Maximum 32 Spdl configuration ...

Page 49: ...MASTER Spdl No 1 Multi Control Barcode Serial Printer SLAVE Spdl No 2 Multi Control Axis Link terminator Axis Link terminator Drive Power Cable Control Power Source 24V DC Noise Filter 3 phase Power Source 200 to 230V AC 50 60Hz Must be grounded CP Circuit Protector Safety stop signal during use of fieldbus controls all spindles Tool Unit 1 CFT RS Tool Unit 2 CFT RS Noise Filter External PLC Emerg...

Page 50: ...C S024 60 3 m FEB 1260 Was FEB 1631 Included with the MFC controller 4 Control Power Connector MC1 5 3 STF 3 81 Included with the MFC controller 5 STOP Signal Connector MC1 5 2 STF 3 81 Included with MFC controllers ordered with Fieldbus Units only 6 PC Communication Cable Crossover 2 m FEB 1331 For direct connection PC Communication Cable Straight 2 m FEB 1268 7 For connection via hub 7 Axis Link...

Page 51: ... FEB 1631 parts are interchangeable Minimum bending radius 120mm Cable Drawing R S T 3 Phase AC Power E Earth Ground Connector Model Type Manf Model No D3200S Receptacle Housing AMP 1 178128 4 Receptacle Contact Pin Crimp type AMP 1 175218 3 Connector Size Controller side Unit mm Controller Side ...

Page 52: ...onnects to either A or B side of connector Minimum bending radius 120mm Cable Drawing R S T 3 Phase AC Power E Earth Ground Connector Model Type Type Type Type Manf Manf Manf Manf Model No Model No Model No Model No D3200M Receptacle Housing AMP 1 917659 5 Receptacle Contact Pin Crimp type AMP 1 175218 3 Connector Size Controller side Unit mm Controller Side ...

Page 53: ...0m Combined Type Motor Cable Resolver Cable and T D preamplifier Cable are in the same cable See Below Separated Type Motor Cable Resolver Cable and T D preamplifier Cable are in separate cables See 3 23 Part FEB 1630 Mx x Length in meters 5 7 5 10 12 5 15 20 25 30 Std lengths Minimum bending radius 150mm Nominal Cable Diameter 16 0mm Cable Drawing Dimension units mm UNIT side Tool side Motor Conn...

Page 54: ...Contact Pin Crimp type AMP 1 175218 2 Connector Size Controller Unit mm Connector Model Resolver Preamplifier Type Manf Model No Connector JST J21DF 20V KX L Receptacle Contact Pin Crimp type JST SJ2F 002GF P1 0 Connector Size Controller side Unit mm Connector Model Tool side Type Manf Model No Connector DDK DCA3106A16 18BS C ...

Page 55: ...FEB 1630E Mx HF x Length in meters 2 3 5 6 7 7 5 10 12 5 15 Std Lengths Minimum bending radius 110mm Nominal Cable Diameter 14 5mm Note When using extension cables it is recommended to keep total combined cable length no more than 20meters Main cable extension cable to reduce succeptibility to electrical noise Cable Drawing Dimension units mm Connector Model No Type Manufacturer Model No 1 Connect...

Page 56: ... connect AFC1500 cables 2 to the MFC controller The cables used for an NFT tool using an RM4 motor FEB 1173 xx and FEB 1605 xx xx length in feet Adapter Drawing Note Obsolete Part used prior to May 2016 FEB 1641 Length in Feet Cables used in conjunction with NFT tool and cable adapter Type Type Type Type Manf Manf Manf Manf Model No Model No Model No Model No Preamp Cable FEC FEB 1173 xx Motor Res...

Page 57: ...2AWG wire can be used to wire the supplied teriminal connector on the front of the controller Wire color shown as reference only wire to local codes Connector Model Controller side Type Manf Model No Connector Phoenix Contact MC 1 5 2 STF 3 81 Connector Case optional Phoenix Contact KGG MC 1 5 3 Note Connector is supplied with controller wiring is responsibility of user Connector Size Unit mm Cont...

Page 58: ... 10 for wiring information Common 20 22AWG wire can be used to wire the supplied teriminal connector on the bottom of the controller Wire color shown as reference only wire to local codes Connector Model Controller side Type Manf Model No Connector Phoenix Contact MC 1 5 2 STF 3 81 Connector Case not required Phoenix Contact KGG MC 1 5 2 Note Connector available from FEC or other sources wiring is...

Page 59: ...d direct from a PC to the Axis controller Note Newer PC s have auto detect Ethernet hardware and a straight cable will work in place of a crossover cable Cable Drawing PC Communication Ethernet Cable Straight Part FEB 1268 7 7ft Used for PC communication through a Ethernet Hub Cable Drawing Frame Frame Shield Shield Frame Frame ...

Page 60: ...communication between spindles Between units Part FEB 1635 1 ft Cable Drawing Electrical Terminator for communication between spindle FEC Part FEB 1642 Cable Drawing Ref DDK Part Number C30 AL2 Frame Frame Shield RJ 45 Connector RJ 45 Connector Controller side ...

Page 61: ...ck 2 IN DATA5 19 Orange Red 2 OUT DATA5 7 Grey Black 2 IN DATA6 20 Grey Red 2 OUT DATA6 8 White Black 2 IN DATA7 21 White Red 2 OUT DATA7 9 Yellow Black 2 IN DATA8 22 Yellow Red 2 OUT DATA8 10 Pink Black 2 IN DATA9 23 Pink Red 2 OUT DATA9 11 Orange Black 3 IN DATA10 24 Orange Red 3 OUT DATA10 12 Grey Black 3 IN DATA11 25 Grey Red 3 OUT DATA11 13 White Black 3 IN DATA12 26 White Red 3 OUT DATA12 Se...

Page 62: ...ansion Unit I O MFC DT 32IN 32OUT Cable Drawing dimension units mm Connector Model No Unit Side No Type Manufacturer Model No Specifications 1 Cable Harness Misumi SD31 HH A 68 3 length 3 meter 2 DIN Rail Terminal CZH Labs MD D1057DBT 1 Both items supplied when ordering part FEB 1643 Cable color code on following page ...

Page 63: ... IN DATA15 51 Grey Red 4 OUT DATA15 18 White Black 4 IN DATA16 52 White Red 4 OUT DATA16 19 Yellow Black 4 IN DATA17 53 Yellow Red 4 OUT DATA17 20 Pink Black 4 IN DATA18 54 Pink Red 4 OUT DATA18 21 Orange Black continuous IN DATA19 55 Orange Red continuous OUT DATA19 22 Grey Black continuous IN DATA20 56 Grey Red continuous OUT DATA20 23 White Black continuous IN DATA21 57 White Red continuous OUT...

Page 64: ...Chapter 4 Installation and Wiring PAGE 4 1 Chapter 4 Installation and Wiring 4 ...

Page 65: ...quired Select an air handling unit applicable to the environmental conditions A C Heat Exch etc PAGE 4 3 6 6 Select an adequate PLC Select a PLC which will facilitate direct connection to the AFC3000 System I O 24 VDC PAGE 4 29 7 Design or review PLC logic A PLC logic program can be written using signal descriptions and timing charts provided PAGE 4 30 37 8 Select NEMA 12 enclosure Keep clearances...

Page 66: ...crew Upper part Two elongated holes M4 screw Lower part 1 60kg No MFC S060 One bell screw hole M4 screw Upper part Two elongated holes M4 screw Lower part 1 96kg No Dimensions of the MFC S024 and MFC S060 are the same Caution Install the unit firmly with specified screws mentioned above to prevent the unit from falling due to vibration which could cause faulty operation 75 0 or longer ...

Page 67: ...Weight Internal fan MFC S024 One bell screw hole M4 screw upper part Two elongate holes M4 screw Lower part 2 52kg No MFC S060 One bell screw hole M4 screw upper part Two elongate holes M4 screw Lower part 2 88kg No The weight of Expansion Unit 1 is 0 42kg and the weight of Expansion Unit 2 is 0 5kg 75 or longer ...

Page 68: ...tion Weight Internal fan MFC S120 Two bell screw holes M6 screw Upper part Two elongated holes M6 screw Lower part 3 70kg 2 Caution Install the unit firmly with specified screws mentioned above to prevent the unit from falling due to vibration which could cause faulty operation ...

Page 69: ...ith an Expansion unit are stated below Type Installation Weight Internal fan MFC S120 Two bell screw hole M6 screw upper part Two elongated holes M6 screw Lower part 4 4kg 2 The weight of Expansion Unit 1 is 0 3kg and the weight of Expansion Unit 2 is 0 4kg ...

Page 70: ...n order to prevent the ambient temperature from exceeding 45 C Ensure no foreign objects enter the inside of the unit To ensure safe removal leave 10mm min between units Side to side Up Down 75 or larger 100 or larger 10 or larger 100 or larger 100 or larger 100 or larger 10 or larger 10 or larger 10 or larger 10 or larger ...

Page 71: ...AGE 4 8 4 1 2 Control Panel Layout The number below is entered into the section depending on Unit Type MFC S024 MFC S060 56mm MFC S120 95mm 40 100 mm or larger 265 265 100 or larger 70 or larger Typical Spacing between units is 10mm min ...

Page 72: ...any object Anything touching tool may prevent transducer from working correctly Failure to provide adequate clearance may result in torque inaccuracies in the monitoring capability of the system or possible damage to the tool assembly Refer to PAGE 4 21 for tool installation 4 2 1 Straight Type Standard Tool CFT 101RS1 S CFT 201RS1 S CFT 281RS1 S CFT 401RS1 S Tool Type Max Torque Nm Max RPM rpm Mi...

Page 73: ...RS1 SL Front mounting dimensions same as standard tool above Tool Type Max Torque Nm Max RPM rpm Min RPM rpm Mass kgf Square Drive mm Length L mm A mm CFT 101RS1 SL 10 3 000 1 1 3 9 5 266 236 CFT 201RS1 SL 20 1 293 1 1 4 9 5 281 251 CFT 281RS1 SL 28 992 1 1 4 9 5 284 254 CFT 401RS1 SL 40 712 1 1 4 9 5 284 254 ...

Page 74: ...01RS3 S CFT 132RS3 S 1 L Version Tool CFT 801RS3 SL CFT 132RS3 S 1 L Front mounting dimensions same as standard tool above Tool Type Max Torque Nm Max RPM rpm Min RPM rpm Mass kgf Square Drive mm CFT 801RS3 S L 80 1 015 1 3 4 12 7 CFT 132RS3 S1 L 130 574 1 3 4 12 7 ...

Page 75: ...ring PAGE 4 12 Standard Tool CFT 202RS3 S L Version Tool CFT 202RS3 SL Front mounting dimensions same as standard tool above Tool Type Max Torque Nm Max RPM rpm Min RPM rpm Mass kgf Square Drive mm CFT 202RS3 S L 200 387 1 4 3 15 9 ...

Page 76: ...ring PAGE 4 13 Standard Tool CFT 302RS3 S L Version Tool CFT 302RS3 SL Front mounting dimensions same as standard tool above Tool Type Max Torque Nm Max RPM rpm Min RPM rpm Mass kgf Square Drive mm CFT 302RS3 S L 300 260 1 5 8 19 0 ...

Page 77: ...O Tool Type Max Torque Nm Max RPM rpm Min RPM rpm Mass kgf Square Drive mm Length L mm A mm CFT 201RS1 O 20 1 293 1 2 3 9 5 332 302 CFT 401RS1 O 40 712 1 2 4 9 5 349 319 CFT 801RS3 O Tool Type Max Torque Nm Max RPM rpm Min RPM rpm Mass kgf Square Drive mm CFT 801RS3 O 80 1 015 1 5 9 15 9 ...

Page 78: ... 15 CFT 132RS3 O 1 Tool Type Max Torque Nm Max RPM rpm Min RPM rpm Mass kgf Square Drive mm CFT 132RS3 O1 130 574 1 7 5 15 9 CFT 202RS3 O Tool Type Max Torque Nm Max RPM rpm Min RPM rpm Mass kgf Square Drive mm CFT 202RS3 O 200 387 1 8 6 15 9 ...

