FEC Handheld Nutrunner HFC3000 Instruction Manual Download

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Chapter 1 Outline

PAGE 1-2

1-1 How to Use This Instruction Manual

This manual describes the system structure, specifications, handling method, etc., of the Handheld

Nutrunner System.

These are described in the following order in this manual:

Chapter

Items

Contents

Chapter 1

Outline

Description of functions

Chapter 2

Specifications

General specifications of the system.

Chapter 3

System Description

Description and function of the respective parts of the system
components.

Chapter 4

Installation & Wiring

Installation procedure, dimensions, input and output signal
descriptions and requirements for PLC programming

Chapter 5

Power up and
Operational Tests

Items to be checked before power up and procedures for
operational tests.

Chapter 6

Fastening Operation

Descriptions of items displayed on the front panel and
instructions for setting the fastening parameter values.

Chapter 7

Troubleshooting

Descriptions of abnormal operation conditions during
operation and corrective actions.

Chapter 8

Options

Optional module description and setup

Chapter 9

Fieldbus I/O Interfaces

Fieldbus interface setting and functions

Summary of Contents for Handheld Nutrunner HFC3000

Page 1: ...HFC3000E HW 2 H Ha an nd dh he el ld d N Nu ut tr ru un nn ne er r H HF FC C3 30 00 00 0 I In ns st tr ru uc ct ti io on n M Ma an nu ua al l January 2019 ...

Page 3: ...fore using the equipment and understand and observe all instructions and recommendations included in this manual Read all instructions and recommendations included in this manual understand the functions and performance of this nutrunner and use this machine correctly Wirings and parameter settings shall be conducted by a professional engineer Indicate the following on all instruction manuals that...

Page 4: ...nction is a condition environment handling etc falling outside that which is indicated in the instruction manual 2 If a malfunction is due to a modification or repair performed by the customer 3 If the cause of a malfunction is an apparatus other than this equipment 4 If a malfunction is due to use outside the specification ranges of this equipment 5 If the cause of a malfunction is an act of God ...

Page 5: ...bserved Even 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 marked with the symbols This instruction manual uses various symbols for instructions that shall be observed Warning This symbol indicates that failure to observe in...

Page 6: ...neer Failure to observe this instruction may cause an electric shock or injury Turn OFF the power when conducting wiring operation and maintenance and inspection Failure to observe this instruction may cause electric shock and injury Never damage the cables apply excessive strength to cables or squeeze the cables Never use damaged power cables Failure to observe this instruction may cause an elect...

Page 7: ...spindles when transporting the tools Failure to observe this instruction may cause injury or malfunction The equipment shall be stored under the following conditions Ambient temperature 5 C 55 C Avoid freezing Ambient humidity 90 RH or lower Avoid moisture Atmosphere Indoors Avoid direct sunlight No corrosive gases or flammable gases No oil mist dust water salt iron powder Avoid direct vibration o...

Page 8: ...p of equipment Failure to observe this instruction may cause injury and malfunction Do not subject the equipment to excessive shock or impact Failure to observe this instruction may cause malfunction Provide proper and firm wiring Failure to observe this instruction may cause injury fault and malfunction Operate the equipment with the specified power supply voltage Failure to observe this instruct...

Page 9: ...unction or fault Never conduct extreme adjustments or setting change that may cause instability of operation Failure to observe this instruction may cause an injury malfunction or fault Do not turn ON and OFF the equipment repeatedly Failure to observe this instruction may cause a malfunction Do not use the equipment at a torque higher than the maximum torque Failure to observe this instruction ma...

Page 10: ... 4 3 1 4 Bottom Panel DIP Switch 2 Settings 3 5 3 2 Tools 3 6 3 2 1 Angle Tool 3 6 3 2 2 Pistol Tool 3 7 Chapter 4 Installation Wiring 4 1 Installation Procedure 4 2 4 2 Controller Installation Dimensions 4 3 4 3 Input Power Source Connection 4 5 4 4 Tool Cable Specifications 4 6 4 5 External Control Signal Connection 4 7 4 5 1 Controller I O Signals BANK SELECT OFF 4 8 4 5 2 Controller I O Signal...

Page 11: ...16 6 3 1 Changing Modes in the PROGRAM Mode 6 16 6 3 2 Parameter Selection Mode 6 17 6 3 3 Parameter Editing Mode 6 19 6 4 Parameter Copy Erasing the Fastening Result History Formatting of the CF Card 6 21 6 5 Fastening Reject NG Result Indications 6 23 6 5 1 Example of Fastening Reject item Display 6 24 6 5 2 Reject Judgment Limits 6 26 6 5 3 Fastening Speed and Time 6 34 6 5 4 Auxiliary Attachme...

Page 12: ...pacity of CF Memory Card 8 7 8 1 7 Formatting the CF Memory Card 8 8 8 2 Expansion RS232C Interface 8 9 8 3 ID Data Input Setting 8 10 Chapter 9 Fieldbus I O Interfaces 9 1 Common Fieldbus Specifications 9 2 9 1 1 Fieldbus I O Signals 9 2 9 1 2 Fieldbus Message Output Format 9 6 9 1 3 Fieldbus Interface Setup HFC3000 Software 9 8 9 2 EtherNet IP 9 9 9 3 CC Link 9 12 9 4 PROFIBUS DP V1 9 35 9 5 Dev...

Page 13: ... English updated Majority June 2019 HFC3000E HW 2 Added note concerning powering on with P OFF remaining in display 5 3 6 7 Manual Numbering Convention HFC3000E HW 1 HW Hardware Operation Manual SW Software Manual DSP1500 Servo Press AFC3000 Nutrunner FUSION DC Hand Tool HFC3000 DC Hand Tool E English Version S Spanish Version Japanese Version furnished by DDK uses DDK numbering convention Version...

Page 14: ...Notes ...

Page 15: ...Chapter 1 Outline PAGE 1 1 Chapter 1 Outline 1 ...

Page 16: ...stem components Chapter 4 Installation Wiring Installation procedure dimensions input and output signal descriptions and requirements for PLC programming Chapter 5 Power up and Operational Tests Items to be checked before power up and procedures for operational tests Chapter 6 Fastening Operation Descriptions of items displayed on the front panel and instructions for setting the fastening paramete...

Page 17: ...to a PLC or other external device are also provided Optional fieldbus interfaces that allow fastening data to be sent of over the same fieldbus connection to the PLC can be installed ie Ethernet I P Devicenet Profinet CCLINK etc Motor A permanent magnet High Speed DC motor provides for improved fastening control The sealed design of the motor provides greater protection from contamination without ...

Page 18: ...ing Tab Preferences Auto Upload Stored Data Storage Content Stored Data Curve Data Stored Data Abnormals Storage Location PC Each controller Storable Records 12000 results 500 results Setting Item Yes No JUDGMENT ACCEPT REJECT ABNORMAL BYPASS STOP RESET STOP START OFF 1 Automatic Save must be enabled during data collection in the Fastening Data screen of the AFC3000 User Console Function Name Stor...

Page 19: ...D Perform Class 3 grounding Make sure the controllers power cable ground pin is connected to a proper ground or DANGER OF ELECTRICAL SHOCK EXISTS Supply primary power with a cable no SMALLER than 1 25mm2 17AWG or the source voltage may drop below 80VAC and a Suply Voltage Abnormal may occur Installation Environment Controller units must be located a minimum of 600 mm from high transient voltage so...

Page 20: ...erate strong electrical noise in the surroundings Make sure that the cables that connect the controller and the tool are not placed inside a duct etc together with a power source line or other wiring Handling and Shipping It is critical that FUSION System components are properly handled and shipped in order to maintain the System s integrity Adhere to the following requirements for shipping and ha...

Page 21: ...Chapter 2 Specifications PAGE 2 1 Chapter 2 Specifications 2 ...

Page 22: ...0 RH Avoid condensation Shipping Conditions Ambient temperature 5 C 55 C Avoid freezing Ambient humidity No more than 50 RH Avoid condensation Packing method Tight seal in static free environment Environment Indoors no direct sunlight free from corrosive gas flammable gas oil mist dust and dirt 2 1 1 Duty Cycle Calculation The duty cycle for HFC series is calculated as follows Duty Cycle Rotating ...

Page 23: ...inimum 0 1 degree Angle internal control 0 1 degree Torque Transducer accuracy 1 of full scale Torque Transducer linearity 0 5 of full scale Fastening method Torque Method Angle Method Torque rate setting Three zones 2 2 2 Controller CPU 32 bit RISC Data communication ETHERNET 1 port RS232C 1 port Optional addition of 1 port Fieldbus 1 port Option Ethernet I P Devicenet Profibus DP V1 CC Link etc ...

Page 24: ... S 15 00 1895 1 99 999 HFC B016 HFC B024A 5 HFT 025M80 A 35 00 1218 1 99 999 HFC B016 HFC B024A 12 HFT 040M80 A 40 00 735 1 99 999 HFC B016 HFC B024A 13 HFT 015M50 A1 15 00 1215 1 99 999 HFC B016 HFC B024A 15 HFT 025M80 A1 25 00 1070 1 99 999 HFC B016 HFC B024A 16 HFT 040M80 A1 40 00 648 1 99 999 HFC B016 HFC B024A 7 HFT 060M80 A 60 0 446 1 99 999 HFC B016 HFC B024A 19 HFT 080M80 A 80 0 330 1 999 ...

Page 25: ...80 P1 60 0 461 1 99 999 HFC B016 HFC B024A 33 HFT 030M80 D 30 00 980 1 99 999 HFC B016 HFC B024A 34 HFT 200M80 A 200 0 117 1 999 99 HFC B016 HFC B024A The decimal point for the torque is the decimal point of the Maximum Torque Tool No Tool Model Maximum Torque N m Maximum Rotation Speed rpm Minimum Rotation Speed rpm Maximum Rate N m deg Controller 35 HFT 080M120 A 80 0 557 1 999 99 HFC B024A 36 H...

