Desoutter CVI3 Function, CVI3 Function eSTOP User Manual

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Page 1

User manual

www.desouttertools.com

CVI3 Function

V 1.7.2.X

Part no 6159930320 Issue no 06 Date 02/2017

Model Part number

CVI3 Function

6159326900

CVI3 Function eSTOP

6159326930

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Table of contents_02/2017 - 3 -

TABLE OF CONTENTS

1 - SAFETY INSTRUCTIONS .....................7

1.1 - General instructions .......................................... 7

1.2 - Personal safety.................................................. 7

1.3 - Tool use hazards ............................................... 7

1.4 - Tool care and service ........................................ 7

2 - GETTING STARTED .............................. 7

2.1 - Front panel ........................................................ 7

2.2 - LEDs color code ................................................ 7

2.3 - Bottom panel ..................................................... 8

2.4 - Installation ......................................................... 8

2.5 - Changing the controller language ..................... 8

3 - TREE VIEW ............................................9

4 - CONTROLLER SETTINGS .................10

4.1 - Using icons and keyboards ............................. 10

4.2 - Secondary controller in a workgroup ............... 10

4.3 - Network ........................................................... 10

4.4 - Ping ..................................................................11

4.5 - Fieldbus ............................................................11

4.6 - Customized protocol.........................................11

4.7 - Date & time.......................................................11

4.8 - Beep ................................................................ 12

4.9 - Zoom in Control mode ..................................... 12

4.10 - Input/Output (reading only)............................ 12

4.11 - Access manager ............................................ 13

5 - MONITORING ...................................... 13

5.1 - Pset/Assembly Process selection ................... 13

5.1.1 - First selection ........................................ 13

5.1.2 - Control mode .......................................... 13

5.2 - Last result ........................................................ 13

5.3 - Report details .................................................. 14

5.4 - Monitoring symbols ......................................... 14

5.5 - Trend symbols ................................................. 14

6 - RESULTS ............................................. 15

6.1 - Display of the last result .................................. 15

6.2 - Display of other results .................................... 15

6.3 - Display of run reverse results .......................... 15

7 - MAINTENANCE ................................... 16

7.1 - Controller ......................................................... 16

7.1.1 - USB key - Firmware upgrade ................. 16

7.1.2 - USB key - Save logs .............................. 16

7.1.3 - USB key - Save cong ........................... 16

7.1.4 - USB key - Save results .......................... 16

7.1.5 - USB key - Advanced diagnostic ............. 16

7.1.6 - CVILOGIX .............................................. 17

7.1.7 - Memory .................................................. 17

7.2 - ePOD............................................................... 18

7.2.1 - Backup/Restore ...................................... 18

7.2.2 - Eject ....................................................... 18

7.2.3 - Repair ..................................................... 18

7.2.4 - Erase results .......................................... 18

7.3 - User information .............................................. 19

7.4 - Firmware version ............................................. 19

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8 - APPENDIX - I/O AND EVENTS ........... 20

8.1 - Logical outputs ................................................ 20

8.2 - Logical inputs .................................................. 25

9 - APPENDIX - USER INFO CODES ......29

10 - APPENDIX - CONNECTIONS ........... 37

10.1 - Tool connector ............................................... 37

10.2 - RS232 - SubD 9pt ......................................... 37

10.3 - Digital inputs (0 – 24V) .................................. 38

10.4 - Digital outputs (0 – 24V) ................................ 38

10.5 - Tightening ow chart and timing chart ........... 39

10.6 - Synchronizing single-channel controllers ...... 41

10.7 - Synchronizing TWINCVI3 controllers ............ 41

10.8 - eBUS (for accessories) ................................. 42

10.9 - Workgroup ..................................................... 42

11 - APPENDIX - EPOD ............................43

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Table of contents_02/2017 - 5 -

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6159930320_06_02/2017 - 6 -

Original instructions.

All rights reserved. Any unauthorized use or copying of the contents or part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings. Use only authorized parts. Any damage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability.