Page 79: ...r loosened Caution regarding Spindle Assemblies Select an adequate spindle assembly for the tools maximum torque When installing the supporting screw ensure that the screw does not go beyond the thickness of the tool flange It may cause the transducer to become less sensitive or operate incorrectly Spindle Assembly numbering convention SA SA SA SA 3S1 3S1 3S1 3S1 2 2 2 2 38 38 38 38 38 38 38 38 x ...

Page 80: ...tput Square Drive Mounting Screw Size Optional Support Screw Size CFT 101RS1 S CFT 201RS1 S CFT 281RS1 S CFT 401RS1 S 2 00 3 8 3 8 3 M5x0 8 M4 SA 3S3 x 50 50 x stroke in inches 2 std 3 or 4 optional Spindle Type Standard Stroke inches Female Input Square Drive Male Output Square Drive Mounting Screw Size Optional Holding Screw Size CFT 801RS3 S CFT 132RS3 S 2 00 1 2 1 2 3 M8x1 25 M6 ...

Page 81: ...Female Input Square Drive Male Output Square Drive Mounting Screw Size Optional Holding Screw Size CFT 202RS3 S 2 00 5 8 5 8 3 M8x1 25 2 M6 SA 3S3 x 75 75 x stroke in inches 2 std 3 or 4 optional Spindle Type Standard Stroke inches Female Input Square Drive Male Output Square Drive Mounting Screw Size CFT 302RS3 S 2 00 3 4 3 4 3 M10x1 5 ...

Page 82: ...Standard Stroke inches Female Input Square Drive Male Output Square Drive Mounting Screw Size CFT 801RS3 O 2 00 1 2 1 2 4 M8x1 0 SA OS3 x 62 62 x stroke in inches 2 std 3 or 4 optional Spindle Type Standard Stroke inches Female Input Square Drive Male Output Square Drive Mounting Screw Size CFT 202RS3 O 2 00 5 8 5 8 4 M8x1 25 ...

Page 83: ...he work piece ensure that the work piece is located as it will be during actual production EXAMPLE if there is a pallet locate and clamp it must be in the clamp position Fasteners should be rundown fully to ensure that the alignment is perform with the fasteners in their final fixed positions 5 Next you should advance the power head slowly to check the alignment to the work piece If there is a mis...

Page 84: ...O Cable connects to PLC External Monitoring Device Cable Upper Panel Connects to monitor device Not used for fastening setting Control Power Cable Connects to input power supply RS232C Cable Connects to PLC PC Communication Cable Connects to PC Axis Link Cable connects to next unit Standard Tool Cable connects to tool Drive Power Cable connects to 3 phase power supply Indicator Indicator Indicator...

Page 85: ...ow 3 White 4A White 4B White Yellow 2 Black 3A Black 3B Black Yellow 1 Green Frame Ground 2A No Connection 2B No Connection 1A Green 1B Green Yellow MFC AMP Type D3200S Receptacle Housing Model No 1 178128 4 Keying X Type Receptacle Contact Pressure bonding type Model No 1 175218 3 MFC MFC MFC MFC S024 MFC S024 MFC S024 MFC S024 MFC S060 S060 S060 S060 4 U U U U 3 V V V V 2 W W W W 1 POWER I O MOT...

Page 86: ...en polarity may cause electrical shock or damage to the controller If 24VDC power drops below 18VDC approx the controller will reboot automatically 24VDC power source should be separate DC supplies if controllers are to be powered from separate power on circuits Pin Number Wire Color Recommended 20 AWG Signal MFC S024 MFC S060 MFC S120 1 RED 24VDC 2 WHITE 0V 3 BLACK Field Ground Cable side connect...

Page 87: ... for standard motors along with the power requirements 200 230VAC 3 phase in KVA for each spindle These already have a safety factor calculated in Use the formula below to compute transformer secondary fuse or circuit breaker sizing 1 5 X TRANSFORMER VA SECONDARY VOLTAGE 3 SECONDARY FUSE SIZE Example 1 5 X 1000 VA 200 VAC 3 4 3 AMP USE 5 AMP FUSES Use a fuse or circuit breaker with next available ...

Page 88: ...ern for proper operation Proper Installation Improper Installation Caution regarding installation Large torque is applied when the tool is fastening and the same amount of torque is applied to the tool connection parts Therefore the tool should be fixed on the proper locations and the specified mounting screws should be used Do NOT apply strong shock or force to a tool or damage may occur Due to s...

Page 89: ...aps are used to affix the cable to the tool they should be loose enough to allow the cable to move but yet hold it in place Cable ties too tight cause a stress point leading to premature cable failure 1 1 1 1 Spindle No Label Spindle No Label Motor Resolver Preamplifier Combined Cable Tool Cable 1 1 1 1 WARNING Do not make motor connections with the power on Turn off all controller power before at...

Page 90: ...nd one another Route cables and connectors away from liquid of any type Protect cable connectors from any impact or abrasion that may cause damage IE pulling cables through cable tray and dropping cables to the floor Check cable route for possible chafing or abrasion points Re route or protect cable at these points with a nylon cable wrap or similar means to avoid future cable damage The use of pl...

Page 91: ...parately Separation is achieved by using Flexible Track separators The following rules should be followed for cable separation o If Cable 1 Diameter Cable 2 Diameter 1 2 x Track Inner Height then no separation is necessary o If Cable 1 Diameter Cable 2 Diameter 1 2 x Track Inner Height then a horizontal or vertical separator must be used to reduce the inner height thereby preventing the entangleme...

Page 92: ...he start of the fastening operation will be disabled 8 PAR SELECT BIT 0 IN NO These 5 inputs when selected in a binary code is capable of selecting up to 32 different parameters 9 PAR SELECT BIT 1 IN NO 10 PAR SELECT BIT 2 IN NO 11 PAR SELECT BIT 3 IN NO 12 PAR SELECT BIT 4 IN NO 13 BANK SELECT IN NO When turned ON all output signals are turned OFF 14 OUT COMMON OUT Common Output signals Bi direct...

Page 93: ...s signal is activated on and maintained 5 START IN NO The Start input automatically resets the previous cycle clears all data to zero and initiates the next fastening cycle 6 BYPASS IN NO Spindle is ignored as if it does not exist as long as this signal is ON 7 SELF CHECK OFF IN NO When activated ON the Self Check of the torque transducer performed at the start of the fastening operation will be d...

Page 94: ...o confirm proper sequence before fastening starts 21 OUT DATA 6 SEQ SELECT BIT 1 22 OUT DATA 7 SEQ SELECT BIT 2 23 OUT DATA 8 SEQ SELECT BIT 3 24 OUT DATA 9 SEQ SELECT BIT 4 25 OUT DATA 10 DATA AVAILABLE Output when the fastening result data is available 26 OUT DATA 11 SPINDLE IN BYPASS Output when any connected spindle is in Bypass ON 15 OUT DATA 0 REJECT NG Spdl only Output when the fastening re...

Page 95: ...dle is a REJECT 16 ACCEPT OK Slave OUT NO Output when the fastening result of the Slave spindle is an ACCEPT 17 ABNORMAL Slave OUT NO Output when an Abnormal condition on the Slave spindle occurs 18 READY Slave OUT NO Indicates the Slave spindle is ready to operate and inputs are enabled 19 BUSY Slave OUT NO Output after a START signal is received from the Slave spindle and active until the fasten...

Page 96: ...F コネクタ出力信号 40mA MAX 出力信号 OV COMMON 24V 0V 入力信号入力信号 24V 2 2KΩ 2 2KΩ 3 9KΩ Input Signal Input Signal Output Signal Connector User side PLC Power Output Hardware Spec Input Hardware Spec Sinking NPN I O connection shown for reference only The MFC Unit may be wired for Sourcing PNP I O by swapping the polarity of the 24VDC power connections I O Points are Bi directional Output Signal ...

Page 97: ...rection is set to clockwise the spindle will turn in the counter clockwise direction during Reverse operation and visa versa The spindle unit will be is BUSY status while is Reverse operation A signal will not be accepted during the following conditions Stop condition While fastening when BUSY While resetting Bypass condition Abnormal condition When a START or another REVERSE signal is output Duri...

Page 98: ...ge level and CAL voltage level of the torque transducer is automatically checked before the fastening cycle begins If the automatic check of the torque transducer is not required turning ON this signal at the time of inputting a START signal will cause this test not to be performed Once a Self Check is completed the unit holds the check value until control power is turned off BANK SELECT Bank Sele...

Page 99: ...0 Pin No 8 Parameter Sequence No OFF OFF OFF OFF OFF 1 OFF OFF OFF OFF ON 2 OFF OFF OFF ON OFF 3 OFF OFF OFF ON ON 4 OFF OFF ON OFF OFF 5 OFF OFF ON OFF ON 6 OFF OFF ON ON OFF 7 OFF OFF ON ON ON 8 OFF ON OFF OFF OFF 9 OFF ON OFF OFF ON 10 OFF ON OFF ON OFF 11 OFF ON OFF ON ON 12 OFF ON ON OFF OFF 13 OFF ON ON OFF ON 14 OFF ON ON ON OFF 15 OFF ON ON ON ON 16 ON OFF OFF OFF OFF 17 ON OFF OFF OFF ON ...

Page 100: ...m will resume normal operation The RESET signal clears the abnormal condition READY Spindle Input Enabled signal and ready to run Normally Open TOTAL READY Total Input Enabled signal Normally Open Output when the system is in the READY condition Indicates system is ready to operate and inputs are enabled This signal is inactive off in the following conditions During the initialization process when...

Page 101: ...er Spindle the output will differ depending on the status of the BANK SELECT signal If BANK SELECT is OFF outputs will reflect the Sequence Selected If BANK SELECT is ON outputs will reflect the Parameter Selected PAR SEQ SELECT BIT 4 Pin No 24 PAR SEQ SELECT BIT 3 Pin No 23 PAR SEQ SELECT BIT 2 Pin No 22 PAR SEQ SELECT BIT 1 Pin No 21 PAR SEQ SELECT BIT 0 Pin No 20 Parameter Sequence No OFF OFF O...

Page 102: ... with a pulse of over 100ms or until BUSY is confirmed Interlock START signal with READY STOP RESET REVERSE ABNORMAL signal All inputs except RESET are disabled when ABNORMAL signal is output When you output a BYPASS signal to a unit BYPASS is output immediately A unit in BYPASS mode does not output I O ACCEPT OK REJECT NG signals ID data is input from the RS232C interface AXIS LINK result outputs...

Page 103: ...ignal OFF ON START command issued if the parameter select above is confirmed PARMSELECT0 OFF ON PARMSELECT1 OFF PARMSELECT2 OFF PARMSELECT3 OFF PARMSELECT4 OFF BANK0 ON BANK Selection Command BANK1 ON OFF OUT DATA3 PARM SEL0 OUT DATA4 PARM SEL1 OUT DATA5 PARM SEL2 Output fastening parameter PARM SELECT 0 4 selected by BANK setting OFF Contact is Open from PLC side ON Contact is Closed from PLC sid...

Page 104: ...o torque to full scale torque and the potential difference is 3 7V The zero voltage is the voltage when the tool is unloaded nothing connected to the output shaft and no torque applied The zero voltage is not 0V Origin voltage range 0 4V 0 4V Also the zero voltage of each tool may vary even for the same type of tool Ex If the zero voltage is 0 3V and the voltage at full scale torque is 3 4V the vo...

Page 105: ... the tool is displayed on the DATA display screen Set the same torque value by using the external monitoring device to adjust the torque voltage The zero torque voltage at no load is not 0V The voltage value of each tool varies Therefore the zero point needs to be corrected by using the external monitoring device 4 7 3 Output Circuit Display torque value on DATA display screen Press CAL Pushbutton...