Page 26: ... When a PLC Bypass input signal is activated the Bypass output signal is activated In this condition the spindle will not START REVERSE CAL OR RESET If a BYPASS condition occurs during the fastening operation the fastening operation will stop 4 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 ...

Page 27: ...is held during fastening Use in combination with a torque reaction device is recommended The number of fastenings steps is selectable among 1 2 and 3 steps 3 Differential Angle Check Method Torque Standard Angle Rate 2 End Torque Rate 2 Start Torque 1st Torque Snug Torque Differential Angle fastening result Angle Differential Low Limit Angle Differential High Limit Angle Seating point calculated f...

Page 28: ...Chapter 2 Specifications PAGE 2 8 Blank Page ...

Page 29: ...Chapter 3 Sysytem Description PAGE 3 1 Chapter 3 System Description 3 ...

Page 30: ...ts ANGLE Lit when in the fastening Angle result display mode TORQUE Lit when in the fastening Torque result display mode 6 dight 7 segment LED Displays a set value fastening result or other data 3 dight 7 segment LED Displays the WORK No parameter 3 digit 7 segment LED COUNT D No Displays the cycle count and parameter Data No TOTAL OK Lights when acceptable OK fastening results are obtained for th...

Page 31: ...tor for input output signal connection Refer to separate section for signal details and precautions Sec 4 5 Ground Fault Breaker When a ground leakage occurs in the controller cable or tool this breaker trips instantaneously to secure safety from the ground fault I ON O OFF TOOL Connector for tool cable connection Twist lock type connector Can be connected and disconnected by twisting 90 degrees F...

Page 32: ... remain ON for the entire cycle the cycle will stop if the START is removed before the end of cycle Requires continuous input OFF Auto type Start Start Input pulse of at least 200msec intiates automatic cycle The fastening operation will continue even if the START signal is OFF after the cycle starts 3 OFF Disabled Used for in house adjustment 4 OFF Parameter FlashRom storage disable disable enabl...

Page 33: ...n OFF Software PLC Function Disabled Standard I O Assignment is used ON Software PLC Function Enabled I O Mapping for software PLC used Refer to Software PLC Manual LD Editor This function available in Firmware Ver 1 305 or later 5 OFF Disabled Used for in house adjustment 6 OFF PLC I O STOP TEST Mode STOP signal Disable When this is set to ON the STOP signal is not required to operate the system ...

Page 34: ...switch is released When loosening a fastener that has already been fastened over 5N m the default REVERSE HIGH TORQUE LIMIT setting will stop the reverse operation as a safety precaution This can be changed in the setting of the fastening REVERSE HIGH TORQUE LIMIT parameter If changed be careful of torque reaction caused by higher torque Judgment Status LED indicators 4 LEDs When the fastening res...

Page 35: ...itch is released When loosening a fastener that has already been fastened over 5N m the default REVERSE HIGH TORQUE LIMIT setting will stop the reverse operation as a safety precaution This can be changed in the setting of the fastening REVERSE HIGH TORQUE LIMIT parameter If changed be careful of torque reaction caused by higher torque Judgment Status LED indicators 4 LEDs When the fastening resul...

Page 36: ...Chapter 3 System Description PAGE 3 8 Memo ...

Page 37: ...Chapter 4 Installation and Wiring PAGE 4 1 Chapter 4 Installation Wiring 4 ...

Page 38: ...r connection 4 3 PAGE 4 3 Connection of tool cable Connection between the controller rear panel CN1 and tool 4 4 PAGE 4 4 Connection of external control signal PLC Input output signal Connection and control signals 4 5 PAGE 4 5 Power up Power up after checking the wiring and checking the power source voltage 5 1 PAGE 5 1 Set Parameter values Torque value angle value speed timer etc settings Chapte...

Page 39: ...uivalent to the installation plate thickness 9mm Weight 8 5 kg 18 7lb Mounting Precautions Do not install the unit at a location that is exposed to vibration Install the controller at a location where the temperature humidity and other operating environmental conditions are satisfied Do not use a mounting screw longer than the above mentioned size ...

Page 40: ...llation and Wiring PAGE 4 4 Mounting Spacing For safe removal of the Controller install with spacing of 10mm or more side to side Caution 100mm or more 10mm or more 10mm or more 250mm or more Upper Lower 250mm or more ...

Page 41: ... Connect the dedicated power cable to the connector at a lower portion of the rear panel of the controller A power cable is provided as standard Cable supplied for 100 120VAC power Standard U S plug Style only Cable over 120VAC to be supplied by customer Primary power connector ...

Page 42: ...fications Tool Cable Cable type FEB 1309 M For old model tools only 01A 02A suffix Tool Cable Cable type C15 F7 M For new model tools only 10x 20x suffix Tool Side Controller side Tool Side Controller Side AWG16 4 AWG24 24 22 shell 19 Total length L Total length L ...

Page 43: ...Model SL 4000CP 12PGY Manufacturer SATO PARTS Rated applicable wire Solid wire 0 8mm φ AWG 20 stranded wire 0 5mm2 AWG 20 Range of useable wires Solid wire 0 4mm φ 1 2mm φ AWG 26 AWG 16 Stranded wire 0 2mm2 to 1 25mm2 AWG 24 AWG 16 Wire outer diameter 0 18mm φ or more Standard wire stripping length 9mm 0 35 Note One wire is connected to one terminal Do not connect two or more wires to one terminal...

Page 44: ...B1 12 BANK SELECT IN 12 NO Bank select input signal changes output signal definition TB3 4 OUT COMMON OUT Common output signal bipolar TB3 5 BATCH OK RESET IN 13 NO Cycle counter ACCEPT count reset signal TB3 6 IN 14 NO Not USED TB3 7 Bank Select Output OUT 6 NO Output definition depends on status of Bank Select Input TB1 12 See next page for output definition TB3 8 Bank Select Output OUT 7 NO TB3...

Page 45: ...ing fastening operation or when not using bank select function If using the BANK SELECT Input signal wait for 20 msec or more after turning the signal ON before checking the output signal status Pin No Signal IN OUT Description of Function Usage TB2 1 REJECT NG OUT 1 NO Output when the fastening operation ends with a fastening result falling outside a judgment range TB2 2 ACCEPT OK OUT 2 NO Output...

Page 46: ...PN type connection example The HFC Unit may be wired for Sourcing PNP I O by swapping the polarity of the 24VDC power connections of the INPUT OUTPUT COMMONS I O Points are Bi directional Controller I O circuit Input circuit Output circuit PLC output circuit DC power source PLC input circuit Input signal Input signal Caution Output signal Output signal ...

Page 47: ...to the tightening direction ex If the tightening direction is set to clockwise the spindle will turn in the counter clockwise direction during Reverse operation and visa versa The spindle unit will be in BUSY status while in Reverse operation START FASTENING START SIGNAL PIN No TB1 4 The controller checks the WORK SELECT signal and SELF CHECK signal at the rising edge OFF ON of this signal and the...

Page 48: ... SELECT 2 PIN No TB1 9 WORK SELECT 1 PIN No TB1 8 WORK SELECT 0 PIN No TB1 7 WORK No OFF OPEN OFF OPEN OFF OPEN OFF OPEN OFF OPEN OFF OPEN 1 OFF OPEN OFF OPEN OFF OPEN OFF OPEN OFF OPEN ON 2 OFF OPEN OFF OPEN OFF OPEN OFF OPEN ON OFF OPEN 3 OFF OPEN OFF OPEN OFF OPEN OFF OPEN ON ON 4 OFF OPEN OFF OPEN OFF OPEN ON OFF OPEN OFF OPEN 5 OFF OPEN OFF OPEN OFF OPEN ON OFF OPEN ON 6 OFF OPEN OFF OPEN OFF...

Page 49: ...N 50 ON ON OFF OPEN OFF OPEN ON OFF OPEN 51 ON ON OFF OPEN OFF OPEN ON ON 52 ON ON OFF OPEN ON OFF OPEN OFF OPEN 53 ON ON OFF OPEN ON OFF OPEN ON 54 ON ON OFF OPEN ON ON OFF OPEN 55 ON ON OFF OPEN ON ON ON 56 ON ON ON OFF OPEN OFF OPEN OFF OPEN 57 ON ON ON OFF OPEN OFF OPEN ON 58 ON ON ON OFF OPEN ON OFF OPEN 59 ON ON ON OFF OPEN ON ON 60 ON ON ON ON OFF OPEN OFF OPEN 61 ON ON ON ON OFF OPEN ON 62...

Page 50: ...N No TB2 10 Duplicates the controller BUZZER Performs output of the REJECT and Batch OK signals to external devices according to the timing below Turns ON for 0 4 seconds by the BATCH OK signal rising edge Turns ON for 0 1 seconds by the QL OK signal rising edge Note if using for a REJECT signal signal must be ON for more than 0 4sec to signify REJECT RELAY CONTACT 3 SIGNAL PIN No TB2 9 OUT 10 REL...

Page 51: ...ntil the problem is corrected and a RESET signal is input READY SIGNAL PIN No TB2 4 OUT 4 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 power is turned on for approx 5 sec STOP condition While fastening is in process when BUSY While Reset sig...

Page 52: ... OFF OPEN OFF OPEN OFF OPEN OFF OPEN ON ON 4 OFF OPEN OFF OPEN OFF OPEN ON OFF OPEN OFF OPEN 5 OFF OPEN OFF OPEN OFF OPEN ON OFF OPEN ON 6 OFF OPEN OFF OPEN OFF OPEN ON ON OFF OPEN 7 OFF OPEN OFF OPEN OFF OPEN ON ON ON 8 OFF OPEN OFF OPEN ON OFF OPEN OFF OPEN OFF OPEN 9 OFF OPEN OFF OPEN ON OFF OPEN OFF OPEN ON 10 OFF OPEN OFF OPEN ON OFF OPEN ON OFF OPEN 11 OFF OPEN OFF OPEN ON OFF OPEN ON ON 12 ...