1 - SAFETY INSTRUCTIONS

1.1 - General instructions

To reduce risk of injury, everyone using, installing, repairing, maintaining, changing accessories on, or working near this tool must read and understand the safety instructions before performing any such task.

Failure to follow all instructions listed below

may result in electric shock, re and / or serious

personal injury.

• Refer to the following booklets:

- General safety instructions

- Quick-start user manual

http://resource-center.desouttertools.com.

SAVE THESE INSTRUCTIONS CAREFULLY.

1.2 - Personal safety

WARNING: This power tool must be earthed.

If the power tool is not earthed, the system will disable the power stage and the tool will not start. The error message "Bad tool ground" will be displayed.

1.3 - Tool use hazards

The selection of the tool takes account of the operating conditions as stated by the user.

When selected, they must not exceed the operating limits as

specied by the manufacturer.

Any excessive internal temperature of the tool electric motor is detected and stops the tool. The motor can start again only after the temperature has decreased.

Motor temperature limits are different for handheld tools and

for xed tools:

- 60°C for handheld tools.

- 100°C for xed tools.

1.4 - Tool care and service

Only experienced and qualied personnel (authorized

electricians) are entitled to open and have access to the inside of the controller.

• If in doubt, return the tool to a Desoutter-authorized service centre. Contact your Desoutter representative for support.

• Disconnect from power supply and wait 10 minutes before starting service operations.

Failure to wait 10 minutes may result in electric shock from not yet unloaded capacitors.

2 - GETTING STARTED

2.1 - Front panel

Legend

1 Report LEDs

2 122 x 32 full graphic display

3 Keypad

4 On / Off switch

5 Dedicated PC software port + USB port

2.2 - LEDs color code

LED color

Designation Action

Green Accept report -

Yellow Incomplete rundown Tighten again

Orange Reject report Loosen and tighten again

Red Above High Angle

Remove and replace fastener.

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2.3 - Bottom panel

Legend

1 Ethernet port dedicated only to PC software

2 USB port for data transfer / rmware updating / access

control management

3 ePOD port for controller backup, memory extension,

customer features activation, workgroup conguration.

4 2 USB ports to connect barcode readers

5 Auto-sensing input voltage mains connector

6 2x8 I/O connector dedicated to customer use + 2 quick

stops.

7 Ground Fault Interruptor: earth fault and overcurrent

protection

8 Fieldbus port for plug & play Fieldbus modules

9 eBUS to daisy-chain up to 15 accessories (e.g. socket

tray)

10 RS232 port (2 serial ports) to connect:

Barcode reader / Delta measuring unit

11 8-pin tool connector

12 4 Ethernet ports for 1 or 2 networks:

1 network

• Plug the Ethernet cable into any port.

2 networks

Ethernet network 1

Ethernet network 2

• Refer to "Appendix - CVI3 connections" to get more information.

• For more information about installing Fieldbus modules, refer to the " Quick start user manual" part no. 6159931440 at http://resource-center.

desouttertools.com.

2.4 - Installation

• To install and power the controller, follow the instructions listed in the Quick-start user manual supplied in the controller box.

The controller should be installed in such a way that it should be easily switched off.

When the controller is powered on, the Desoutter logo is displayed and the LEDs are blinking.

• Wait for a few seconds while the rmware is being initialized.

The monitoring screen is displayed:

2.5 - Changing the controller language

• Keep pressing this key up to the following screen.

• Press any key. The name of the language is blinking.

• Select the language.

• Validate

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3 - TREE VIEW

The controller is waiting for the selection of a Pset or Assembly Process.

The tool is locked.

- to display the last result.

- to select the next Assembly Process and/or Pset.

- to display the results.

- to display the user info codes.

- to save the results, the

congurations and the logs

on a USB key.

- to upgrade the rmware.

- to backup/restore/erase the results from the ePOD..

- to eject the ePOD

- to repair the ePOD

- to erase the results, the user info codes and the Pset/

AP conguration from the

controller.

- to launch a CVILOGIX program.

- to set up the network.

- to customize the controller.

- to set up the role of the controller in the workgroup.

- to display the status of the Input/Output.