Page 106: ...ormat The default communication setting of the MFC unit front RS232C port is indicated below and can be confirmed changed in the parameter settings Data No 208 211 in the system setting mode PAR No indicated by SYS on display NOTE This RS232C Communication port communication setup can only be changed using the Display Keypad The AFC3000 software RS232C Output Format Setup does NOT change this MFC ...

Page 107: ...Input DTR 4 20 4 DTR 6 6 DSR RTS 7 4 7 RTS CTS 8 5 8 CTS GND 5 7 5 GND Connection diagram with data dump D SUB 9 Female Pins D SUB 25 Male Pins 9Female Pins TXD 3 3 2 RXD Result data output RXD 2 2 3 TXD RS232C 2 only DTR 4 20 4 DTR 6 6 DSR RTS 7 4 7 RTS CTS 8 5 8 CTS GND 5 7 5 GND MFC S024 MFC S060 MFC S120 Device Side MFC S024 MFC S060 MFC S120 Device Side The RS232C on the MFC Unit front panel ...

Page 108: ...0 7 1 0 1 2 3 4 Byte 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Item Time ID Data ASCII Hex 3AH 35H 36H 41H 42H 43H 44H 45H 46H 00H 3AH 35H 33H 33H 33H 31H DATA 5 6 A B C D E F 4 5 3 3 3 1 Byte 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Item ID Data ASCII Hex 00H 00H 00H 00H 00H 00H 00H 00H 00H 00H 00H 00H 00H 00H 00H 00H DATA Byte 49 50 51 52 53 54 55 56 57 58 59 Item ID Data Spindle No...

Page 109: ... DATA 1 2 3 0 1 2 3 Byte 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 Item 2 1st Time 1 2 2nd Time ASCII Hex 20H 20H 20H 31H 2EH 32H 33H 34H 20H 20H 20H 20H 20H 32H 2EH DATA 1 2 3 4 2 Byte 152 153 154 155 156 157 158 159 160 161 162 163 164 165 Item 2nd Time 1 2 Cycle Time ASCII Hex 33H 34H 35H 20H 20H 20H 20H 20H 33H 2EH 35H 37H 39H 20H DATA 3 4 5 3 5 7 9 Byte 166 167 168 169 1...

Page 110: ...ent definition SpindleJudgment Output Format REJECT 52H 45H 4AH 20H R E J ACCEPT 41H 43H 43H 20H A C C ABNORMAL 41H 42H 4EH 20H A B N STOP 53H 54H 4FH 50H S T O P RESET STOP 52H 53H 54H 20H R S T BYPASS 42H 59H 50H 20H B Y P START OFF 53H 4FH 46H 46H S O F F ...

Page 111: ...e at the end of fastening SNUG Torque Judgment Occurrence 84 91 12 34 Torque value when SNUG torque was detected Final Angle Judgment Occurrence 92 99 123 4 Rotating angle value at the end of fastening Degrees Differential Angle Judgment Occurrence 100 107 12 3 Differential judgment angle value Rate 1 Judgment Occurrence 108 116 1 234 Rate 1 value from Start torque to the rate 1 End torque TQ Deg ...

Page 112: ...hru Spindle No 32 Footer the output conditions of the header can be changed The spindle Axis data is output for the number of spindles that are configured in the system Multi Format Output Items Output Items Number of Bytes Fastening Data Multi Format PLC Input Data Character String Date 10 2013 5 28 2 0 1 3 0 5 2 8 Time 8 12 34 56 1 2 3 4 5 6 ID 1 32 ABCDEF A B C D E F NUL NUL NUL NUL NUL SEQ No ...

Page 113: ...2 3 Judgment Occurrence Rate 1 3 10 1 234 1 2 3 4 Judgment Occurrence Rate 1 Increment Torque 6 12 34 1 2 3 4 Rate 1 Increment Angle 6 123 4 1 2 3 4 Rate 2 3 10 0 123 0 1 2 3 Judgment Occurrence Rate 2 Increment Torque 3 6 12 34 1 2 3 4 Rate 2 Increment Angle 3 6 123 4 1 2 3 4 Rate 3 3 10 0 123 0 1 2 3 Judgment Occurrence Rate 3 Increment Torque 6 12 34 1 2 3 4 Rate 3 Increment Angle 6 123 4 1 2 3...

Page 114: ...H Reject after 1st Reject item Output Data Format BCD The BCD format for the fastening result data is output in the order as follows Header Spindle 1 data Spindle No 2 thru Spindle No 32 Footer the output conditions of the header can be changed The spindle data is output for the number of spindles that are configured in the system Multi Format Output Items Output Items Number of Bytes Fastening Da...

Page 115: ...Angle 2 4 123 4 00 12 34 01 Differential Angle 2 4 12 3 00 01 23 11 Rate 1 2 4 1 234 00 12 34 03 Rate 1 Increment Torque 2 4 12 34 00 12 34 02 Rate 1 Increment Angle 2 4 123 4 00 12 34 01 Rate 2 2 4 0 123 00 01 23 13 Rate 2 Increment Torque 2 4 12 34 00 12 34 02 Rate 2 Increment Angle 2 4 123 4 00 12 34 01 Rate 3 2 4 0 123 00 01 23 03 Rate 3 Increment Torque 2 4 12 34 00 12 34 02 Rate 3 Increment ...

Page 116: ... 4 4 digits right of the decimal point 5 5 digits right of the decimal point 3 With each of Spdl Cycle Count 4 digits and Tool Cycle Count 4 digits numerical values of the millions hundred thousand ten thousands and thousands places are output as 4 digit BCD data 4 Judgment Flag When the fastening ends with a result falling outside the preset limits the details of the fastening reject failure item...

Page 117: ...lution high limit bit5 Rundown revolution low limit bit6 bit7 bit Fastening Reject Item bit0 High current limit warning bit1 Low current limit warning bit2 Differential angle bit3 Differential angle bit4 SNUG torque high limit bit5 Start torque inhibit high limit bit6 bit7 Item 5 on next page bit7 bit 6 bit 5 bit 4 bit 3 bit 2 bit 1 bit 0 bit7 bit 6 bit 5 bit 4 bit 3 bit 2 bit 1 bit 0 ...

Page 118: ... angle high limit 05 Final angle low limit 06 Differential angle 07 Differential angle 08 Rate 1 high limit 09 Rate 1 low limit 10 Rate 2 high limit 11 Rate 2 low limit 12 Rate 3 high limit 13 Rate 3 low limit 14 1st time high limit 15 1st time low limit 16 2nd time high limit 17 2nd time low limit 18 Rundown revolution high limit 19 Rundown revolution low limit 20 SNUG torque high limit 21 Start ...

Page 119: ...urrent limit warning bit7 bit 6 bit 5 bit 4 bit 3 bit 2 bit 1 bit 0 0 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 Output Item Spdl Format 1 word 2 word 3 word Judgment Flag 28 00 04 00 00 17 bit7 bit 6 bit 5 bit 4 bit 3 bit 2 bit 1 bit 0 0 0 0 0 0 0 1 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 Output Item Spdl Format 1 word 1 word Judgment Flag 02 04 02 00 00 11 bit7 bit 6...

Page 120: ...5 0 factory setting Default Gateway 192 168 11 1 factory setting Communication Protocol IEEE 802 3 compliant ETHERNET Standard 100BASE T Communication Speed 100Mbps Cable Category 5 or higher category 5 is recommended Connector Shape RJ 45 1 to 1 Direct Communication with the PC Newer PC s have auto detect Ethernet hardware for signal direction and may not require a Crossover cable A common Ethern...

Page 121: ...PAR No indication part SYS of the Display Unit The IP Address set in the MFC unit can also be changed using the MFC display at the parameter Data Numbers listed below Set Values of Factory Settings System Parameters SYS D No 011 012 IP address 192 168 11 10 SYS D No 013 014 Subnet Mask 255 255 255 0 SYS D No 015 016 Default Gateway 192 168 11 1 The TCP IP setting method in the case of Windows 7 is...

Page 122: ...hapter 4 Installation and Wiring PAGE 4 59 4 Select Properties in Local Area Connection Status 5 In Local Area Connection Properties select Internet Protocol Version 4 TCP IPv4 and then select Properties ...

Page 123: ...e sure the IP address setup in the PC does NOT match ANY other number in the network Set the subnet mask of the PC to the same values as the factory set values of the Unit Make note or write down the settings that were used before you make this change you will most likely need to return the PC to the prior settings if you try to connect back to your PC network 7 Register the IP address in the AFC3...

Page 124: ...C3000 User Console has already been opened select Communication C Communication Setting in the Menu 2 Select the communication setting window and then select the Unit List tab Register the new TCP IP settings set in the controller you would like to communicate with 2 1 Enter the station name 30 letters at max 2 2 Enter the IP address 0 to 255 4 positions hit TAB or to adv to next position The sett...

Page 125: ...ning result indications etc can be executed 4 B If connection with the controller fails Connection to IP address failed where is the IP address set in procedure 2 is displayed and Connection Failure is displayed at the lower left status bar of the User Console If another PC is already connected to the Unit when Procedure 3 is executed A communication error has occurred Please confirm the communica...

Page 126: ... STOP IN STOP signal input DC 0V Action when external STOP is ON with a Fieldbus Connection At the point at which the external STOP signal is set to OFF the fastening operation is stopped and STOP is displayed in the upper section of the MFC display unit Also the PLC I O output signal READY turns OFF Action of External Emergency Stop Signal according to System Communication mode System Structure C...

Page 127: ...NK IN of the Master unit and the AXIS LINK OUT of the last connected spindle The communication between spindles cannot be conducted by connecting IN to IN or Out to OUT because the signals of the Pin No for IN and OUT connectors are different The first spindle s IN and the last spindle s OUT should be connected via cable communicating between spindles or via a terminator Example of 4 Spindle Wirin...

Page 128: ...ng No Setting No Setting 01 1st Axis 09 9th Axis 17 17th Axis 25 25th Axis 02 2nd Axis 10 10th Axis 18 18th Axis 26 26th Axis 03 3rd Axis 11 11th Axis 19 19th Axis 27 27th Axis 04 4th Axis 12 12th Axis 20 20th Axis 28 28th Axis 05 5th Axis 13 13th Axis 21 21st Axis 29 29th Axis 06 6th Axis 14 14th Axis 22 22nd Axis 30 30th Axis 07 7th Axis 15 15th Axis 23 23rd Axis 31 31st Axis 08 8th Axis 16 16th...

Page 129: ...sing tool changers where the tool cable is frequently disconnected reduces the possibility of Tool ID corruption OFF Enable Tool Cycle Count to Tool ID 4 OFF Analog Angle Output Pulse Selects the number of angle pulses output from the external monitor output See 4 7 External Monitoring Interface ON 0 1 deg per pulse OFF 1 0 deg per pulse 5 OFF Not used For standalone configuration only ON SYNC sig...

Page 130: ...PLC I O input signal BYPASS will be the only method for changing to the BYPASS mode in this case 3 OFF STOP signal always ON STOP signal disable When this is set to ON the PLC I O input signal STOP will always be ON This can be used to test the system without I O being connected or when a fieldbus interface is installed and no PLC control is available Be sure to set this function to OFF if this eq...

Page 131: ...Chapter 4 Installation and Wiring PAGE 4 68 Blank Page ...

Page 132: ...Chapter 5 I O Expansion Unit Page 5 1 Chapter 5 I O Expansion Unit 5 ...

Page 133: ...two additional RS232C serial Ports One dedicated for I D data input for Part ID data marriage 5 2 List of External Control Interfaces 1 Expansion I O 24VDC Discrete Input 32ch Output 32Ch 2 CC Link Ver 2 00 Ver 1 0 3 DeviceNet 4 PROFIBUS DP V1 5 PROFINET IO 6 EtherNet IP 7 EtherCat If an external control interface other than the expansion I O is to be used the Fieldbus Setting must be set to the M...