Page 53: ...F OPEN OFF OPEN OFF OPEN 41 ON OFF OPEN ON OFF OPEN OFF OPEN ON 42 ON OFF OPEN ON OFF OPEN ON OFF OPEN 43 ON OFF OPEN ON OFF OPEN ON ON 44 ON OFF OPEN ON ON OFF OPEN OFF OPEN 45 ON OFF OPEN ON ON OFF OPEN ON 46 ON OFF OPEN ON ON ON OFF OPEN 47 ON OFF OPEN ON ON ON ON 48 ON ON OFF OPEN OFF OPEN OFF OPEN OFF OPEN 49 ON ON OFF OPEN OFF OPEN OFF OPEN ON 50 ON ON OFF OPEN OFF OPEN ON OFF OPEN 51 ON ON ...

Page 54: ...ontinually input another cycle cannot be performed until the START signal transitions to OFF one time 3 An input time of 100msec or more is required for the RESET signal or the STOP signal If the signal is continually input another cycle cannot be performed 4 When the Data Save operation completes the RS232C data communication output is performed only once for approximately 90 msec Before firmware...

Page 55: ...Chapter 4 Installation and Wiring PAGE 4 19 Basic control signals Controller software version V 1 303 or earlier MANREV Output signal timing chart BANK Output Reverse Reverse Fastening Fastening ...

Page 56: ...UE OUT Torque Analog Voltage Signal Monitoring voltage is indicated from zero 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 In addition the zero voltage of each tool may vary even for the same type of tool...

Page 57: ... 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 Output Circuit Torque Current Speed Voltage Output Angle Pulse Normal Reverse Output Current Speed Voltage ...

Page 58: ...00bps fixed Communication Mode Half duplex system Start Bit 1 bit fixed Data Bit 8 bits fixed Stop Bit 1 bit fixed Flow control None Parity None fixed Pin No Signal IN OUT Details 1 NC Not used 2 RXD IN Not used 3 TXD OUT Operation result data output 4 DTR OUT Always ON output 5 GND Signal ground 6 NC Not used 7 RTS OUT Always ON output 8 NC Not used 9 NC Not used Clear the PLC receiving buffer wh...

Page 59: ... 18 19 20 21 22 23 24 25 26 27 28 PEAK TORQUE JDG OCR FINAL ANGLE JDG OCR 31H 32H 2EH 33H 34H 20H 20H 20H 20H 31H 32H 33H 20H 20H 1 2 3 4 1 2 3 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 FINAL TORQUE JDG OCR RATE1 JDG OCR 31H 32H 2EH 33H 34H 20H 20H 20H 30H 2EH 31H 32H 33H 20H 20H 20H 1 2 3 4 0 1 2 3 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 RATE2 JDG OCR RATE3 JDG OCR 30H 2EH 31H 32H 3...

Page 60: ...32H 33H 20H 20H 20H 31H 2EH 31H 32H 33H 48H 58H 20H 0 1 2 3 1 1 2 3 H X 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 1ST TIME JDG OCR 2ND TIME JDG OCR 20H 31H 30H 2EH 30H 20H 20H 20H 20H 20H 32H 2EH 30H 20H 20H 20H 1 0 0 2 0 77 78 79 JDG CR LF 58H 0DH 0AH X 1st CAUSE OF REJECT OCR X 58H This is set for the initial cause of the REJECT condition during this cycle JDG Judgment OCR Occurrence PEAK ...

Page 61: ...tings can be changed once connected IP address 192 168 11 10 factory setting Subnet Mask 255 255 255 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 ...

Page 62: ...AR No indication SYS of the Front Panel Display The IP Address set in the controller can also be changed using the front panel 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 W...

Page 63: ...hapter 4 Installation and Wiring PAGE 4 27 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 64: ...se is on the same network then make 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 R...

Page 65: ...0 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 settings...

Page 66: ...ening 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 controller when Procedure 3 is executed A communication error has occurred Please confirm the co...

Page 67: ...Chapter 5 Power Up and Operational Tests PAGE 5 1 Chapter 5 Power Up and Operational Tests 5 ...

Page 68: ...ble for power source Confirm that the GROUND is connected at the power source of the power cable 4 Check the power source voltage Check that the input power source voltage of the controller is in a range of single phase 100V AC 240V AC The recommended wiring size for the primary power is no less than 1 25mm2 AWG16 If a voltage drop occurs due to undersize wiring etc a Source Voltage Abnormal error...

Page 69: ...ing the HFC3000 software and then re power the controller turn off turn off Follow the below safety precautions when powering on the controller Caution Powering the controller ON OFF After turning OFF the power do not turn 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 mul...

Page 70: ...d the red NG Reject LED is not on 2 CAL Point Check Press the CAL button on the front panel display and check that the red NG Reject LED is not on Before performing the following tests make sure nothing is in the area of the nutrunner tool prior to activating a spindle or other moveable component 3 Manual REVERSE Check Rotate the tool REVERSE ring switch so that the LED status lights flash yellow ...

Page 71: ...Chapter 6 Fastening Operation PAGE 6 1 Chapter 6 Fastening Operation 6 ...

Page 72: ... fastening operation and the fastening result judgment are indicated Parameters can be changed in the PROGRAM setting mode Changing between the RUN and PROGRAM modes can be performed using the PLC I O BYPASS signal or the PRG key button pressing the PRG button holding for more than 1 5 seconds Switches for Data Indication Operations Indication LEDs Operation Check Switches Program Button circled ...

Page 73: ...nds changes the operation mode from Run to Program or from Program to Run alternately 2 Indication LEDs OK LED Green QL OK Lights when the fastening ends with all results within the various programmed setting limits When the TOTAL OK LED lights up this LED is OFF NG LED Red NG Lights when the fastening ends with a result falling outside any of the various programmed setting limits Additionally lig...

Page 74: ... fastener that has already been fastened over 5N m the default REVERSE HIGH TORQUE LIMIT setting will stop the reverse operation as a safety precaution This can be changed in the setting of the fastening REVERSE HIGH TORQUE LIMIT parameter If changed be careful of torque reaction caused by higher torque LED for judgment and status indications 4 LEDs During the fastening process all judgment LEDs a...

Page 75: ...if sequence operation is disabled the parameter No is indicated When an Abnormal occurs the abnormal code No is indicated COUNT D No Display In the real time mode fastening result mode and parameter system setting mode the Data No of the preset data is indicated Also in the run mode the current speed state is indicated while fastening and the current cycle count value C is indicated when the faste...

Page 76: ...he PAR No display indicating the Sequence number or Parameter number being run The fastening Status display is displayed during the time between the beginning and end of the fastening operation In addition it s displayed when an abnormal condition occurs when the STOP signal is turned OFF the BYPASS signal is turned ON etc The selected WORK No is changed with the or buttons this function is disabl...

Page 77: ...e RESET signal is input when any of the D Nos 3 7 is displayed the torque will not be indicated the check being performed will be displayed instead When the CAL button is depressed or the RESET signal is input when in the Real Time display mode CAL or RES will not be indicated in the D NO display P oFF is displayed in the upper display when the drive power supply in the controller is not yet turne...

Page 78: ...erload factor The current monitor load factor is displayed If the load factor goes over 100 an overload A08 10 abnormal occurs 5 Current value The current value in amps is displayed A 6 I O monitor 12 bits of the standard Inputs Outputs are monitored and indicated as shown in the diagram below When DIP SW2 SW No 6 on the bottom of the controller is ON the display will be as shown in the diagram be...

Page 79: ...Buzzer related command 18 Tool Command Gan Gyro Restriction Angle 0 255 Deg 19 Fieldbus Status Monitor FbS Fieldbus connection condition In the normal state 4 is indicated Any other number indicates a disconnected state STOP mode is activated and operation is disabled 20 Angle Head Torque Variation Displays the current torque variation rate of the angle head after the fastening operation When the ...

Page 80: ... displayed WORK COUNT D NO DATA Peak Torque Final Angle Rate 1 ACCEPT count Please refer to the List of Contents Displayed in the Real Time Mode on the next page regarding the respective data contents indicated in the DATA Display when COUNT D No is changed Rate 1 Low 1st NG Item 300 Rate 1 Rate 1 2 3 Judgment Rate 1 low Number of Fastening Steps Fastening Method Torque Method Reverse Flag The dis...

Page 81: ...d 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 SL ON servo lock performed OFF servo lock not performed Nm 017 1st Peak Torque tq Nm 018 2nd Peak Torque tq Nm 019 SNUG Torque Judgment tq H 020 Final Torque Offset Torque tq H L Nm 021 Rate 1 Incremental Torque Nm 022 Rate 1 Increme...

Page 82: ... 1s digits The D No Display can be changed by pressing pushbuttons and the content of that data No is displayed 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 Please refer to the Parameter List regarding parameter setting value details WORK COUNT D No DATA Fastening Method Fastening Steps Fastening Option Unuse...

Page 83: ...y area 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 to Parameter List regarding the details about parameters WORK COUNT D No DATA Torque Unit Software Version Amplifier Version Touch Panel Number of Retries 0 0 1 0 0 0 0 0 2 5 0 4 S Y S or button skip 10 at a time while holding down ...

Page 84: ...lay Ordinary View When the state of the system is changed due to an Abnormal occurrence or the STOP signal set to OFF etc transition to the status display is performed automatically and the contents indicated in the respective display When an error occurs ABNORMAL signal ON When the BYPASS signal is turned ON When the RESET button is turned ON When the STOP signal is turned OFF When the CAL button...

Page 85: ...ation examples during a fastening operation of parameter No 1 During initial speed During freerun speed During 1st speed During 2nd speed During 3rd speed The display content of the upper section of the indicator is maintained during reverse operation During reverse 1 speed During reverse 2 speed During reverse 3 speed WORK Work No 01 Work No 02 Work No 03 Work No 64 The operation cannot be perfor...

Page 86: ... of the controller is indicated in this mode Display in this mode is performed immediately after changing from the RUN mode to the PROGRAM mode by pushing the PRG Key Changing to the set value selection mode is performed by the and buttons In the Parameter Program Mode and the System Setting Mode the mode is changed directly to the set value selection mode Parameter Selection Mode A parameter can ...