- to enable/disable the data protection of the controller.

- to display the controller

rmware version.

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4 - CONTROLLER SETTINGS

• Use CVI CONFIG software to create Psets and Assembly Processes.

4.1 - Using icons and keyboards

to quit without changing

to validate

to navigate

to change

Pset symbol

Assembly Process symbol

? • Select a Pset or an Assembly Process.

The tool is locked.

• Select a Pset or an Assembly Process

The screen is locked.

• Refer to chapter "Access manager".

The screen is unlocked.

4.2 - Secondary controller in a workgroup

A workgroup is a system designed to drive from 2 to 14

xtured tools with cable connection.

The controller can be selected as one of the secondary controllers of the workgroup.

The controller is stand-alone.

• Select the value to change

The controller is selected as one of the secondary controllers of the workgroup.

• Validate

• Select the tool ID (position of the tool in the workgroup).

The monitoring screen will be as follows:

When changing from "Secondary" to "None", the

network conguration previously set for the stand-

alone controller will be restored.

• Refer to "Appendix - CVI3 connections" to get more information.

4.3 - Network

1 network

• Plug the Ethernet cable into any port.

2 networks

Ethernet network 1

Ethernet network 2

• Enter the controller IP address, Subnet mask and Gateway parameters.

• Select the value to change

• Change the value

• Validate

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4.4 - Ping

This function is used to check the network connection with any device connected on the network.

• Select the IP address to ping.

There are 4 attempts.

• Select the value to change

• Change the value

• Validate

4.5 - Fieldbus

• For more information about how to setup Fieldbus, refer to the CVI CONFIG user manual at http://

resource-center.desouttertools.com.

4.6 - Customized protocol

• Plug the "ePOD customer" into the bottom panel of the controller.

Depending on the protocol used, the following icons are displayed in the monitoring screen.

XML protocol

PFCS protocol

IPM protocol

The controller is connected to the server.

The controller is not connected to the server.

"Customized protocol status" events are available.

• Refer to "Appendix - CVI3 I/O and events" to get more information.

• For further information, contact your Desoutter representative for support.

4.7 - Date & time

This function is used to synchronize the controller date and time to ensure that the tightening results are stored with the correct date and time.

• Change the current date if necessary.

• Change the current time if necessary.

• Use CVI CONFIG software to select the date format and the synchronization source.

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4.8 - Beep

If enabled, this function enables a "Beep" sound each time a button is pressed.

The beep is disabled.

The beep is enabled.

4.9 - Zoom in Control mode

The "Zoom" mode can be used to display:

- the torque value

- the angle value

- the report

When the "Zoom" mode is activated, the last result and the selected Pset are alternatively displayed full screen.

If any key is pressed, the zoom is removed and the default

conguration is displayed.

• Validate your selection.

4.10 - Input/Output (reading only)

This part shows the status of the physical I/O of the controller.



OFF



• Refer to "Appendix - CVI3 I/O and events" to get more information.

• Refer to "Appendix - CVI3 connections" to get more information.

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4.11 - Access manager

It is recommended to protect the controller parameters against hazardous changes.

When the controller is delivered, the access manager is not

activated and any modication can be done.

To activate the access manager on the controller,

you need to have a USB stick with the right prole (congured with the Desoutter CVIKEY software).

• If not, contact your CVIKEY manager for support.

• Connect your USB stick to the front panel of the controller. The padlock will open to let you have access to the menu.

The padlock is not locked anymore.

By default, the protection of the data is not activated.

• Select to activate or not the protection of the data.

• Validate your selection.

• Remove the USB key from the controller.

The padlock is locked.

The controller protection is activated.

5 - MONITORING

5.1 - Pset/Assembly Process selection

5.1.1 - First selection

Upon delivery, the controller is waiting for the selection of a Pset or Assembly Process.

The tool is locked.

• Select the value to change.

The question mark is blinking.

• Change the value

• Validate

5.1.2 - Control mode

• Select the value to change

• Change the value

• Validate

5.2 - Last result

The report status is displayed: OK or NOK.