Page 134: ... in MUTLIPLE Spindle systems where individual spindle output status is desired using one connection point Compatible Connector Manufacturer Hirose Electric Type Cable connector Type DX31A 68P 50 Specifications Applicable wire size AWG 28 or 0 08mm2 Type Cable connector case Type DX 68 CV1 The connecting cable is included with the equipment model FEB 1643 Be sure to connect the cable with all power...

Page 135: ...N NO Not used 15 INPORT 1 IN NO Linked with the sequence command Port 1 input wait 16 INPORT 2 IN NO Linked with the sequence command Port 2 input wait 17 INPORT 3 IN NO Linked with the sequence command Port 3 input wait 18 INPORT 4 IN NO Linked with the sequence command Port 4 input wait 19 BYPASS No 1 IN NO When this signal is ON spindle 1 is put in BYPASS mode 20 BYPASS No 2 IN NO When this sig...

Page 136: ... the contents of the output signals will be changed Input signal mapping is fixed cannot be changed Use the AFC3000 User Console Software for sequence programming Be careful of the following points when using the BYPASS No 1 to 10 spindle signals If a certain Controller is to be put in the BYPASS mode set the corresponding signal among the BYPASS No 1 to 10 signals to ON with the START signal of t...

Page 137: ... TOTAL ACCEPT 38 2 ACCEPT No 1 39 3 TOTAL ABNORMAL 39 3 ABNORMAL No 1 40 4 TOTAL READY 40 4 BYPASS No 1 41 5 TOTAL BUSY 41 5 REJECT No 2 42 6 END 42 6 ACCEPT No 2 43 7 SEQ SELECT BIT 0 43 7 ABNORMAL No 2 44 8 SEQ SELECT BIT 1 44 8 BYPASS No 2 45 9 SEQ SELECT BIT 2 45 9 REJECT No 3 46 10 SEQ SELECT BIT 3 46 10 ACCEPT No 3 47 11 SEQ SELECT BIT 4 47 11 ABNORMAL No 3 48 12 SPINDLE IN BYPASS 48 12 BYPA...

Page 138: ... 13 REJECT No 12 49 13 50 14 ACCEPT No 12 50 14 51 15 ABNORMAL No 12 51 15 52 16 BYPASS No 12 52 16 53 17 REJECT No 13 53 17 54 18 ACCEPT No 13 54 18 55 19 ABNORMAL No 13 55 19 56 20 BYPASS No 13 56 20 57 21 REJECT No 14 57 21 58 22 ACCEPT No 14 58 22 59 23 ABNORMAL No 14 59 23 60 24 BYPASS No 14 60 24 61 25 REJECT No 15 61 25 62 26 ACCEPT No 15 62 26 63 27 ABNORMAL No 15 63 27 64 28 BYPASS No 15 ...

Page 139: ...e sequence cycle count is set to 1 at the start of the next fastening operation The sequence counting method is changed using the AFC3000 User Console the factory setting is Automatic Count Up CYCLE COUNT UP Sequence Cycle Counter Increment Signal When the CYCLE COUNT UP signal is set to ON with the sequence counting method set as Signal Input the cycle count of the selected sequence No is increme...

Page 140: ...mode is performed while the fastening operation is in cycle the fastening operation will stop and the fastening data up to the point of stopping will be held ID SELECT ENABLE Sequence Select by Part ID enabled When the ID SELECT ENABLE signal is set ON it enables the function to select the sequence from the part ID data In conjunction with this input it also has to be setup in the AFC3000 User Con...

Page 141: ...utput 3 Sequence Output2 Sequence Output1 Sequence Output0 Selected Fastening Sequence No OFF OFF OFF OFF OFF 1 OFF OFF OFF OFF ON 2 OFF OFF OFF ON OFF 3 OFF OFF OFF ON ON 4 OFF OFF ON ON ON OFF 15 OFF ON ON ON ON 16 ON OFF OFF OFF OFF 17 ON OFF OFF OFF ON 18 ON ON ON ON ON OFF 31 ON ON ON ON ON 32 ...

Page 142: ...when the system is in the READY condition Indicates system is ready to operate and inputs are enabled This signal is inactive off when the BUSY output is active on Busy NO Output after a START signal is received and active until the fastening cycle is complete and the READY signal is output End NO Output when a fastening cycle is complete Remains active until the START RESET or REVERSE signal is i...

Page 143: ...age data bank has been changed and what bank number is selected by the message bank select inputs See CCLink Fieldbus Expansion Manual Message Response Ready NO Output confirmation signal when Fieldbus Message offset is being used and data is ready to read Used to confirm proper reply data before retrieving message data Compact Flash Storage Warning NO Output when the remaining Compact Flash CF st...

Page 144: ...fastening parameter D No 006 After Fastening Operation Torque Recovery is enabled Parameter Select 1 4 NO Output confirmation of PARAMETER SELECT 1 4 input selections Parameter Select bits are active according to what sequence is set from the sequence select inputs Parameter Select 1 4 Individual NO Output confirmation of INDIV PARAMETER SELECT 1 32 input selections Parameter Select bits are activ...

Page 145: ...ons At the start of CAL voltage check by the CAL switch of the MASTER spindle CURRENT WARNING Total Current Value Warning Signal This signal is set ON when any spindle peak current value during the fastening operation falls outside the range of the fastening parameter D No 522 High Current Limit or the fastening parameter D No 521 Low Current Limit CAL WARNING Total CAL Voltage Warning Signal This...

Page 146: ...to 32 Busy Signal of Spindle 1 32 Output after a START signal is received and remains active until the fastening cycle is complete and the READY signal is output CURRENT WARNING No 1 to 32 Current Value Error Warning Signal of Spindle 1 32 Active when the high current limit has been exceeded This can be used to identify potential motor failure before total failure occurs by identifying high curren...

Page 147: ...nal Angle Low Limit Differential ANG REJ No 1 to 32 Differential Angle Signal of Spindle 1 32 The signal is set ON if the value of the differential angle exceeds the fastening parameter D No 206 Differential Angle Differential ANG REJ No 1 to 32 Differential Angle Signal of Spindle 1 32 The signal is set ON if the value of the differential angle is below the fastening parameter D No 207 Differenti...

Page 148: ...sole Software OUTPUT PORT 1 to 8 Output Signal Ports 1 to 8 These signals will output when the fastening sequence reaches a step that has a PLC OUTPUT instruction inserted Used to provide sequence operation status to external PLC s and or control outputs for slide motion lights buzzers etc without the use of a PLC The AFC User Console Software can set these outputs on and off in the fastening sequ...

Page 149: ...bination Judge Bits 1 to 8 No 1 to 32 Programmable combination Bits Used to create special outputs formed by using a combination of MFC Unit outputs in AND OR logic The signal is set ON if the value of the REJECT condition is detected in one of the programmable combination bits Message Spindle Offset Bit 0 4 Fieldbus Message Spindle Offset Select bit confirmation Output confirmation echo of the Fi...

Page 150: ...tional and accommodates both positive and negative current flow Both NPN sinking and PNP sourcing type connections may be used NPN Sinking is shown PNP can be wired by reversing and commons DC Power Source PLC I F Connector Input Hardware Specifications User Side PLC Input Signal Output Hardware Specifications Input Signal Output Signal Output Signal ...

Page 151: ...xpansion Unit Page 5 20 5 3 7 Timing Chart Basic Control Signals Master 100msec OFF Contact is Open from the PLC ON Contact is Closed from the PLC Input Signals Output Signals Fastening Operation in progress Operation ...

Page 152: ...ple Processing time for a 10 axis system 170 to 180msec 3msec 10 axes The respective SLAVE spindle are thus started up 200 to 210msec after the MASTER spindle is started up Operation Operation Operation in progress Output Signals Input Signals Fastening OFF Contact is Open from the PLC ON Contact is Closed from the PLC Fieldbus Message Output Fastening Output Signals Output started renewed at the ...

Page 153: ... ID data Timing of Fastening Sequence Select Signals and Start Signal Input Signals Output Signals Input Signals Fastening ID Input ID Output Operation in progress Operation Caution Sequence No 2 is selected OFF Contact is Open from the PLC ON Contact is Closed from the PLC Fastening sequence selection command SEQ SELECT BIT 0 to 4 Wait 20msec or more to confirm the sequence select output matches ...

Page 154: ...ge Capacity Approximately Number of Stored Data Sets 1Spdl 2Spdl 4Spdl 8Spdl 16Spdl 32Spdl 4GB 900 000 450 000 300 000 200 000 100 000 50 000 8GB 1 800 000 900 000 600 000 400 000 200 000 100 000 16GB 3 400 000 1 700 000 1 200 000 800 000 400 000 200 000 32GB 7 000 000 3 500 000 3 500 000 1 600 000 800 000 400 000 Precautions Concerning Memory Card Usage Be careful as the data stored in the memory...

Page 155: ... have been made so that a card cannot be inserted in the wrong orientation damage may occur to the controller or card if it is forced in DO NOT insert the memory card with POWER ON 2 Data storage to the memory card is executed after the fastening operation has ended Do not extract the card from the slot or turn OFF the control power of the Unit while memory storage is in progress Otherwise the sto...

Page 156: ...C3000 User Console Software can be stored in the TSV format Fastening Results Multi Format The fastening results are stored in the RESULT folder which is generated automatically Inside the RESULT folder folders each with a name expressing the year and month such as 201309 are generated automatically and a folder is automatically generated in the manner of 201310 201311 201312 etc Inside the 201309...

Page 157: ...ening waveforms have been stored the next file is generated automatically inside the 20130901 folder Also besides the fastening waveforms index txt for folder identification is generated inside CURVE The contents of index txt are erased each time a folder is generated automatically CURVE 20130901 20130901_123456 nracd 自動生成自動生成自動生成 20131001 201309 自動生成自動生成 201310 20130902 自動生成自動生成 index txt 123...

Page 158: ...o make the System Setting Mode as indicated below 3 Use the and switches of the display Unit to cursor to 400 in the D No section 4 The value indicated at the upper stage of the indicator is the storable capacity units of the memory card When the storable capacity of the memory card falls to less than 0 1 memory storage is discontinued to prevent damage of the stored data contents of the fastening...

Page 159: ...S mode 3 Operate the arrow switches to make SYS be indicated at the PAR No area of the display unit and 021 for Erase Retention be indicated at the D No area Then press the SET switch 4 Use the and switches to select CF from among the types of data to be erased and then press the SET switch 5 Within 2 seconds press the and switches to change Erase NO to Erase YES and within 2 seconds thereafter pr...

Page 160: ...t format is performed on the MASTER Spindle from RS232C Output Format of the AFC3000 User Console Software The factory settings of the RS232C 2 and RS232C 3 ports of the Expansion Unit 2 are as shown below and these can be confirmed with D No 401 to 408 of the System Setting Mode PAR No area SYS Factory Set Values System Parameters D No 401 RS232C 2 Communication Speed 38400bps D No 405 RS232C 3 C...

Page 161: ...he fastening operation The data should therefore be cleared using the Clear ID Data input if new data is not being input with each cycle The ID data equipment No that is input is acquired at the start of the fastening operation and therefore the data transfer should be completed before the start of the fastening operation If the PLC I O input signal ID DATA CLEAR signal is set ON the ID data buffe...

Page 162: ...ted as the data input method and Add STX ETX is selected the ID data can be cleared when the STX signal is received via the RS232C 2 and data can be re input by ending the input data when the ETX signal is received Data is stored used excluding the STX ETX control characters ...

Page 163: ...ole With Select by ID Input a maximum of 5 ASCII letters can be set for each sequence No that would match a model code as an example If the ID data is not input or the ID data and the sequence select setting do not match the PLC IO input signal ABNORMAL is set to ON when the PLC IO input signal START or REVERSE is turned ON The ID data is not updated if the ID data and the sequence select setting ...

Page 164: ...Chapter 6 Power up and Initial Checks PAGE 6 1 Chapter 6 Power Up and Initial Checks 6 ...