Page 87: ...the push button is pressed When the push button is pressed the 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 Editing Mode SET SET SET ...

Page 88: ...e WORK Display is decreased by 1 The current cursor blinking position can be moved by pressing the or button and by holding down the or button the value in the WORK Display can skip by 5 at a time or the value in the WORK Display can be skipped by 10 at a time Please refer to the List of Parameters regarding the detail of the setting values WORK COUNT D No DATA Torque controller Software Version A...

Page 89: ...the RESET button is pressed in the Parameter Editing Mode the display is changed back to the parameter selection mode without changing the set value When the changed set value is outside the allowable setting range of that particular parameter the following error is indicated and the data will revert back to the data before attempting to edit it The changed parameter becomes effective when the PRO...

Page 90: ...UN or 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 ...

Page 91: ... and then press the SET pushbutton again within 2 seconds 6 Copying one parameter to another parameter is complete 7 Press and hold the PROG button of the Controller until the 022 stops blink Batch Copying Ex Copy parameter 1 to parameter 2 32 1 Operate the arrow pushbuttons to make Copy with SYS indicated in the PAR No display and 022 indicated in the D No display 2 Press and hold the PROG button...

Page 92: ...ng erased ErASE in the DATA Display flashes for a few seconds and the flashing stops when the erasure is completed CF Card Formatting Operation 1 Operate the arrow pushbuttons to display Erase with SYS indicated in the PAR No display and 021 indicated in the D No display 2 Press and hold the PROG button of the Controller until the 021 blinks 3 Press the or button to select CF and then press SET 4 ...

Page 93: ...ternating indication ends Example of fastening display in the case of an OK judgment The fastening peak torque value is indicated Example of Peak Torque High Limit reject judgment Fastening result indication The indication alternates every 1 second Fastening reject item display The judgment H is displayed first followed by the reject item NG content symbol Judgment result Fastening result display ...

Page 94: ...t Judgment Rate1 Low limit Reject Cause Thread problem large rotation with little torque rise thread fastener yielding Rate1 High limit Reject Cause Thread Problem very little rotation with a large torque rise Crossthread trying to fasten on a bolt already torqued fastener being torqued into blind hole fastener hits bottom Rate2 Low limit Reject Cause Fastener or thread is yielding stretching Rate...

Page 95: ...imit Reject Cause Fastener is yielding fastener is cutting threads socket disengaged 5 Rundown Revolutions High Limit Judgment Rundown Revolutions High Limit Reject Cause Bolt length wrong socket disengaged 6 Others Start trigger Off Reject Cause Start Trigger was released before the end of fastening Gyro Stop Reject Cause Gyro sensor swing detection detected a safety Stop ...

Page 96: ...value that is no more than the high limit standard value Low limit standard value REJECT A value less than the low limit standard value Low limit standard value ACCEPT A value that is no less than the low limit standard value REJECT Low Limit Standard Value ACCEPT High Limit Standard Value REJECT Caution The fastening judgment is not performed regardless of the high and low limit set values when t...

Page 97: ...used for fastening in cases where the starting torque is higher than your targeting torque The fastening operation is ended when during operation within D No 205 Torque Inhibit Angle the start torque inhibit high limit value is exceeded Additionally from the start of fastening to the point at which D No 205 Torque Inhibit Angle is attained torque related set values besides the starting torque inhi...

Page 98: ...o the time low limit if the fastening operation reaches its target in a time less than the time set in the low limit a low limit reject will occur If the 1st and 2nd time high limit is exceeded during the fastening operation the operation is stopped and a High Limit reject will occur When 2 or 3 steps is selected as the number of fastening steps the delay times between fastening steps are not coun...

Page 99: ...ngle of the respective rates can be set freely without any relation to the order of the rates and the set values of the other rates To Customers Using the older FUSION Handheld Nutrunner Systems There are parameter D Nos that are changed in name and function Please reference the corresponding table on the following page for correct parameter setup 117 Rate 3 End Torque 116 Rate 3 Start Torque 115 ...

Page 100: ... the end point of measurement of torque rate 1 1E 2nd Rate Start Torque 114 Rate 2 Start Torque The torque value sets the start point of measurement of torque rate 2 18 CROS Torque 2nd Rate End Torque 3rd Rate End Torque 115 Rate 2 End Torque The torque value sets the end point of measurement of torque rate 2 116 Rate 3 Start Torque The torque value sets the start point of measurement of torque ra...

Page 101: ...e of the fastening curve data and the value of the differential angle of the fastening result contain a measurement error of a maximum of 5deg 2 5deg If rate 2 start torque cannot be detected during the fastening operation the differential angle check will not be performed Under the following conditions the torque at the end of fastening is judged as the rate 2 end torque If the set values are set...

Page 102: ...een 2 3 Steps PLC I O input signal REVERSE Reversing switch operation less than V1 002 Disable 0 Without limit Enable 1 D No 110 Reverse Torque High Limit Without limit V1 002 V1 204 Disable 0 Without limit D No 110 Reverse Torque High Limit Enable 1 D No 110 Reverse Torque High Limit V1 205 or later Disable 0 1 3 times D No 100 Calibration torque D No 110 Reverse Torque High Limit Enable 1 D No 1...

Page 103: ...ased on the motor used and is set automatically for the controller smodel used Do not change this value if there is no special reason to do so The max current value differs depending on the motor type of the tool used M50 10 A M 80 16 A M 120 21 A Additionally the Fastening Current Limit value D No 523 limits the maximum value of the current during the fastening operation If a value lower than the...

Page 104: ... should be set to mitigate shock occurred at the fastening start time or to engage a bolt and a socket b Upon completion of INITIAL TIME the system switches to FREERUN SPEED for the period specified by FREERUN REVOLUTIONS The number of revolutions required to complete INITIAL TIME will be deducted from the number of revolutions ran at FREERUN SPEED c Once RAMP DOWN START TORQUE is detected or FREE...

Page 105: ...g the system will fasten to Standard Torque Angle using 3rd Torque Speed during the specified 2nd Time Limits Standard Torque Angle must be reached within the 2nd Time Low High Limits or a reject will occur The fastening result will output as REJECT NG The time judgment cannot be disabled If D No 109 2nd Torque is set to 95 100 of D No 103 Standard Torque the fastening speed is automatically set t...

Page 106: ... head special programming options MUST be set up to enable the Tubenut socket automatic return function along with various other considerations Tubenut head applications inherently present safety concerns especially in the area of the open U shaped socket The opening of the U shaped socket presents a PINCH POINT while rotating WARNING KEEP ALL BODY PARTS AWAY FROM THE TUBENUT HEAD SOCKET OPENING D...

Page 107: ...ity 4 Torque Inhibit Limit PAR 01 thru 64 D No 111 When using the Tubenut function the Torque Inhibit Limit parameter sets the MAX amount of torque that can be sensed during the Torque Inhibit Revolution setting This is used to set the max torque to be sensed during the start of rotation of the socket or until the socket U opening moves to a closed position This will protect from damage anything b...

Page 108: ...trigger Hold the start trigger until the socket is re aligned and the tool shuts off tool automatically shuts off NOTE If the socket is turning in the wrong direction to re align the head Re alignment must turn CCW for proper operation the Gear Head Selection is wrong SYS D No 036 Return to Home Position after Fastening After fastening a part the tubenut socket must be re aligned in order to remov...

Page 109: ...P 62 Parameter No P 03 Parameter No P 02 Parameter No P 01 000 Fastening Method 001 Fastening Steps 002 Fastening Option 003 Judge Item 1 004 Judge Item 2 599 Unused Parameter No SYS System Parameters 000 Torque Unit 001 Software Version 002 Amplifier Version 003 System Indication 504 Touch Panel Number of Retries ...

Page 110: ...ask lower 6 digits 255 0 015 Default Gateway upper 6 digits 192 168 016 Default Gateway lower 6 digits 11 1 017 MAC Address upper 6 digits 001F98 018 MAC Address lower 6 digits 001000 019 RTC Year Month Day 130725 July 25 2013 020 RTC Time 123456 12 34 56 021 Erase Fastening Record Format CF Card 022 Parameter Copy 023 For Adjustment by the Manufacturer 024 For Adjustment by the Manufacturer 025 F...

Page 111: ...e Version 203 Sequence Setting File Version 204 PLC Output Layout Setting File Version 205 Fieldbus Setting File Version 206 Fieldbus Message Setting File Version 207 RS232C Input Output Setting File Version 208 controller RS232C 1 Communication Speed bps 209 controller RS232C 1 Parity 210 controller RS232C 1 Stop Bit bit 211 controller RS232C 1 Word Length bit Option Information1 300 Connected Fi...

Page 112: ...04 RS232C 2 Word Length bit 405 Not used 406 Not used 407 Not used 408 Not used 409 ID Input Selection 410 Add STX ETX 411 External Input Select 412 Reference Data Start 413 Reference Data End Touch Panel 500 Touch Panel Connection IP Address upper 6 digits 501 Touch Panel Connection IP Address lower 6 digits 502 Touch Panel Language Select 503 Touch Panel Connection Port Number 504 Touch Panel Nu...

Page 113: ...rates only in the single system setting D No 004 External Gear Ratio Setting range 0 300 3 000 standard setting 1 000 Used to 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 005 006 For adjustment by the manufacturer ...

Page 114: ...oG no longer displayed in upper display before powering down or the change will not be stored to memory D No 017 MAC Address upper 6 digits D No 018 MAC Address lower 6 digits Cannot be changed The MAC address is indicated D No 019 RTC Year Month Day Setting range 13 99 year 1 12 month 1 31 day D No 020 RTC Time Setting range 0 23 hours 0 59 minutes 0 59 seconds The date and time of the real time ...