The torque and angle values are displayed.

The trend is displayed

The report details are available.

• Press this key to display the report details.

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5.3 - Report details

- Result number

- Report status

- Date

- Time

- Pset number

- Step number

- Stop source

to display the message when too long.

The last step is done.

The Pset has stopped before the last step.

OK The report is successful.

NOK The operation has failed.

5.4 - Monitoring symbols

Monitorings OK

Torque

Time

Overall time

Current

Torque rate

Angle

Overall angle

Second part angle 1

Second part angle 2

Rundown angle

5.5 - Trend symbols

The torque is below the minimum torque.

The torque is above the maximum torque.

The angle is below the minimum angle.

The angle is above the maximum angle.

The torque is in the tolerance of the target torque.

The angle is in the tolerance of the target angle.

The torque is above the assembly torque limit.

The angle is above the assembly angle limit.

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6 - RESULTS

6.1 - Display of the last result

6.2 - Display of other results

• Press one of these keys to select another result.

• Keep pressing the key to display the results by 10.

6.3 - Display of run reverse results

This icon indicates a run reverse operation.

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7 - MAINTENANCE

7.1 - Controller

7.1.1 - USB key - Firmware upgrade

• Plug the USB key into the front panel port.

• Check you have 1 ".cvi3" image and

1 ".cvi3.md5" le only on your USB key.

The controller beeps during 2 seconds and starts the process.

• Do not switch off the controller.

• Wait for the automatic reboot. The update lasts a few minutes.

When the upgrade is successful, the green LED is on.

7.1.2 - USB key - Save logs

• Plug any USB key into the front panel port.

7.1.3 - USB key - Save cong

• Plug any USB key into the front panel port.

7.1.4 - USB key - Save results

• Plug any USB key into the front panel port.

7.1.5 - USB key - Advanced diagnostic

• Plug any USB key into the front panel port.

• Select how often the logs are saved on the USB key.

Period 1/2/6/12/24 hour(s)

The period is blinking.

• Change the period.

• Do not unplug the USB key from the front panel.

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7.1.6 - CVILOGIX

Pre-requisite:

- ePOD including the CVILOGIX function

- USB key including your own CVILOGIX program.

• Plug in the ePOD into the bottom panel.

• Plug in the USB key into the front panel.

The CVILOGIX program is running.

In the control mode, the CVILOGIX logo is activated and displayed on the top left of the monitoring screen.

The program is running.

The program is stopped.

Other functions:

to save the program on any USB stick connected to the controller front panel.

Mandatory

• Use the "Eject" command to unplug the ePOD from the controller.

• Contact your local Desoutter representative for more information.

7.1.7 - Memory

• Select which type of information to erase from the controller memory:

- results

- user information

- Psets and Assembly Processes congurations

For example:

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7.2 - ePOD

• Plug in the ePOD into the controller.

• For more information about installing the ePOD, refer to the installation manual" part no. 6159931050 at http://resource-center.

desouttertools.com.

7.2.1 - Backup/Restore

• Select rst the backup mode: manual or automatic.

The ePOD is a snapshot of the controller.

Each modication is saved in

real-time in the ePOD. The ePOD acts as the controller mirror.

In both modes:

• Select "Backup" to start the process.

• Select "Restore" to transfer the data from the ePOD to the controller.

7.2.2 - Eject

Mandatory

• Use the "Eject" command to unplug the ePOD from the controller.

• Unplug the ePOD.

7.2.3 - Repair

• Use this function to start a recovery attempt of the data and results from the ePOD.

7.2.4 - Erase results

• Use this function to erase all results stored in the ePOD.

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7.3 - User information

to display the description.

to display the next code.

This icon indicates that the user information can be acknowledged.

• Press this key to clear the screen.

• Refer to "Appendix - User info codes" to get more information.

7.4 - Firmware version

This information is useful to exchange information with Desoutter Servicing.

• Refer to chapter "7.1.1 - USB key - Firmware upgrade" to update the controller.