Page 165: ...n 6 min and follow cabling guidelines WARNING DO NOT make motor connections with the power on Turn off all controller power before attempting to connect or disconnect any motor cables or system damage may occur Check MFC Controller I O cable wiring Section 4 6 Connections with external control equipment are done between MFC Controller I O connectors and or Fieldbus Expansion unit I O connectors Ve...

Page 166: ...rn power back ON without a brief wait recommended 20 seconds before turning power back on Single or random incidents of powering up with less waiting time is acceptable However multiple power ON OFF in succession may cause the following The inrush current protection circuit would shut down the power supply circuit The power supply circuit would then automatically shutdown As a result the power sup...

Page 167: ... other moveable component 3 Manual REVERSE Check Set the RUN BYPASS switch on each MFC Controller as follows 1 Verify MFC Controller 1 is set to RUN 2 Set all other MFC Controllers to the BYPASS position Press the manual REV button on front of the Keyboard display Unit Verify that spindle 1 is turning in the appropriate direction opposite the preset direction and that all other spindles are motion...

Page 168: ...Chapter 7 Fastening Instructions PAGE 7 1 Chapter 7 Fastening Instructions 7 ...

Page 169: ...d thread Torque Hold between steps of the torque value is maintained while the fastening operation stops between steps 1st step 2nd step Save Curve Disable The fastening curve will not be saved in the controller if this is enabled REJECT ABNORMAL curves will be saved regardless of this setting Disable Angle count below Snug Torque When enabled the angle measurement is stopped if the torque drops b...

Page 170: ...1ST TORQUE ANGLE 2 The system will fasten to the 1ST TORQUE ANGLE value during the specified 1ST TIME 1ST TORQUE ANGLE must be reached within the 1ST TIME limits or a reject will occur 3 Upon reaching 1ST TORQUE ANGLE 1ST TIME ends and 2ND TIME begins 1ST TORQUE ANGLE is the shift point to 2ND SPEED 4 Upon reaching 2ND TORQUE ANGLE the system with shift to 3RD SPEED The system will then fasten to ...

Page 171: ...t Torque and 2nd Torque equal to the Full Scale Torque Set 1st Angle and 2nd Angle higher than the Final Angle High Limit Standard Torque Ramp Down Start Torque 1st Torque 2nd Torque Snug Torque 1st Time 2nd Time Torque Angle Time Standard Torque Ramp Down Start Torque 1st Angle 2nd Angle Snug Torque 1st Time 2nd Time Torque Angle Time ...

Page 172: ...r a reject will occur Fastening Parameter Function Ramp Down Start Torque Set this torque 10 of the Standard Torque or 30 of SNUG Torque Set the value right before fastener seating 1ST Torque 1ST Angle Set this torque 30 of the Standard Torque or 80 of SNUG Torque 1st Time end point 2nd Speed start point and synchronization point for the 2nd step SNUG Torque Used for angle measurement start point ...

Page 173: ...rque SNUG Torque when a spindle synchronizes with other spindles at 1st Torque or when you want to improve the accuracy of the angle judgment Due to spindle relaxation during synchronizing Set 1st Angle and 2nd Angle higher than the Final Angle High Limit Angle Time Snug Torque 1st Time 2nd Time Standard Torque Ramp Down Start Torque 1st Torque 2nd Torque Angle Time Snug Torque 1st Time 2nd Time S...

Page 174: ...e Standard Torque or 30 of SNUG Torque Set the value right before fastener seating 1ST Torque 1ST Angle Set this torque 30 of the Standard Torque or 80 of SNUG Torque 1st Time end point 2nd Speed start point and synchronization point for the 2nd step SNUG Torque Used for angle measurement start point Set the value when the torque increase gets stable after fastener seating 2ND Torque 2ND Angle Set...

Page 175: ...er than the Final Angle High Limit and 2nd Torque equal to Full Scale Torque 1st Torque needs to be set lower than SNUG Torque 1st Torque SNUG Torque when a spindle synchronizes with other spindles at 1st Torque or when you want to improve the accuracy of the angle judgment Due to spindle relaxation during synchronizing Set 1st Angle and 2nd Angle higher than the Final Angle High Limit Torque Angl...

Page 176: ...e equal to Full Scale Torque and 2nd Angle higher than the Final Angle High Limit Set 1st Torque and 2nd Torque Equal to Full Scale Torque Torque Angle Time 1st Time 2nd Time Standard Torque Ramp Down Start Torque 1st Angle 2nd Torque Torque Angle Time 1st Time 2nd Time Standard Torque Ramp Down Start Torque 1st Angle 2nd Angle Snug Torque Snug Torque ...

Page 177: ...RAMP DOWN START TORQUE is reached or FREERUN REVOLUTIONS expires the system will switch from FREERUN SPEED to 1ST SPEED and continue to fasten to 1ST TORQUE ANGLE 2 The system will fasten to the 1ST TORQUE ANGLE value during the specified 1ST TIME 1ST TORQUE ANGLE must be reached within the 1ST TIME limits or a reject will occur 3 Upon reaching 1ST TORQUE ANGLE 1ST TIME ends and 2ND TIME begins 1S...

Page 178: ...st Torque and 2nd Torque equal to the Full Scale Torque Set 1st Angle and 2nd Angle higher than the Final Angle High Limit Standard Angle Ramp Down Start Torque 1st Torque 2nd Torque Snug Torque 1st Time 2nd Time Torque Angle Time Standard Angle Ramp Down Start Torque 1st Angle 2nd Angle Snug Torque 1st Time 2nd Time Torque Angle Time ...

Page 179: ...imits or a reject will occur Fastening Parameter Function Ramp Down Start Torque 30 of SNUG Torque Set the value right before fastener seating 1ST Torque 1ST Angle 80 of SNUG Torque 1st Time end point 2nd Speed start point and synchronization point for the 2nd step SNUG Torque Used for angle measurement start point Set the value when the torque increase gets stable after fastener seating 2ND Torqu...

Page 180: ...r than SNUG Torque 1st Torque SNUG Torque when a spindle synchronizes with other spindles at 1st Torque or when you want to improve the accuracy of the angle judgment Due to spindle relaxation during synchronizing Set 1st Angle and 2nd Angle higher than the Final Angle High Limit Angle Time Snug Torque 1st Time 2nd Time Standard Angle Ramp Down Start Torque 1st Torque 2nd Torque Angle Time Snug To...

Page 181: ... right before fastener seating 1ST Torque 1ST Angle 80 of SNUG Torque 1st Time end point 2nd Speed start point and synchronization point for the 2nd step SNUG Torque Used for angle measurement start point Set the value when the torque increase gets stable after fastener seating 2ND Torque 2ND Angle Set this torque 60 of the Judgment Torque 3rd Speed start point and synchronization point for the 3r...

Page 182: ... Set 1st Angle higher than the Final Angle High Limit and 2nd Torque equal to Full Scale Torque 1st Torque needs to be set lower than SNUG Torque 1st Torque SNUG Torque when a spindle synchronizes with other spindles at 1st Torque or when you want to improve the accuracy of the angle judgment Due to spindle relaxation during synchronizing Set 1st Angle and 2nd Angle higher than the Final Angle Hig...

Page 183: ... stops Set 1st Torque equal to Full Scale Torque and 2nd Angle higher than the Final Angle High Limit Set 1st Torque and 2nd Torque Equal to Full Scale Torque Torque Angle Time 1st Time 2nd Time Standard Angle Ramp Down Start Torque 1st Angle 2nd Torque Torque Angle Time 1st Time 2nd Time Standard Angle Ramp Down Start Torque 1st Angle 2nd Angle Snug Torque Snug Torque ...

Page 184: ...his function Note Disable Angle Count Below Snug Torque must not be set 203 1ST Angle 201 Final Angle High Limit 204 2nd Angle 201 Final Angle High Limit If configured as a Multi system the reverse operation will not be executed before the start of the fastening operation even if Reverse Before Fastening is enabled Use the fastening sequence commands Reverse 1 Reverse 2 and Reverse 3 if desired wh...

Page 185: ...les or during Sequence programmed Time Wait commands This helps compensate for drastic torque relaxation during multiple spindle fastening and ensures that sockets remain engaged on the fastener between steps Save Curve Disable Torque Curves will not be automatically stored in the controller after the fastening end if this selected REJECT and ABNORMAL curves will still be stored Torque Angle Time ...

Page 186: ...g Torque the system triggers the angle count and keeps counting the rotation angle even if the torque drops below Snug Torque Disable Angle Count below Snug Torque selected Angle value is not counted when torque falls below Snug Torque When Standard Angle is 90 deg Disable Angle Count below Snug Torque NOT selected Normal Operation Once Snug Torque is reached angle value is counted regardless of t...

Page 187: ...w Reject Rate 2 Low Reject and Rate 3 Low Reject signals together PLC output signals for this reject condition o Example of Fastener Slip detection Snug Torque 30Nm Fastener Slip Torque 10Nm Fastener Slip Angle 50 Degree o Example of Fastener Slip not detected Torque Snug 30Nm Angle D No 121 10Nm Slip Start Point D No 215 50 Deg Fastener Slip Reject Standard Torque Peak Torque of fastening Torque ...

Page 188: ...ops below Ramp Down Start Torque o Without this option selected o With this option selected Torque Revolution Speed Revolution Ramp Down Start Torque 1st Step Torque Freerun Speed 1st Speed Torque Revolution Speed Revolution Ramp Down Start Torque 1st Step Torque Freerun Speed 1st Speed Freerun Revolutions 50ms delay after torque drop speed returns to Freerun Speed stays at 1st Speed ...

Page 189: ...ay However surface drive sockets may need more than 10 degrees of rotation It is recommended to set 1 Pulse Reverse Torque High Limit to less than 50 of the fastening torque to ensure the bolt does not loosen 1 Pulse Reverse Speed can be as slow as 1 rpm and 1 Pulse Reverse Time can be 0 25 0 5 Seconds Revolutions Revolutions Reduce Torque Reaction The Reduce Torque Reaction function is used to av...

Page 190: ...ABN 08 10 may result Premature motor failure could result if prolonged to overload abnormals Torque Recovery time should be kept to a minimum for the application requirements 103 Standard Torque 204 2nd Angle 109 2nd Torque 203 1st Angle 105 1st Torque 106 SNUG Torque Angle Time 1st Time 2nd Time 500 Freerun Revolutions 401 Freerun Speed 403 2nd Speed 404 3rd Speed Angle Time 1st Time 2nd Time Ser...

Page 191: ...r when an Offset Check is desired The system must be started using this assigned parameter The average value of the torque detected during the offset check operation will be judged Data parameters D No 409 Offset Check Speed Speed at which the Offset Check is performed Should be set to 60rpm or lower for stable results D No 505 Offset Check Revolutions Number of revolutions used for the Offset Che...

Page 192: ...I system this is output if a sequence calls a parameter that has an error in it ie the parameter is setup as a 1 STEP fastening and the sequence calls 2nd STEP RESET STOP This is output when the PLC I O input signal RESET is set ON during the cycle or when the RESET button on the display of the MASTER Spindle is pressed START OFF This is output when the PLC I O input signal START is set OFF during...

Page 193: ...hed before reaching the desired Standard Torque value TORQUE CONTROL REJECT TYPE CAUSES PEAK TORQUE HIGH LIMIT Re hit of pre secured fastener or high speed crash Incorrect parameter set up PEAK TORQUE LOW LIMIT Reject condition caused by another monitor item reject Peak Torque High Limit Peak Torque Low Limit Rundown Revolution Low Limit Rundown Revolution High Limit Final Torque High Limit Final ...

Page 194: ...for Angle Control operations if it is reached before attaining the desired angle ANGLE CONTROL REJECT TYPE CAUSES PEAK TORQUE HIGH LIMIT Reduced joint compression Increased joint friction Incorrect parameter set up PEAK TORQUE LOW LIMIT Increased joint compression Reduced joint friction High initial prevailing torque Incorrect parameter set up Reject condition caused by another monitor item reject...