Page 115: ... are indicated in the two upper right LED segments 00H means 00 hex The ON OFF states of SW No 1 No 8 are indicated in 8 bit hexadecimal code in the part in which 00H is indicated in the drawing above SW setting examples Indication examples All OFF 00H Only No 1 ON 01H Only No 2 ON 02H Only No 3 ON 04H Only No 4 ON 08H Only No 5 ON 10H Only No 6 ON 20H Only No 7 ON 40H Only No 8 ON 80H All ON FFH ...

Page 116: ...le Set to 1 to perform the Zero CAL check at the fastening start only in the first cycle If the first cycle gets a judgement other than an ACCEPT the check will be performed on the next fastening cycle as well 1xxxxx Part ID input selection 0 Fieldbus 1 RS232C 3 For selecting whether the part ID data will be input from a fieldbus message or by the RS232C 3 port the part ID input is used for marryi...

Page 117: ...ignal START REVERSE OFF ON xx1xxx CW CCW Change Select 0 Ignore Tool CW CCW switch 1 Use Tool CW CCW Switch When using a PLC START input signal selects to ignore the tools CW CCW switch or use the CW CCW switch for direction control 0 Ignores the tool CW CCW switch position and starts the fastening directed by the programmed parameter direction 1 Starts the fastening in the direction the tool CW C...

Page 118: ...age V The ZERO voltage of the tool is displayed D No 106 Tool Internal Gear Ratio 100 The value obtained by multiplying the gear ratio of the tool by 100 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 displayed D No 109 Tool Rotation Direction The rotation direction of the tool is indicated CW 0 CCW 1 D No 110 Tool Order No upper 2 digits...

Page 119: ...in the controller is displayed D No 204 PLC Output Layout File Version The version of the PLC output layout file programmed in the controller is displayed D No 205 Fieldbus File Version The version of the fieldbus file programmed in the controller is displayed D No 206 Fieldbus Message File Version The version of the fieldbus message file programmed in the controller is displayed D No 207 RS232C I...

Page 120: ...s Only The ANYBUS CompactCom interface version of the Expansion unit 1 is indicated D No 302 Fieldbus Setup Information Any fieldbus internal setup in the controller is indicated See next page for use table No Fieldbus setting No Expansion Unit 1 installed Standard IO MFC CC Installed CC Link MFC DN Installed DeviceNet MFC PB Installed PROFIBUS DP V1 MFC PN Installed PROFINET IO MFC EN Installed E...

Page 121: ...n speed of the installed fieldbus is displayed Fieldbus Type System Parameter D No 304 0 1 2 3 4 CC Link 156kbps 625kbps 2 5Mbps 5Mbps 10Mbps DeviceNet 125kbps 250kbps 500kbps D No 305 Occupied Stations Setting range 1 4 CC Link only The CCLINK programmed number of occupied stations is displayed D No 306 Extended Cyclic Setting Setting range 1 2 4 8 CC Link Only The CCLINK programmed extended cycl...

Page 122: ...e Setting Byte Length HFC3000 PLC byte Fieldbus only The programmed message setting byte length for HFC3000 PLC of the installed fieldbus is indicated D No 312 IP Address upper 6 digits D No 313 IP Address lower 6 digits Setting range 0 255 PROFINET IO EtherNet IP The programmed IP address of the installed fieldbus is indicated D No 314 Subnet Mask upper 6 digits D No 315 Subnet Mask lower 6 digit...

Page 123: ...ot used D No 407 Not used D No 408 Not used D No 409 ID Input Selection The selected ID input method is displayed Fieldbus RS232C 2 SYS 410 Add STX ETX When ID Data input is selected as RS232C 2 it displays if STX or ETX tis added to data output SYS 411 External Input Select Displays the Work Parameter Number selection method PLC Input Signal ID input HFC3000 Software SYS 412 Reference Data Start ...

Page 124: ...3 TCPIP Port Number Standard setting 1024 Setting range 1024 65535 The TCPIP Port Number of the touch panel connected in the controller is displayed SYS 504 Touch Panel Number of Retries Standard setting 0 Setting range 0 9 Allows the setting of automatic communication retries if the fastening result is experiencing communication errors Sets the number of automatic retires in the case of communica...

Page 125: ... 104 Ramp Down Start Torque 105 1st Torque 107 Snug Torque 108 Snug Torque High Limit 109 2nd Torque 110 Reverse Torque High Limit 111 Torque Inhibit Limit 112 Rate 1 Start Torque 113 Rate 1 End Torque 114 Rate 2 Differential Angle Start Torque 115 Rate 2 Differential Angle End Torque 116 Rate 3 Start Torque 117 Rate 3 End Torque 118 Final Torque Low Limit 119 Final Torque High Limit 120 Option 12...

Page 126: ...Time Speed rpm P 01 P 64 400 Initial Speed 401 Freerun Speed 402 1st Speed 403 2nd Speed 404 3rd Speed 405 Reverse 1 Speed 406 Reverse Speed between 1 2 Step 407 Reverse Speed between 2 3 Step 408 Ramp Up Time 409 FreeRun Ramp Down Time 410 1 Pulse Reverse Speed Revolution rev Current P 01 P 64 500 Freerun Revolutions 501 Reverse Revolutions between 1 2 Step 502 Reverse Revolutions between 2 3 Ste...

Page 127: ...it Time ms 554 Pulse Fastening Operation Time ms 555 Pulse Fastening Operation Angle deg 556 Pulse Fastening Ramp Up Time ms Gyro P 01 P 64 560 CW Swing Stop Angle deg 561 CW Swing Pause Angle deg 562 CW Swing Pause Servo Lock Time ms 563 CW Swing Resume Dwell Time ms 570 CCW Swing Stop Angle deg 571 CCW Swing Pause Angle deg 572 CCW Swing Pause Servo Lock Time ms 573 CCW Swing Resume Dwell Time m...

Page 128: ...single system Before the start of the fastening operation reverse rotation at D No 405 Reverse 1 Speed is executed for D No 505 Reverse Revolutions before Fastening 1 Fastening Direction CCW This is a special fastening option for performing a screw loosening operation or for fastening left hand screws etc Using this setting normal rotation is performed in the CCW direction counterclockwise directi...

Page 129: ... control method 1 Final Angle Check Cannot be Disabled Judge final angle at the end of the fastening operation is within the high and low limit ranges The starting point of angle measurement is D No 107 Snug Torque 1 Rate 1 Check Judge the 1st torque rate slope from D No 112 Rate 1 Start Torque to D No 113 Rate 1 End Torque is within the high and low limit ranges when D No 113 Rate 1 End Torque is...

Page 130: ...m the start to end of fastening is within the high and low limit ranges 1 Differential Angle Check Judges the differential angle calculated from the rate 2 from D No 114 Rate 2 Start Torque to D No 115 Rate 2 End Torque and the final torque is within the high and low limit ranges 1 Snug Torque Check Judges the torque value is below the Snug high limit when D No 107 Snug Torque is detected 1 Break ...

Page 131: ...ng on this backlash The servo lock function is also performed if a reverse operation occurs from the use of the REVERSE signal The servo lock can be released by turning On the PLC I O input signals START RESET or BYPASS or turning STOP to OFF The fastening result mode D No 16 Servo Lock Flag will show ON when it is used Depending on the controller version to turn Off the Servo Lock after fastening...

Page 132: ...arted with the tool in motion the angle measurement becomes unstable and the safety stop function may not work properly 1 Angle Head Torque Variation Monitor With an angle head tool the torque variation is monitored when this is set to 1 ON 1 Reverse Between 1st 2nd Step If this is set to ON using a 2 step fastening a reverse operation is performed before restarting in the diagram below 1 Reverse ...

Page 133: ...0 as the sample number of the fastening results When the calibration torque is changed confirm that other torque related parameters are lower than the changed calibration torque The other torque related parameters must be set to values lower than the maximum torque value of the tool and the calibration torque D No 101 Peak Torque Low Limit N m Setting range 0 D No 100 Calibration Torque 1 1 D No 1...

Page 134: ...e as D No 100 Calibration Torque D No 107 Snug Torque N m Setting range 0 D No 100 Calibration Torque 1 0 This is the torque at which angle measurement begins If D No 000 Fastening Method is the angle method this is the start point of fastening Angle measurement and judgment are started from the Snug torque Example In the case Snug torque is 10N m D No 202 Standard Angle of 90deg D No 108 Snug Tor...

Page 135: ...e Inhibit ignores the torque at the start of fastening for the given rotation D No 205 Torque Inhibit Angle This high limit sets a maximum torque that will be ignored during this process If the torque inhibit high limit is exceeded during the torque inhibit process a REJECT fastening judgment is made D No 112 Rate 1 Start Torque N m D No 113 Rate 1 End Torque N m Setting range 0 D No 100 Calibrati...

Page 136: ...s of the fastening torque at the point at which the standard angle is reached Note it is common when using Angle Control that fastener yielding takes place In this case the peak torque reports the highest torque seen during the fastening while the final torque would show the lower yielded torque when the standard angle is met and fastening ends If the fastening torque exceeds the final torque high...

Page 137: ...nal Angle High Limit If 2 step or 3 step fastening is used set a Standard Angle value greater than D No 203 1st Angle to D No 204 2nd Angle D No 205 Torque Inhibit Angle deg Setting range 0 9999 9 Sets the torque inhibit rotation angle if used The tool will rotate this number of degrees ignoring the torque but will still monitor torque that it does not exceed the Torque Inhibit high limit When the...

Page 138: ...imum torque rate of tool maximum torque rate of tool Sets the high limit value of Rate 2 slope of torque vs angle between the two points of D No 114 Rate 2 Start Torque D No 115 Rate 2 End Torque A judgment is made at the point at which D No 115 Rate 2 End Torque is attained D No 304 Rate 3 Low Limit N m deg Setting range maximum torque rate of tool maximum torque rate of tool Sets the low limit v...

Page 139: ... Time High Limit sec Setting range 0 0 999 9 Sets the value of the 2nd time high limit until D No 103 Standard Torque or D No 202 Standard Angle is attained from D No 105 1st Torque or D No 203 1st Angle If the 2nd time high limit is exceeded a REJECT judgment is made D No 315 Torque Recovery Time sec Setting range 0 0 5 0 After Standard Torque is reached standard torque is maintained for the dura...

Page 140: ...tween 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 Speed will be switched over to D No 403 2ND Speed D No 403 2ND Spe...

Page 141: ...ep rpm Setting range Minimum tool speed to maximum tool speed Sets the speed during reverse operation between 1st and 2nd Step if used This is the speed used in D No 006 Fastening Interrupt Operation Reverse Between 1 2 Steps ON D No 407 Reverse Speed between 2 3 Step rpm Setting range Minimum tool rotation speed to maximum tool rotation speed Sets the speed during reverse operation between 2nd an...

Page 142: ...h Limit rev Setting range 0 99 9 Sets the low and high limit values for the number of revolutions rotated from the start of fastening to the end of fastening If the number of revolutions at the end of fastening exceeds the rundown revolution high limit or falls below the rundown revolution low limit a REJECT judgment is made D No 505 Reverse Revolutions before Fastening rpm Setting range 0 99 9 Th...

Page 143: ...e msec Default value 15 Setting range 0 200 Sets the pause time no rotation after the fastening has stopped between steps when function is enabled When the restart time is increased the fastening time is correspondingly increased Can be used during 2 step fastening or 3 step fastening only D No 544 Ramp Down Time Setting range 0 200ms Default value 0 D No 545 Final Ramp Down Time Setting range 0 2...

Page 144: ...en 2 3 Steps ON D No 547 CCW Wait Time Between Steps msec Setting range 0 500 Default setting 200 Sets the stopped waiting time when normal rotation changes to reverse rotation when fastening is interrupted by a reverse rotation operation Note 200ms is the minimum recommended wait time Setting lower than this may affect tool life due to sudden shock generated by high speed motor direction changes ...

Page 145: ...ation speed Recovery pulsing speed D No 551 Limiting by the current value is applied at the end of fastening 103 Standard Torque 105 1st Torque 550 Recovery Pulsing Count 0 50 times 551 Recovery Pulsing Speed rpm Note as shown below Be sure to set the parameters so that Pulse Fastening Operation Time Pulse Fastening Wait Time If the Standard torque is not reached within the operating time extend t...

Page 146: ...dingly increased D No 554 Pulse Fastening Operation Time msec Setting range 0 200 Default value 30 Sets the time required to restart the next pulse from the last stop position The fastening operation pauses only when the torque value is reached after the elapse of the pulsing cycle time A cycle represents the running time set at the Pulse Fastening Operation Time or the fastening up to the set ope...

Page 147: ... paused Pauses when this limit is exceeded Rotation is started again after the CW CCW Swing Motor Resume Dwell Time set as Data No 563 or 573 has elapsed When the operation is paused the detected angle value from the gyrosensor is reset to 0 degrees D No 562 CW Swing Stop Servo Lock Time msec Default value 5 D No 572 CCW Swing Stop Servo Lock Time msec Default value 5 Setting range 0 200 Once the ...

Page 148: ...occurs The curve data for each stage cannot be read or saved via the HFC3000 user console The curve data at the end of sequence is only read saved but may include data from a previous stage if curve range length is setup high enough to include it and Include Last Curve is checked in the curve screen Only the torque angle curve 540deg fixed length is saved in the curve history of the CF card D No 5...

Page 149: ...equence the sequence is interrupted if the start trigger returns no longer depressed during the sequence If 0 is set as the parameter No for stages 2 8 the prior stage becomes the sequence end position and the judgment would be from the last stage performed Precautions on the result display of D No 581 Sequence Operation Stage 1 When using the continuous sequence 2 3 setting the fastening result p...

Page 150: ...583 03 00 00 Fastening using parameter 3 followed by 0 0 sec dwell 4 584 00 00 00 Sequence end 5 585 00 00 00 6 586 00 00 00 7 587 00 00 00 8 588 00 00 00 Parameter No Operation 1 Fastening 10Nm 2 Loosening operation angle method CCW 360 degrees 3 Fastening 15Nm 2 In Continuous Sequence 1 mode if the start trigger is released in the middle of the sequence the sequence is ended without judgment no ...

Page 151: ...Chapter 7 Troubleshooting PAGE 7 1 Chapter 7 Troubleshooting 7 ...

Page 152: ...ars at the right side 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 ...

Page 153: ...units Reinitialize 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 i...

Page 154: ...fter 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 when...

Page 155: ...rely connected 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 ex...

Page 156: ...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 HFC unit or change tool to proper tool 3 Confirm TOOL ID data has not been corrupted or is missing Reprogr...

Page 157: ...t power sources Relocate as required and reinitialize the system 2 Turn control power off to the unit for at least 5 minutes then re apply power 3 Replace controller Code A04 02 SYSTEM MEMORY ERROR FLASH ROM READ ERROR Communications error to internal HFC Unit Flash ROM during a READ attempt CAUSE 1 Corrupt memory data in the fieldbus configuration area 2 If the controller is located in an electri...

Page 158: ...tialize the system 2 Turn control power off to the unit for at least 5 minutes then re apply power 3 Replace controller Code A04 06 SYSTEM MEMORY ERROR RTC WRITE ERROR An error occurred during a WRITE attempt to the Real time Clock chip 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 ...

Page 159: ...rom turning 4 System Parameter 523 Fastening Current Limit is not set to the correct value or set to 0 may be set 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 ...

Page 160: ...ntroller servo thermal sensor has detected an overheat condition CAUSE 1 If the environmental temperature is more than 113 degrees Fahrenheit 45 degree centigrade without any air flow or cooling unit 2 Source voltage is very close to the limit 253 VAC and the environment temperature is also close to 113 degrees F 3 Maximum torque or duty cycle is being run or exceeded by the tool every cycle Duty ...

Page 161: ...ly or the input voltage is above the maximum limit CAUSE 1 The controller internal power supply has failed 2 Source voltage is very close to the limit 253 VAC 3 Internal regenerative voltage surge caused by motor ramp down RECOVERY 1 Replace the controller 2 Verify and correct the source voltage as required 3 Reduce fastener rundown speed or reduce the difference between the fastener rundown speed...

Page 162: ...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 cabl...

Page 163: ...ower failure occurred RECOVERY 1 Verify that the input power cable is connected and not damaged 2 Verify and correct the source voltage as required on all three phases 3 Replace the controller Code A08 17 SERVO AMPLIFIER ERROR SYSTEM CPU ERR The controller has detected a failure of the Servo CPU CAUSE 1 The Servo CPU has failed RECOVERY 1 Replace the controller Code A08 20 SERVO AMPLIFIER ERROR CU...

Page 164: ...rsed may be over torqued 3 Verify there is no excessive binding in the fastener transmission or end of tool square drive keeping the motor from turning Code A09 09 PARAMETER ERROR SPINDLE NUMBER SETTING ERROR The spindle address of the HFC Unit has been set to something other than 1 RECOVERY 1 Set the HFC Unit Address rotary switch located on the bottom of controller to 1 Code A09 10 PARAMETER ERR...

Page 165: ...s shown in the figure above with the numeral indicated at being the parameter No of the last parameter used during operation the parameter No will not be updated unless a fastening operation is performed Confirmation of the Reason for Fastening Stoppage Procedure 1 After the end of fastening press the and buttons to select COUNT D No 09 The reason for the fastening stopping is indicated in the upp...

Page 166: ...of category 5e or higher Section 4 8 Is network connection enabled in the PC to be used for Ethernet communication Set up the PC to enable network connection or check with another PC Confirm by Command Prompt functions The PC s ethernet setting can be confirmed by Command Prompt functions Next page Is PC connected with a wired LAN and wireless LAN from the PC at the same time Disconnect the wirele...

Page 167: ...f the displayed settings IP Address Subnet Mask and Default Gateway are not correct set the PC s setting again 4 If a normal response is made as in the screen above and yet connection with the HFC3000 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 controller and the PC after ping command The followi...

Page 168: ...ging the Date Time of a controller display 1 Press and hold the PROGRAM switch of the controller to enter program mode 2 Depress the arrow buttons so SYS is indicated in the Work No Display and 019 or 20 RTC Year Month Day Time is indicated in the COUNT D No Display and then press the SET switch 3 After transitioning to the set editing mode depress the arrow buttons to change to the desired date o...

Page 169: ...Chapter 8 Options PAGE 8 1 Chapter 8 Options 8 ...

Page 170: ...ata Sets 4GB approx 900 thousand sets 8GB approx 1 8 million sets 16GB approx 3 4 million sets 32GB approx 7 0 million sets Precautions Concerning Memory Card Usage Care must be taken as the data stored in a memory card may be erased under the following conditions When a user handles a memory card incorrectly When a memory card is used or stored in an environment with static electricity or electri...

Page 171: ...ompleted data save Green Saving data Formatting in progress Orange 1 The storable capacity of the CF card falls to less than 200MB Capacity is 1 to 10 before Controller software version V1 209 Red 2 CF card is not inserted Failed to save data Format failed The storable capacity of the CF card falls to less than 20MB Capacity is 1 or less before Controller Software Version V1 209 1 if a CF Card For...

Page 172: ... inserted in the opposite orientation a malfunction of the controller or the CF card may occur if the card is forcibly pressed in 2 Data storage is executed after the fastening operation has ended once the CF data storage is enabled Do not remove the card from the slot or turn OFF the control power while data storage is in progress or damage may occur to the CF card and or data may become damaged ...

Page 173: ...ncerning curve display using the HFC software Fastening Results 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 at each turn of the month or year Inside the...

Page 174: ...ts of fastening curves have been stored the next file is generated automatically inside the 20130901 folder Also besides the fastening curves 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...

Page 175: ...System Setting Mode is indicated as SYS 3 Use the and buttons on the controller until 400 is indicated at the COUNT D No Display 4 The value indicated at the upper stage of the display is the storable capacity units MB of the CF memory card For firmware version 1 209 or earlier Units When the CF ACCESS LED lights RED storage into the memory card is discontinued to prevent mismatch of the stored co...