Page 195: ...e only selectable when Torque Recovery is enabled and are typically set based upon the engineering specification for that specific fastener TORQUE CONTROL TORQUE RECOVERY ENABLED REJECT TYPE CAUSES FINAL TORQUE HIGH LIMIT Excessive chatter of the torque signal due to slip stick friction Incorrect parameter set up FINAL TORQUE LOW LIMIT Loss of torque during Torque Recovery function Reject conditio...

Page 196: ...NGLE CONTROL REJECT TYPE CAUSES FINAL TORQUE HIGH LIMIT Reduced joint compression Increased joint friction Excessive chatter of the torque signal due to slip stick friction Incorrect parameter set up FINAL TORQUE LOW LIMIT Increased joint compression Reduced joint friction Excessive yield of fastener or broken fastener High initial prevailing torque Incorrect parameter set up Reject condition caus...

Page 197: ...ific fastener The fastening operation will stop if the Fianl Angle High Limit is exceeded ANGLE CONTROL REJECT TYPE CAUSES FINAL ANGLE HIGH LIMIT Reduced Joint Friction Incorrect parameter set up FINAL ANGLE LOW LIMIT Reject condition caused by another monitor item reject Peak Torque High Limit Peak Torque Low Limit Torque Angle Time Snug Torque Ramp Down Start Torque 1st Torque 2nd Torque Final T...

Page 198: ...eck for bolts that reach torque but are not seated This is especially the case where different length fasteners are used and placed by hand The number of rundown revolutions until fastening end is monitored and judged Rundown Revolutions is measured from the start of revolution to fastening end This can be used in conjunction with the Low 1st Time Limit Note Since fastener engagement is not always...

Page 199: ...tion for that stage Torque Rate Calculation Areas Typical for 1 or 2 step 3rd Rate Start and End Torque set above FASTENING END TORQUE STAGE START POINT STOP POINT 1ST TORQUE RATE 1ST RATE START TORQUE 1ST RATE END TORQUE 2ND TORQUE RATE 2ND RATE START TORQUE 2ND RATE END TORQUE Torque Rate Calculation Areas Typical for 3 step however can be used on 1 or 2 step STAGE START POINT STOP POINT 1ST TOR...

Page 200: ...art Torque 1st Rate End Torque 1st Rate Low Limit 2nd Rate High Limit 1st Rate High Limit 2nd Rate Low Limit 2nd Rate End Torque Torque Angle Time 1st Time 2nd Time 2nd Rate Start Torque Standard Torque 1st Rate Start Torque 1st Rate End Torque 1st Rate Low Limit 3rd Rate High Limit 2nd Rate High Limit 1st Rate High Limit 2nd Rate Low Limit 3rd Rate Low Limit 3rd Rate Start Torque 2nd Rate End Tor...

Page 201: ...rque 115 2nd Rate End Torque Set the torque value of 2nd torque rate measurement end point 116 3rd Rate Start Torque Set the torque value of 3rd torque rate measurement start point 13 Standard Torque 3rd Rate End Torque 117 3rd Rate End Torque Set the torque value of 3rd torque rate measurement end point 23 1st Angle 1st Rate End Angle Set the angle value of 1st torque rate measurement end point 2...

Page 202: ...e point This function is useful to detect bolt stretch in applications where the fastener torque rates may vary making it difficult to set normal Final Angle limits Differential Angle Check is not performed if the 2nd Rate judgment is disabled even when Differential Angle Check is enabled Differential Angle Check is not performed when the 2nd Rate Start Torque is not detected during fastening If t...

Page 203: ...nhibit Angle 103 Standard Torque 109 2nd Torque 105 1ST Torque 107 SNUG Torque 1ST Time 2nd Time Angle Time The set values stated below are ignored during the time between fastening start and D No 205 Torque Inhibit Angle when Torque Inhibit Check is enabled D No 103 Standard Torque D No 104 Slow Down Start Torque D No 105 1st Torque D No 107 SNUG Torque D No 109 2nd Torque D No 112 1st Rate Start...

Page 204: ...disabled The full scale current is set automatically in accordance with the model of the controller Do not change this value because it is set based on the tool motor used Additionally the fastening current limit limits the maximum value of the current output during the fastening operation If a value lower than the full scale current is set the fastening operation will be limited to this value and...

Page 205: ...il 1st TORQUE ANGLE is attained or the 1ST TIME HIGH LIMIT is reached 1st SPEED is switched right before the fastener is seated and is intended to provide adequate speed to seat the fastener without getting a load to the tool 2 Upon reaching 1ST Torque Angle 1st Time ends and 2ND Time begins 1ST Torque Angle is the shift point from 1st Speed to 2nd Speed and the synchronization point prior to comm...

Page 206: ... time requirements This speed is used to fasten the bolt at high speed after the socket engagement and before fastener seating 1ST Speed 1st Speed is the fastening speed until the 1st Torque Angle is detected Set based upon the joint type to allow for a controlled seating Set less than 100rpm in order to prevent the damage or seizure between the object to be fastened and the fastener 2ND Speed 2nd...

Page 207: ... Blank Page ...

Page 208: ...Chapter 8 System Operation PAGE 8 1 Chapter 8 System Operation 8 ...

Page 209: ...rt mode a pulse of 200 500 ms activates the cycle If the start mode is DEADMAN the signal has to be active until the fastening ends otherwise the cycle will be stopped and results stored from the point the cycle was stopped If the the 1st Torque or Angle is not reached the fastening results and torque curve will not be stored See section 4 12 2 for switch SW1 settings concerning start mode operati...

Page 210: ...ected spindles including the Master will be checked In addition when the CAL switch is pressed in the state where D No 1 Torque Voltage Value Indication of the real time mode PAGE 8 7 is indicated the value converted in terms of the potential difference of approximately Δ3 75V is indicated on the upper digits of the display Do not press the CAL button during fastening operation The sudden stopping...

Page 211: ...n the system is in the BYPASS state SET Pushbutton This push button is used to set data and to confirm data setting changes when the system is in BYPASS state and Pushbutton These push buttons are used for switching the display data or changing the set Data The content of each display LED will be different based on the controller mode RUN or BYPASS Refer to Page 8 5 RUN State and Page 8 14 BYPASS ...

Page 212: ...ntroller Refer to section 4 12 3 regarding the setting of Dip Switch SW2 on the bottom panel of the controller RUN operate Mode PLC I O BYPASS Input Signal OFF AND RUN BYPASS Switch on the front panel of the controller RUN position BYPASS LED light is off when the system is in RUN operate mode BYPASS Mode PLC I O BYPASS Input Signal ON OR RUN BYPASS Switch on the front panel of the controller BYPA...

Page 213: ...ated by the D No PAR No Display The fastening parameter No Or Sequence No for the Master is displayed When an abnormal condition occurs the abnormal No will be displayed in Status Mode D No Display The data number of the data which is displayed on the upper digits will be displayed The operating speed is displayed while in cycle in the Status display mode The Controller setting and spindle number ...

Page 214: ...tion during the fastening operation is displayed Sxx or Pxx appears in the PAR No display The fastening Status display is displayed during the time between the beginning and end of the fastening operation Also it s displayed when the abnormal condition occurs or when the STOP signal is turned OFF the BYPASS signal is turned ON etc Fastening Result Mode When this mode is activated the fastening res...

Page 215: ...s procedure repetitively or the motor will overheat Nm 003 Angle rotation display The rotation angle of the output shaft since the last time the display mode was switched to Real Time Display Mode is displayed Turning the tool output square will also read in this mode deg 004 Overload factor The current monitor load factor is displayed If the load factor goes over 100 an overload A08 10 abnormal o...

Page 216: ...pter 8 System Operation PAGE 8 9 Real Time Display Mode Example D No DATA Torque value Torque voltage Peak torque value Tool Rotation Speed or push button Skip 5 numbers while holding down 000 001 002 008 ...

Page 217: ...T signal loss during BUSY while operating signal 010 1st NG item The D No of the fastening NG item that occurred first is displayed 011 Rate 1 2 3 judgment H L 012 Fastening method trq torque method ang angle method offset offset check 013 Number of fastening steps 014 Self Check Flag SC ON Check Performed OFF Check Not Performed 015 Reverse Flag RV ON Reversed OFF Not reversed 016 Servo lock flag...

Page 218: ...ment Rate 1 low No of Fastening Steps Fastening Method Torque Reverse Flag The displayed contents of the following D Nos are not stored in the fastening result retention in the controller D No 12 Fastening Method D No 13 Number of Fastening Steps D No 14 Self Checking Flag D No 15 Reverse Flag and D No 16 Servo Lock Flag or push button Skip 5 numbers while holding down 000 001 002 035 ...

Page 219: ...ed By pressing the or push button the D NO can be changed 1 The numbers can be advanced 10 at a time by holding the or push button longer Refer PAGE 24 Parameter List regarding the detailed about parameters D No PAR No DATA 01 32 Fastening Method 01 32 Fastening Steps 01 32 Fastening Option 01 32 Low limit current 01 32 Current limit When using a system setup as a multi system in addition to faste...

Page 220: ... pressing the or push button the D NO can be changed 1 The numbers can be advanced 10 at a time by holding the or push button longer Refer PAGE 24 Parameter List regarding the detailed about parameters D No PAR No DATA SYS Torque unit SYS Firmware version SYS Amplifier version SYS Expansion RS232C 3 Stop Bit SYS Expansion RS232C 3 Data Bit switch or switch Skip 10 numbers while holding down 000 00...

Page 221: ...ay In the status view the currently selected parameter sequence No 01 to 32 is displayed in the PAR No display The Spindle No of the Unit is indicated by the 10s and 1s digits of the D No display The indication at the 100s digit of the D No Display differs according to the currently used system and whether the Controller is the MASTER Axis or the SLAVE axis see below Ordinary View Multi MASTER Axi...

Page 222: ...e and subcode A03_02 shown below The code can be used to lookup further diagnostic troubleshooting information in the manual See Chapter 10 When the BYPASS signal is turned ON When the RESET signal is turned ON When the STOP signal is turned OFF When the indicator CAL switch is turned ON Sub code indication Abnormal code Bypass Stop Reset CAL ...

Page 223: ...g operation Transition to the Fastening Result Mode is performed automatically after the fastening ends The following are display examples during a fastening operation of parameter No 1 During initial speed During freerun speed During 1st speed During 2nd speed During 3rd speed During 2nd step wait 1 End During 3rd step wait 2 End During offset check The display content of the upper stage DATA of ...

Page 224: ...YPASS state The Data No and parameter setting of each parameter No is displayed on the displayed Controller Display BYPASS Mode DATA Display Parameter set value is displayed PAR No Display Parameter No is displayed D No Display Data No of the data displayed or DATA Display PAR No Display D No Display ...

Page 225: ...mode is switched to Parameter Display mode by pressing the or push button However in the Parameter Select Mode and the System Select Mode the mode is changed directly to the set value selection mode Parameter Selection Mode This mode selects the parameter The cursor position can be changed by pressing the or push button The display set value can be changed with the or push button Parameter Edit Mo...

Page 226: ... cursor blinking number is displayed on the D No Display The display set value of the cursor blinking character can be changed by 1 using the or push button The numbers can be advanced 10 at a time by holding the or push button longer Parameter Edit Mode can be entered by pressing the SET push button Parameter Edit Mode PAGE 8 18 SET SET SET By pressing the or pushbuttons you can quickly change mo...

Page 227: ... blinking character can be moved left or right by 1 digit using the or push button Pressing the SET push button after editing the parameter will change the parameter and bring up the Parameter Display Mode Pressing the RESET push button in the Parameter Editing Mode will bring up the Parameter Display Mode without changing the parameter If the changed parameter is out of the setting range the para...

Page 228: ...r when the BYPASS signal turns from ON to OFF If the power is turned off when changing the set value in BYPASS mode the changed value will be canceled and will be set back to the original value Some of the system parameters PAR No 000 are not changed until the control power is rebooted D No 003 Function Version D No 011 016 TCP IP Setting etc When the Controller Tool No PAR No SYS D No 200 is chan...

Page 229: ...YPASS position and then press the SET pushbutton 3 After transition to the Parameter Edit Mode use the or pushbuttons to change to Single 4 After pressing the SET pushbutton use the or pushbuttons to change the indication from NO to YES within 2 seconds and then press the SET pushbutton again 5 Change the RUN BYPASS switch of the Controller to the RUN position 6 Turn OFF the control power to the C...

Page 230: ...SET pushbutton again 5 Switch the RUN BYPASS switch of the Controller to the RUN position 6 Turn OFF the control power to the Controller 7 By turning on the control power 10 seconds later changing to the Multi System is accomplished 8 To confirm the change to the Multi System confirm that Multi is indicated at the upper part of the display in System Display with SYS indicated in the PAR No display...

Page 231: ...play 2 Change the RUN BYPASS switch of the Controller to the BYPASS position and then press the SET pushbutton 3 Select the copy source parameter No in the first 2 digits of the upper stage of the display DATA 4 Select the copy destination parameter No in the last 2 digits of the upper stage of the display DATA 5 Press the SET pushbutton press the or pushbuttons to change the indication from Copy ...

Page 232: ...the copy source parameter No in the first 2 digits of the upper area of the display DATA 4 Select 99 in the last 2 digits of the upper area of the display DATA and then press the SET pushbutton 5 Press the or pushbuttons to change the indication from Copy NO to Copy YES within 2 seconds and then press the SET pushbutton within 2 seconds 6 Parameter 1 will be copied to parameter 2 32 SET Parameter ...

Page 233: ...n to select Multi as the type of result history to be erased and then press the SET pushbutton 4 Press the or pushbutton to change the indication from Erase NO to Erase YES within 2 seconds and then press the SET pushbutton within 2 seconds 5 When the erasing of the fastening results history is started Erase in the upper stage of the display flashes the MULTI LED and the COM LED become lit in oran...

Page 234: ...ameter No 002 Parameter No 001 000 Fastening Method 001 Fastening Steps 002 Fastening Option 003 Judge Item 1 004 Judge Item 2 521 Low Current Limit 522 High Current Limit 523 Fastening Current Parameter No SYS System Parameter 000 Torque Unit 001 Software Version 002 Amplifier Version 003 System Type 408 Expansion RS232C 3 Data Bit ...

Page 235: ...digits 192 168 016 Default Gateway lower 6 digits 11 1 017 MAC Address upper 6 digits 001F98 Cannot be changed 018 MAC Address lower 6 digits 001000 Cannot be changed 019 RTC Year Month Day 130725 July 25 2013 020 RTC Time 123456 12 34 56 021 Erase Fastening Result History Format CF Card 022 Parameter Copy 023 For in house adjustment Cannot be changed 024 FPGA version of the controller Cannot be c...

Page 236: ...ntroller Setting Fieldbus Information 303 Station No Node Address 1 to 64 or 0 to 63 304 Communication Speed 0 to 4 305 Occupied Stations 1 2 3 4 306 Extended Cyclic Setting 1 2 4 8 307 I O Setting Byte Length PLC MASTER Axis 308 I O Setting Byte Length Master Axis PLC 309 Message Block Byte Length 310 Message Setting Byte Length PLC MASTER Axis 311 Message Setting Byte Length Master Axis PLC 312 ...

Page 237: ...UG Torque P 01 P 32 108 SNUG Torque High Limit P 01 P 32 109 2ND Torque P 01 P 32 110 Reverse Torque High Limit P 01 P 32 111 Starting Torque Inhibit High Limit P 01 P 32 112 1ST Rate Start Torque P 01 P 32 113 1ST Rate End Torque P 01 P 32 114 2ND Rate Start Torque P 01 P 32 115 2ND Rate End Torque P 01 P 32 116 3RD Rate Start Torque P 01 P 32 117 3RD Rate End Torque P 01 P 32 118 Final Torque Lo...

Page 238: ... Speed P 01 P 32 402 1ST Speed P 01 P 32 403 2ND Speed P 01 P 32 404 3RD Speed P 01 P 32 406 Reverse 1 Speed P 01 P 32 407 Reverse 2 Speed P 01 P 32 408 Reverse 3 Speed P 01 P 32 409 Offset Check Speed Revolution rev Current A P 01 P 32 500 Freerun Revolutions P 01 P 32 501 Reverse 2 Revolutions P 01 P 32 502 Reverse 3 Revolutions P 01 P 32 503 Rundown Revolution Low Limit P 01 P 32 504 Rundown Re...

Page 239: ...adjust the gear ratio when an external head that has a gear ratio other than 1 1 is connected to the output shaft of the tool Do not use a value other than the standard setting 1 000 unless an external offset gear is attached D No 005 In house adjustment D No 006 In house adjustment Not used D No 007 Axis Communication MASTER SLAVE Display This indicates whether the controller is the MASTER for PC...

Page 240: ...d The MAC ID address of the Ethernet port is indicated D No 019 RTC Year Month Day Setting range 13 to 99 year 1 to 12 month 1 to 31 day D No 020 RTC Time Setting range 0 to 23 hours 0 to 59 minutes 0 to 59 seconds The date and time of the real time clock RTC are indicated The range for the year is 2013 to 2099 This is not indicated at a SLAVE spindle in a MULTI system D No 021 Erase Fastening Res...

Page 241: ...f the tool is indicated D No 105 Tool ZERO Voltage V The ZERO voltage of the tool is indicated D No 106 Tool Internal Gear Ratio 100 The value obtained by multiplying the gear ratio of the tool by 100 is indicated D No 107 Tool Serial No upper 3 digits D No 108 Tool Serial No lower 4 digits The serial No of the tool is indicated D No 109 Tool Rotation Direction The rotation direction of the tool i...

Page 242: ...ion The version of the PLC output layout file set in the controller is indicated D No 205 Fieldbus Setting File Version The version of the fieldbus file set in the controller is indicated D No 206 Fieldbus Message Setting File Version The version of the fieldbus message file set in the controller is indicated D No 207 RS232C Input Output Setting File Version The version of the RS232C input output ...

Page 243: ...dbus Information Secondary version type of fieldbus set in the controller parameter is indicated D No 303 Station No Node Address CC Link DeviceNet PROFIBUSDP V1 The station No node address of the fieldbus set in the Unit is indicated Fieldbus Type CC Link DeviceNet PROFIBUSDP V1 1 64 0 63 0 125 Fieldbus not set Expansion Unit 1 Uninstalled Standard IO MFC DT Installed Expansion IO MFC CC Installe...

Page 244: ... for PLC MASTER Axis of the fieldbus set in the Unit is indicated D No 308 I O Setting Byte Length Master Axis PLC byte besides standard IO and expansion IO The I O setting byte length for MASTER Spindle PLC of the fieldbus set in the Unit is indicated D No 309 Message Block Byte Length byte besides standard IO and expansion IO The message block byte length of the fieldbus set in the Controller is...

Page 245: ...nsion Unit 2 is indicated D No 404 Expansion RS232C 2 Data Length bit The data length of the RS 232C 2 interface of the Expansion Unit 2 is indicated D No 405 Expansion RS232C 3 Communication Speed bps The communication speed of the RS 232C 3 interface of the Expansion Unit 2 is indicated D No 406 Expansion RS232C 3 Parity The parity of the RS 232C 3 interface of the Expansion Unit 2 is indicated ...

Page 246: ...stening Single System Only Reverse at D No 406 Reverse 2 Speed for D No 501 Reverse 2 Revolutions before fastening starts 00010 Fastening Direction CCW Specialized for fastening with a left hand screw etc which need to fasten in the opposite direction of normal fastening CW direction right hand thread Reverse rotation is in the CCW direction 00100 Hold Torque Between Steps For 2 Step Fastening the...

Page 247: ...eout Check Judges whether the fastening time from fastening start to D No 105 1st Torque or D No 205 1st Angle OR from D No 105 1st Torque or D No 205 1st Angle to fastening end is within the Time 1st 2nd High Low limits 000010 Revolutions Check Performs judgment if the revolutions during fastening is within the Rundown Revolutions High Low limits 000100 Differential Angle Check Judges whether the...

Page 248: ...0100 Torque Recovery Once Standard Torque is reached the torque is maintained for D No 315 Torque Recovery Time The fastening speed during torque recovery is set at D No 404 3rd Speed Should be no more than 3rpm or 5rpm 1000 Servo Lock At the end of a cycle with Servo Lock enabled the motor rotor is electrically locked to prevent rotation of the tool External gears socket and or socket extensions ...

Page 249: ... needs to be changed the mean of the fastening result data is used as the measured value The number of samples of fastening result data is recommended to be at least 10 as a statistical standard When the calibration value is changed confirm that other torque parameters are lower than the new Calibration value or the new CAL value may not be able to be entered Other torque related parameters should...

Page 250: ...que is not used as a fastening control D No 107 SNUG Torque Nm Setting Range 0 D No 010 Full Scale Torque 1 0 SNUG Torque is the start torque for angle measurment It is the start point of angle measurement When D No 000 Fastening Method is Angle Control Method it is the fastening start point Angle measurement and judgment are started from D No 107 SNUG Torque Ex When D No 107 SNUG Torque is 10Nm D...

Page 251: ... applications Torque Inhibit is conducted from fastening start to the D No 205 Torque Inhibit Angle value If the torque exceeds D No 111 Torque Inhibit Limit before reaching the D No 205 Torque Inhibit Angle the fastening result will be REJECT D No 112 1ST Rate Start Torque Nm D No 113 1ST Rate End Torque Nm Setting Range 0 D No 100 Full Scale Torque 1 0 Set the start and end points for measuring ...

Page 252: ...orque Control Method this does not need to be set Only in the case TORQUE RECOVERY is used to check that fastener breakage does not occur during torque recovery When D No 000 Fastening Method is Offset Check final torque is set as the high limit value of the average torque detected during D No 505 Offset Check Revolutions If the average torque exceeds the final torque high limit fastening judgment...

Page 253: ...d point of 1st Time and beginning of 2nd Time It is a synchronization point of the 1st STEP prior to commencing 2 STEP or 3 STEP fastening operations Input the same value as D No 201 Final Angle High Limit if the 1ST Angle is not used as a fastening control D No 204 2ND Angle deg Setting Range 0 9999 9 The angle value that the speed is shifted from D No 402 2nd Speed to D No 403 3rd Speed It is a ...

Page 254: ...point when the D No 115 2ND Rate End Torque is reached D No 303 2ND Rate High Limit Nm deg Setting Range Tool s minimum torque rate tool s maximum torque rate Set the high limit for the slope of torque and angle measured between two points from D No 114 2ND Rate Start Torque to D No 115 2ND Rate End Torque Judgment is conducted at the point when the D No 115 2ND Rate End Torque is reached D No 304...

Page 255: ...astening judgment will be REJECT D No 314 2ND Time High Limit sec Setting Range 0 999 9 Set the time high limit between D No 105 1ST Torque or D No 203 1ST Angle and the point D No 103 Standard Torque or D No 202 Standard Angle is reached Allow enough time to reach Standard Torque from 1st Torque When the 2ND Time High Limit is exceeded the fastening judgment will be REJECT D No 315 Torque Recover...

Page 256: ... Tool s minimum to maximum number of rotations Set the speed between D No 401 Freerun Speed and D No 403 2ND Speed The system rotates at the 1ST Speed until D No 105 1ST Torque is detected from D No 104 Slow Down Start Torque or until D No 203 1ST Angle is detected from D No 104 Ramp Down Start Torque If D No 105 1ST Torque or D No 203 1ST Angle is reached during the D No 401 Freerun Speed 1ST Spe...

Page 257: ...ngle System this is the speed used for D No 002 Fastening Option Reverse Before Fastening When the D No 110 Reverse Torque High Limit is exceeded during the reverse operation the fastening will stop and the abnormal signal A 9 8 Reverse Torque Error will be displayed D No 408 Reverse 3 Speed rpm Setting Range Tool s minimum to maximum number of rotations Set the speed during the reverse operation ...