Page 176: ...UNT D No Display Procedure 3 Hold the PROGRAM button on the controller Front Panel to put the controller in the BYPASS mode and then press the SET button Procedure 4 Press the or buttons to select CF in the upper part of the display as the type of data to be erased and then press the SET button Procedure 5 Within 2 seconds press the and buttons to change Erase NO to Erase YES and within 2 seconds ...

Page 177: ... The factory settings of the RS232C 2 ports of the Expansion controller 2 are shown below The respective set values can be confirmed with D No 401 404 of the System Setting Mode PAR No Display SYS The settings cannot be changed using the front panel display The settings can be changed using HFC Software ver 1 130 or later Factory default setting SYS System Parameters D No 401 RS232C 2 Communicatio...

Page 178: ...f ASCII code data from 0x20 to 0x7E is possible except for the following 0x22 0x27 0x2A 0x2F 0x3A 0x3C 0x3E 0x3F 0x5C 0x7C If other characters than above are used there is a possibility data display is garbled or unreadable Maximum data size Up to 32 characters 32 Byte If a value more than 32 bytes is sent only the first 32 bytes are used All ID data received before the fastening operation will be...

Page 179: ...2 and data will be updated by the input data when the ETX signal is received The STX ETX data will be excluded in the stored data not be output as well ID Data Output Timing A in the figure requires an input time of 100msec Example 1 the ID data is input continuously before the fastening operation Example 2 the ID data is input during the fastening operation Example 3 the ID data is not re entered...

Page 180: ...ut ID HFC3000 Software Select by User Console Using Select by Input ID a maximum of 5 ASCII characters can be setup for each Work No allowing the work No to be selected by an ASCII data string that comes from the Input ID Data If the ID data is not input or the ID data and the selected setting do not match the PLC I O output signal ABNORMAL is set ON when the PLC I O input signal START or REVERSE ...

Page 181: ...Chapter 9 Fieldbus I O Interfaces PAGE 9 1 Chapter 9 Fieldbus I O Interfaces 9 ...

Page 182: ...tting this signal ON FirmwareV1 301 8 IN No 02 0 Unused NO Always off 9 1 Unused NO Always off 10 2 Unused NO Always off 11 3 Unused NO Always off 12 4 Work Select Bit0 NO Selects Parameter No 1 64 Work Select 0 5 13 5 Work Select Bit1 NO 14 6 Work Select Bit2 NO 15 7 Work Select Bit3 NO IN No 02 0 IN No 03 0 STOP NO or NC Emergency Stop 1 1 RESET NO See RESET signal above 2 2 REVERSE NO Spindle w...

Page 183: ...lways off 10 2 Unused NO Always off 11 3 Unused NO Always off 12 4 Unused NO Always off 13 5 Unused NO Always off 14 6 Unused NO Always off 15 7 Unused NO Always off IN No 04 0 IN No 07 0 Unused NO Always off 1 1 Unused NO Always off 2 2 Unused NO Always off 3 3 Unused NO Always off 4 4 Unused NO Always off 5 5 Unused NO Always off 6 6 Unused NO Always off 7 7 Unused NO Always off 8 IN No 08 0 Unu...

Page 184: ... inputs ON 13 5 Work OUTPUTBit1 NO 14 6 Work OUTPUTBit2 NO 15 7 Work OUTPUTBit3 NO OUT No 02 0 OUT No 03 0 REJECT NO Outputs when fastening result is outside of set limits 1 1 ACCEPT NO Outputs when fastening result falls within set limits 2 2 ABNORMAL NO Outputs when a system abnormal occurs 3 3 READY NO Outputs when system is ready to run 4 4 BUSY NO Outputs during fastening or reverse operation...

Page 185: ...7 Unused NO Always OFF OUT No 04 0 OUT No 07 0 Unused NO Always OFF V1 209 V1 309 CF WARNING Output when the CF card remaining capacity is less than 200 MB on the controller with the CF card option V1 210 V1 308 V1 310 1 1 Unused NO Always OFF V1 209 V1 309 BATCH SEQ END Output when the fastening operation of the final stage of the batch sequence is OK V1 210 to V1 308 V1 310 2 2 Unused NO Always ...

Page 186: ... 77 78 SIGN DIFFERENTIAL ANGLE JDG OCR SIGN RATE 1 JDG OCR 2DH 20H 20H 31H 33H 20H 20H 20H 20H 30H 2EH 31H 32H 33H 20H 20H １００１２３ 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 SIGN RATE 2 JDG OCR SIGN RATE 3 JDG OCR 20H 30H 2EH 31H 32H 33H 20H 20H 20H 30H 2EH 31H 32H 33H 20H 20H ０１２３０１２３ BANK ON START 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 1ST TIME JDG OCR 2ND TIM...

Page 187: ...20H 20H 31H 37H 20H ３８９１７ OFF 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 ON 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 RATE3 INC TORQUE RATE3 INC ANGLE RUNDOWN REVO 20H 20H 30H 2EH 30H 20H 20H 20H 20H 20H 30H 20H 20H 33H 2EH 35H ０００３５ OFF 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 ON 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 CALIBRATION ...

Page 188: ...HFC3000 software and a fieldbus configuration file is different a warning window is displayed in the software Bus Type Select Selects the type of fieldbus interface from a pull down list When Upload is performed the bus type is shown in the Bus Type Select window Configuration File Browse Afieldbus configuration file nrfcf is read from the PC Save Afieldbus configuration file nrfcf is saved in the...

Page 189: ...mmunication Due to conformance with the open field network EtherNet IP System connections with EtherNet IP devices master slave of other manufacturers are enabled Also remote I O communication and message communication can be executed at the same time 9 2 1 System Structure HFC3000 EtherNet IP System Remote I O Communication Message Communication EtherNet IP Slave Station EtherNet IP Slave Station...

Page 190: ...Chapter 9 Fieldbus I O Interfaces PAGE 9 10 9 2 2 Hardware Setting Module Status LED Network Status LED EtherNet IP connector Link Activity LED ...

Page 191: ... EDS file is included in the installation CD and or downloadable from the FEC website Please refer to the PLC instruction manual for the EtherNet IP configuration software concerning the appropriate method for using the EDS file Module Pin Configuration No Signal Description 1 TD Send data 2 TD Send data 3 RD Receive data 4 Not used 5 Not used 6 RD Receive data 7 Not used 8 Not used The cable is n...

Page 192: ...stablished online connection is not establishe Red Lit up Error Fatal error has occurred Conflicting IP address Flash Connection timeout One or more connection timeout has occurred B Module Status LED Off Off Power OFF Power is not supplied Gree n Lit up Online Controlled by a scanner in RUN state Flash Communication not established Incomplete wrong configuration or scanner in idle state Red Lit u...

Page 193: ...ength HFC Controller to PLC 16 bytes 128 bits Message Data Length PLC to HFC Controller 32 bytes 256 bits Message Data Length HFC Controller to PLC 200 bytes 1600 bits The number of message block bytes is fixed at 200 bytes I O Size setting Data Length PLC to HFC Controller Setting range 2 bytes 16 bits to 8 bytes 64bits Data Length HFC Controller to PLC Setting range 2 bytes 16 bits to 32 bytes 2...

Page 194: ...tLogix L32E If the system is not the same as listed above setup may be different Please contact to PLC manufacturer for detail as each PLC may be different 1 Register MASTER Spindle Fieldbus unit to network In the PLC I O configuration right click on Ethernet Port Local ENB and select New Module Select Generic Ethernet Module from module list and click the OK button ...

Page 195: ... matches the parameters set to the Fieldbus setup using the HFC3000 User Console software Note Input Output size MUSTmatch the settings programmed in the Ethernet I P setting of the HFC3000 Fieldbus setup or PLC Ethernet I P error will occur Click on the Connection tab and set connection setup as below AFC3000 ...

Page 196: ...1500 in above screenshot Input signals from AFC3000 controller FEC to PLC HFC1500_2 O shown as AFC1500 in above screenshot Output signals toAFC3000 controller PLC to FEC HFC1500_2 C shown asAFC1500 in above screenshot Message communication data from the HFC3000 controller HFC Controller to PLC for fastening result data An additional program command needs to be added for sending retrieving the data...

Page 197: ...output to the PLC in the format shown in section 9 1 2 Fieldbus Message Output Format The data will be retrieved by the PLC using the PLC logic messaging command PLC program 1 Read_Tag needs be added to the Controller Tags for message transfer This data tag contains the configuration of themessage transfer Each MSG command needs to have its own Read_ tag The MSG command is used for transferring th...

Page 198: ...ervice Type GetAttribute Single Service Code E Class A2 Instance 1 Attribute 5 Destination The controller tag C should be selected Note Eachmessage command can only handle 200 bytes The HFC3000 only has a total of 182 bytes of data per cycle so only one command is necessary to retrieve all fastening data from one cycle A2 5 HFC3000 C Data 0 ...

Page 199: ...ter 9 Fieldbus I O Interfaces PAGE 9 19 At the communication tab screen select Path The HFC3000 controller will show up in the browser as shown below ETHERNET MODULE HFC3000 AFC3000 AFC3000 AFC3000 AFC3000 ...

Page 200: ...I O addresses are not actual and should reflect the fixed I O layout as shown in section 9 1 1 Fieldbus I O Layout Note The above information contained in this procedure are meant for REFERENCE ONLYwhen configuring an FEC Ethernet I P interface using FEC HFC3000 User Console Software FEC HFC3000 Nutrunner System RockwellAutomation RSlogix 5000 software andAllen Bradley CompactLogix L32E hardware A...

Page 201: ...1500 System showing the C register data Note that screens and data for the HFC3000 would vary slightly this is an example only for reference what the message data will look like in the PLC AFC1500 would be HFC3000 for HFC3000 system AFC1500 User Console MONITOR Screen for above Data ...

Page 202: ...controller The message information sent from the PLC to the HFC Controller will be reflected in the part ID data in the HFC3000 User Console and the RS232C Data port output The standard set value for the ID input data is 32 bytes 16 words Be careful because even when a value beyond this is set only the 32 bytes from the start are saved in the fastening result retention of the Controller Do not use...