Page 258: ...it at the time of fastening end or if D No 503 Rundown Revolution Low Limit is not reached the fastening result will be REJECT D No 505 Offset Check Revolutions rev Setting Range 0 99 9 Used for D No 002 Fastening Option Reverse Before Fastening Also it is used for fastening sequence command Reverse 2 D No 520 Full Scale Current A D No 521 Low Current Limit A D No 522 High Current Limit A D No 523...

Page 259: ...Chapter 8 System Operation PAGE 8 52 ...

Page 260: ...Chapter 9 Maintenance Inspection PAGE 9 1 Chapter 9 Maintenance Inspection 9 ...

Page 261: ...que and stress generated during each fastening is applied directly to the spindle assembly Inspect each assembly and ensure the following specifications are met Inspect Monthly The spindle assembly is producing normal levels of noise and vibration The assembly is free from excessive contamination and foreign matter The spindle assembly is securely mounted with mounting bolts properly tightened The...

Page 262: ...gular intervals P FEC INC recommends performing this procedure initially after equipment has been in use for two years or 1 000 000 cycles whichever is reached first PWhen the initial maintenance is performed the condition of the transmission assembly should be analyzed to determine future maintenance requirements Systems operating under more severe conditions Full scale torque in high temperature...

Page 263: ...utput shaft to align the transmission planetary gears with the motor output square shaft Connect the transducer to the transmission with 3 screws Install the snap ring onto the output shaft to hold the outer bearing in place If the transmission does not rotate freely after reassembling the tool then disassemble the tool again to isolate and correct the cause Re connect transducer cable and re asse...

Page 264: ...ET pushbutton and make sure the value displayed is near zero Also make sure the JUDGE LED turns green 5 Press the CAL pushbutton and make sure the value displayed is near the calibration value of the tool Also make sure the JUDGE LED turns green You can also check the Origin voltage value or CAL voltage value by the following process Zero Level Voltage and Calibration Voltage Test 1 Make sure the ...

Page 265: ...indings To check the motor or resolver windings measure the winding s resistance and the isolation resistance Perform measurement of the resistance value after turning off the power to the Unit and the tool device equipment 1 Disconnect the motor connector from the tool assembly 2 Measure the resistance between windings Check that the resistance is within 10 of the specified value 3 Measure the is...

Page 266: ...nit are clearly marked for reconnection 2 Disconnect all cables from the unit 3 Loosen do not remove the three 3 screws that secure the MFC unit to the back panel The upper bracket of the MFC unit has one slotted hole and the bottom bracket has two open ended slots 4 Lift up and out on the unit to remove 5 Verify the new MFC unit s rotary address switches are set to the appropriate spindle number ...

Page 267: ...fy all System power is off 2 Ensure that the homerun cable is marked for reconnection then disconnect it from the tool 3 Ensure the spindle assembly and nutrunner are supported and remove the 3 bolts securing them to the mounting plate WARNING These bolts also secure the nutrunner Some tool models are very heavy Use precautions when disconnecting removing and installing these components 4 Follow a...

Page 268: ...Chapter 10 Troubleshooting PAGE 10 1 Chapter 10 Troubleshooting 10 ...

Page 269: ... of the blinking character This code refers to some specific type of failure detailed in the tables shown in the following sections w Abnormal Sub code display The number shown at the most right position in the D NO display area is a sub code that can be used in conjunction with the Abnormal failure code to further narrow down the cause of the fault See the following sections Note If all display s...

Page 270: ... the system after each exchange to determine which component may have caused the failure abnormal 7 Replace the defective component Code A01 02 TORQUE TRANSDUCER CAL MASTER ERROR The System detected a Calibration Voltage Check error during power on initialization CAUSE 1 When the tool torque transducer is sensing excessive torque due to pressure on the tool body during power on initialization when...

Page 271: ...after each exchange to determine which component may have caused the failure abnormal 7 Replace the defective component Code A01 04 TORQUE TRANSDUCER CAL CHECK ERROR The System detected a Calibration Voltage Check error after a fastening START was attempted CAUSE When the tool torque transducer is sensing excessive torque due to pressure on the tool body during a START signal to the controller whe...

Page 272: ...cted at both ends and free from cuts abrasive wear or kinks 4 Verify that the tool cable or controller are not located near any high voltage transient power sources Relocate as required and reinitialize 5 Turn control power off to the unit for at least 5 seconds then re apply power 6 Exchange tool cable tool and or controller with known working units Reinitialize the system after each exchange to ...

Page 273: ...rameter 200 This error may occur when controllers or tools are replaced with the wrong type unit or the parameter program does not match the tool size installed RECOVERY 1 Verify the tool size model number matches the tool programmed in the controller parameter 2 Program proper tool number into the controller MFC unit or change tool to proper tool 3 Confirm TOOL ID data has not been corrupted or i...

Page 274: ...controller is not located near any high voltage transient power sources Relocate as required and reinitialize the system 3 Turn control power off to the unit for at least 5 seconds then re apply power 4 Replace controller Code A04 03 SYSTEM MEMORY ERROR SERVO AMP FLASH ROM ERROR Communications error to internal MFC Unit Servo Amp flash ROM CAUSE 1 If the controller is located in an electric or mag...

Page 275: ...p CAUSE 1 If the controller is located in an electric or magnetic noise field 2 RTC chip has malfunctioned RECOVERY 1 Verify that the controller is not located near any high voltage transient power sources Relocate as required and reinitialize the system 2 Turn control power off to the unit for at least 5 seconds then re apply power 3 Replace controller Code A04 07 SYSTEM MEMORY ERROR RTC READ ERR...

Page 276: ... the motor from turning 4 System Parameter 523 Fastening Current Limit is not set to the correct value may be too low 5 Torque Transducer damage error will not allow motor to start turn RECOVERY 1 Verify that the tool cable is securely connected at both ends and free from cuts abrasive wear or kinks 2 Connect a known good spare tool cable to the existing tool 3 Exchange tool and or controller with...

Page 277: ...o type tag with the motor type tag 2 Controller may have the wrong parameter downloaded with wrong tool size 3 There are 3 types of MFC Units controllers available they must be connected to the correct motor size as shown below Tool Number Tool Type Controller Type 1 CFT 101RS1 MFC S024 2 CFT 201RS1 8 CFT 281RS1 3 CFT 401RS1 4 CFT 801RS3 MFC S060 5 CFT 131RS3 6 CFT 202RS3 7 CFT 302RS3 100 NFT xxxR...

Page 278: ...8 02 SERVO AMPLIFIER ERROR WATCHDOG TIMER ABNORMAL The MFC controller watchdog timer is not functioning properly CAUSE 1 The controller watch dog circuit has malfunctioned or failed RECOVERY 1 Turn control power off to the unit for at least 5 seconds then re apply power 2 Replace the controller Code A08 04 SERVO AMPLIFIER ERROR OVER CURRENT The MFC controller servo circuit experienced a current ov...

Page 279: ...as detected improper input power voltage either above or below the specified limits CAUSE 1 The controller internal control power circuit has failed 2 Source voltage is out of the limit 24VDC 10 and or unstable RECOVERY 1 Replace the controller 2 Check the control power connections 3 Verify and correct the source voltage as required Code A08 07 SERVO AMPLIFIER ERROR CONTROL POWER INTERRUPT ABNORMA...

Page 280: ... Torque and or 2nd Torque and speeds to keep motor from running slow under load for long durations 5 Check the cable connections 6 If the problem remains a larger tool assembly may be required for this application Please contact FEC Code A08 11 SERVO AMPLIFIER ERROR RESOLVER SIGNAL ERROR The resolver signal received from the tool in the controller is not correct RECOVERY 1 Verify that the tool cab...

Page 281: ...o Current Sensor has failed RECOVERY 1 Replace the controller Code A08 21 SERVO AMPLIFIER ERROR MOTOR HUNTING DETECTION ERROR Motor oscillation is detected during fastening detects CCW rotation during CW command and vice versa This function added at firmware version 1 417 CAUSE 1 Deterioration of the servo isolation amplifier circuit due to use duty and heat over a long period of time typically mo...

Page 282: ... Tigh Limit A09 05 400 401 402 403 404 409 Speed setting out of range Code A09 08 PARAMETER ERROR REVERSE TORQUE OVER The torque value exceeds the Reverse Torque High Limit value during a reverse operation RECOVERY 1 Verify that the programmed parameter value is correct D No 110 2 If the value is correct check the application The size of the tool may not be adequate for this application or the fas...

Page 283: ... are turned on or more than two bits are turned on when the start signal or manual reverse signal is turned on this error will occur Code A10 02 SPINDLE NOT FOUND ERROR The system received a START signal or Manual REVERSE signal while the Axis Link cable was disconnected The system did not receive a reply from the spindle Axis specified in the sequence program when the system started a fastening c...

Page 284: ...put If the USE INDIVIDUAL SEQUENCE SELECT bit bit 11 is turned off the system uses the combination of SEQUENCE SELECT BIT 0 4 for selecting sequence program between 1 32 b Individual Sequence Select Input If the USE INDIVIDUAL SEQUENCE SELECT bit bit 11 is turned on the system uses individual sequence select signals bit 16 47 for selecting sequence program 1 32 If none of these bits are turned on ...

Page 285: ...rollers Spindle is out of sequence With a Master controller ver 1 400 or later with this function enabled if a controller with a firmware version that does not support this function before version 1 400 which is mixed in the connected spindles will generate this abnormal In this case see 3 below RECOVERY 1 Check the communication cable s between spindles 2 Confirm the Axis Link Terminators are in ...

Page 286: ... To confirm the sequence No used for operation the D No value is changed by operating the and pushbuttons When 33 is selected as the D No indicated at the D No indication part the numeral indicated at of S at the upper part of the display is the sequence No used for operation only indicated at the MASTER Axis Confirmation of Reason for Stopping of Fastening Procedure 1 When after the end of fasten...

Page 287: ...ocument will help diagnose the fastening reject data that is seen when monitoring the fastening data Some of the explanations below are obviously simple but use this simply as information to help understand what the equipment may be detecting telling you Note This is only meant as a guide and may not contain all possible reasons each application is different The chart below shows the type of Faste...

Page 288: ...r ETHERNET communication capable of using a network connection Set the PC to be able to use network or use another PC which has network capability Setting of Windows firewall Disable the firewall temporarily because the security level is high with the fire wall 10 11 Verify connection using the command prompt Enable to check the ETHERNET setting on PC by using the command prompt 10 11 Even if the ...

Page 289: ...ubleshooting PAGE 10 22 10 11 1 Confirming the Windows Firewall Windows Firewall Settings Windows 7 1 Click Control Panel in the Start menu 2 Click System and Security Category display shown 3 Click Windows Firewall ...

Page 290: ...Chapter 10 Troubleshooting PAGE 10 23 4 Click Turn Windows Firewall on or off 5 Click Turn off Windows Firewall Also if antivirus software is installed turn off the antivirus software ...

Page 291: ...nit and the PC with the PC communication cable 2 In the Windows Start menu click All Programs Accessories Command Prompt 3 When the command prompt screen appears enter ipconfig and then press the Enter key The current PC settings are displayed If the displayed settings are not correct set the PC s setting again ...

Page 292: ...he AFC3000 User Console fails make the command prompt screen appear again and then enter ping 192 168 3 199 or ping 192 168 3 198 Enter the IP address of the Unit and the PC after the ping The following will be displayed if normal communication between the Unit and the PC is enabled In the case of normal communication ...

Page 293: ... Unit Indicator 1 Switch the RUN BYPASS switch of the Unit to the BYPASS side 2 Operate the arrow pushbuttons to make SYS to be indicated at the PAR No indication part and 019 or 20 RTC Year Month Day Time be indicated at the D No indication part and then press the SET pushbutton 3 After transition to the set value editing mode operate the arrow pushbuttons to change to the desired date or time fo...

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