Page 203: ...FEC HFC Controller will be Married with the fastening result data so that the fastening data would now contain the part ID number providing a birth history for the part being fastened The Write_Tag contains the configuration of the message transfer A MSG command Message command in the PLC logic must be used in conjunction with a Write_Tag to send data In the case below VIN_Number_Write tag has bee...

Page 204: ...ice Code 10 Class A2 Instance 1 Attribute 5 Destination The controller tag VIN_Number or whatever Write Tag you setup should be selected Note The FEC HFC Controller will only take a maximum of 32 Bytes for the Write_Tag Part ID data configurable between 0 32 bytes in the HFC3000 software for the Fieldbus Message Setup So an instance of 1 is all that is required in the above setup forWRITING data u...

Page 205: ...re the cycle START is given before the cycle is started Once received the data is buffered and will be used until new message data is received or the ID DATA CLEAR Input signal is enabled See Input signals The ID data received by the FEC HFC Controller will be married with the fastening data and will continue to use the same message data it receives until new data is sent or the ID Data Clear sign...

Page 206: ... Link Ver 2 00 System connections with a CC Link Ver 2 0 master station Ver 1 10 2 00 remote device stations and Ver 1 10 remote I O stations are enabled Also I O communication and message communication can be executed at the same time 9 3 1 System Structure HFC3000 CC Link System I O Communication Message Communication CC Link Ver 2 00 Remote Device Station CC Link Ver 1 10 2 00 Remote Device Sta...

Page 207: ...Chapter 9 Fieldbus I O Interfaces PAGE 9 27 9 3 2 Description of the hardware RUN LED ERROR LED CC Link Connector ...

Page 208: ...he node status of the HFC3000 CC Link System and the network state List of LED Indications LED Color State Details A RUN LED OFF Off Offline Power is not supplied or connection is not established Green Lit on Online Communicating normally Red Lit on Error Acritical error has occurred B ERR LED OFF Off Offline No error Red Lit on Error Acritical error has occurred Flickering CRC error Acyclic redun...

Page 209: ...s 32 words RWr 2 7 words 15 words 23 words 31 words Area per Station 4 Times Setting Type 1 StationOccupied 2 StationsOccupied 3 StationsOccupied 4 StationsOccupied Number of Occupied Points Number of Available Points Number of Occupied Points Number of Available Points Number of Occupied Points Number of Available Points Number of Occupied Points Number of Available Points RX 64 points 1 48 point...

Page 210: ... Link V1 Extended Cyclic Setting 8 times CC Link V2 1 time CC Link V1 Message Block Bytes is fixed at 176 bytes max by CCLINK Station Setting range 1 64 Speed Setting range 156kbps 625kbps 2 5Mbps 5Mbps 10Mbps CC Link Version Setting range CC Link V2 CC Link V1 Occupied Stations Setting range 1 station 2 stations 3 stations 4 stations fixed at 4 stations with CC Link V1 Extended Cyclic Setting Set...

Page 211: ...ct Count 3 for number of connected Remote Device stations 3 Set the refresh device Remote Input X100 Output Y100 at Remote Output RX RY 4 Set the refresh device Remote Register read D1000 at Remote Register RWr 5 Set the refresh device Remote Register write D4000 at Remote Register RWw The allocated set values differ according to the station No of the Controller used 6 Set the station information ...

Page 212: ...0 Part ID message output toAFC3000 Controllers D4000 D4072 D4144 Fastening result message from AFC3000 controllers D1000 D1072 D1144 CC Link Request address X478 X7F8 XB78 CC Link Enable address Y478 Y7F8 YB78 In the case of the first HFC3000 System 1 shown in the table above the PLC program is set so that when the 888th 378h bit Initial Data Processing Request in the CC Link Reserved system area ...

Page 213: ...ng BitsAccording to Size Configuration Cyclic Cycles Setting 1 Occupied Station 2 Occupied Stations 3 Occupied Stations 4 Occupied Stations 1 24th bit 18h 56th bit 38h 88th bit 58h 120th bit 78h 2 24th bit 18h 88th bit 58h 152th bit 98h 216th bit D8h 4 56th bit 38h 184th bit B8h 312th bit 138h 440th bit 1B8h 8 120th bit 78h 376th bit 178h 632th bit 278h 888th bit 378h Location of Initial Data Proc...

Page 214: ... PLC control OnlyASCII Data can be recognized by FEC controller The message information sent from the PLC to the HFC Controller will be reflected in the part ID data in the HFC3000 User Console and the RS232C Data port output The standard set value for the ID input data is 32 bytes 16 words Be careful because even when a value beyond this is set only the first 32 bytes are saved in the fastening r...

Page 215: ...n Due to conformance to the open field network PROFIBUS DP V1 system connections with PROFIBUS DP V1 devices master slave of other manufacturers are enabled Also cyclic I O communication and acyclic message communication can be executed at the same time 9 4 1 System Structure HFC3000 PROFIBUS DP V1 System Acyclic Message Communication PROFIBUS DP V1 Slave Station PROFIBUS DP V1 Slave Stations of O...

Page 216: ... the System Reference CD for the HFC3000 system Module Pin Configuration No Signal Description 1 Connection prohibited 2 Connection prohibited 3 RxD TxD P Data sending receiving B line P side 4 CNTR P RTS 5 DGND Communication power ground side 6 VP 5 Communication power 5V side 7 Connection prohibited 8 RxD TxD N Data sending receiving Aline N side 9 Connection prohibited The connector D SUB 9 pin...

Page 217: ... Clearing data Red Flash 1 Parameter error There is an error in the parameter setting Flash 2 Configuration error An error has occurred in the Profibus configuration setting B Status LED OFF Off Power OFF Uninitialized Power is not supplied Network is being initialized Module is being set up Green Lit on Normal operation The module has transitioned from the initial state Flash 1 Diagnosis event Th...

Page 218: ...ftware The node address the I O settings and the message settings can be changed Default the settings are set to the factory settings NodeAddress 3 Setting I O PLC to Controller 8bytes 64bits Setting I O Controller to PLC 16bytes 128bits Message Bytes Settings PLC to Controller 32bytes Message Bytes Settings Controller to PLC 200bytes Message Block Bytes is fixed at 64 bytes NodeAddress Setting ra...

Page 219: ...ation Conformance to the open field network DeviceNet System enables connections with DeviceNet devices master slave of other manufacturers Also remote I O communication and Explicit message communication can be executed at the same time 9 5 1 System Structure HFC3000 DeviceNet System Remote I O Communication Explicit Message Communication DeviceNet Slave Station DeviceNet Slave Stations of Other ...

Page 220: ...exists for each device The EDS file is necessary for using the Device Net configuration software to connect the MFC DN and the PLC The EDS file is included in the installation CD and or downloadable from the FEC website Please refer to the PLC manufacturer instruction manual for the Device Net configuration software concerning the appropriate method for using the EDS file Module Status LED Network...

Page 221: ...ll power OFF List of LED Indications The module LEDs indicate the node status of theAFC3000 Device Net System and the network state LED Color State Details A Network Status LED OFF Off Offline Offline or power is not supplied Green Lit on Online Communicating normally Flash Connection unestablished Although online connection is unestablished Red Lit on Error Acritical error has occurred Flash Conn...

Page 222: ...in the Device Net window The communication speed the node address the I O settings and the message settings can be changed Default the settings are set to the factory settings NodeAddress 0 Speed 500k bps Setting I O PLC toAxis 8bytes 64bits Setting I O Axis to PLC 16bytes 128bits Message Bytes Settings PLC toAxis 32bytes Message Bytes Settings Axis to PLC 200bytes Message Block Bytes is fixed at ...

Page 223: ... I O Interfaces PAGE 9 43 Message Bytes Settings PLC to Controller Setting range 0byte 32bytes Controller to PLC Setting range 0byte 4096bytes PLC Setting Example Please reference the Ethernet I P PLC example Section 9 2 ...

Page 224: ...nformance to the open field network PROFINET I O System enables connections with PROFINET I O devices master slave of other manufacturers Remote I O communication and cyclic message data communication can be executed at the same time 9 6 1 System Structure HFC3000 PROFINETI O System Cyclic Message Communication PROFINET IO Slave Station PROFINET I O Slave Stations of Other Manufacturers Remote I O...

Page 225: ...he installation CD and or downloadble from the FEC website Please refer to the PLC instruction manual for the PROFINET I O configuration software concerning the appropriate method for using the GSDMLfile Module Pin Configuration No Signal Description 1 TD Send data 2 TD Send data 3 RD Receive data 4 Not used 5 Not used 6 RD Receive data 7 Not used 8 Not used The cable is not provided with the equi...

Page 226: ...ough online connection is unestablished Red Lit on Error A critical error has occurred Redundant IP address Flash Connection timeout Aconnection timeout has occurred once or more B Module Status LED Off Off Power OFF Power is not supplied Green Lit on Online Normal state Flash Communication unestablished Due to incomplete configuration or connection failure the devicemust be re recognized Red Lit ...

Page 227: ...01 Setting I O PLC to Controller 8bytes 64bits Setting I O Controller to PLC 16bytes 128bits Message Bytes Settings PLC to Controller 32bytes Message Bytes Settings Controller to PLC 200bytes Message Block is fixed at 250 bytes Network Settings IPAddress 0 0 0 0 255 255 255 255 Subnet Mask 0 0 0 0 255 255 255 255 Default Gateway 0 0 0 0 255 255 255 255 Station Name Setting range ASCII characters h...

Page 228: ...tting I O PLC to Controller Setting range 2bytes 16bits 8bytes 64bits Controller to PLC Setting range 2bytes 16bits 32bytes 256bits Message Bytes Settings PLC to Controller Setting range 0byte 32bytes Controller to PLC Setting range 0byte 4096bytes ...

Page 229: ...Chapter 9 Fieldbus I O Interfaces PAGE 9 49 Blank Page ...

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