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Appendix - I/O and events_02/2017 - 19 -

APPENDIX - I/O AND EVENTS

1 - LOGICAL OUTPUTS

Name Description Raising condition Falling condition

General status

Ready The system is free of any internal issue that could prevent it

from being fully operative. Communication between controller and tool is OK.

No error in controller nor in tool

- Quick stop activated

- Error coming from the system

Identier OK Identier received (e.g. barcode) matches masks (stays during

0.5 s at active level).

Identier received and identied

0.5 s after rising

Identier NOK Identier received (e.g. barcode) does not match masks (stays

during 0.5 s at active level).

Identier received but not identied

0.5 s after rising

User info present

User info (Info, Warning or Error) is present. User info present on

screen

No user info on screen

Keep alive ack This output is the copy of the "Keep alive" input.

It can be used by the PLC to check the controller is still running.

When "Keep alive" input raises.

When "Keep alive" input falls.

Fieldbus fault No Fieldbus.

The "Fieldbus fault" is on as long as the Fieldbus communication is not established. It switches off automatically when the communication works again.

Communication lost and/or keep alive missing.

Fieldbus communication established and keep alive present

Reporting Alarm When working with ToolsNet or CVINet: FIFO Threshold Alarm

reached. Results are stored in the controller memory and are erased when sent to ToolsNet or CVINet. This way the controller memory will never be full. A full controller memory induces result losses and traceability error. To detect communication issues with ToolsNet or CVINet, the software measures the

ll in rate (%) of the memory. When the rate overpasses

the target threshold, the Reporting alarm will switch on; maintenance operators are then able to solve the issue before loosing results.

FIFO Threshold Alarm reached

FIFO under threshold alarm.

Open Protocol activated

Open Protocol is activated in conguration Protocol is enabled Protocol is disabled

Open Protocol connected

Open Protocol is connected to the Tightening Unit At least 1 peer

connected

No peer is connected

Time synchro done

Time synchronisation completed successfully using Fieldbus data (Q_SYN in VWXML)

- -

Emergency stop Emergency stop is activated Emergency stop

activated

Emergency stop deactivated

TU running This indicates that the fastening operation has actually started:

at least one involved tool is running. The signal switches off as

soon as the fastening operation is nished (all reports sent).

Pset is started. The fastening

operation is nished

(all reports sent)

Tool status

Tool ready The tool is ready:

- communication between controller and tool is ok

- a valid Pset has to be selected

- the tightening strategy must cope with the tool"

Tool connected AND valid Pset.

Tool disconnection, Pset selection.

Tool not locked forward

There is no tool lock in forward direction. Tool unlocked in

forward direction

New lock in forward direction

Tool not locked reverse

There is no tool lock in reverse direction. Tool unlocked in

reverse direction

New lock in reverse direction

Tool running The tool is running (CW or CCW, tightening or loosening). Tool starts to run. Turns off when the

tool stops.

Tool direction Indicates if the tool is in tightening mode.

Active: tightening mode Inactive: run reverse mode Note: independent if tool is running or not.

Entering tightening mode.

Entering run reverse mode.

Tool tightening Tool is running in tightening mode.

Pset threshold is not taken into account.

Tool start in tightening mode.

Tool stops.

Tool middle course trigger

Reects the raw state of tool middle course start trigger,

independently from Tightening Unit state.

Middle course of main trigger is reached

Main trigger is completely released.

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Appendix - I/O and events_02/2017- 20 -

Name Description Raising condition Falling condition

Tool main start trigger

Reects the raw state of tool main course start trigger,

independently from the Tightening Unit state.

Trigger is pushed. Trigger is released

Tool push start or front start trigger

Reects the raw state of tool push start or front start trigger,

independently from the Tightening Unit state.

Trigger is pushed. Trigger is released

Manual reverse in progress

The operator has selected the reverse direction on the tool and is running the tool.

Manual runreverse selected and trigger pushed.

Stays on as long as the operator is running the tool

Fastener loosened

There is a xed minimum torque value to declare that the

fastener was "loosened".

Run reverse Result generation.

New start (tool trigger or external start)

Tube nut open Indicates that the tube nut is open.

The tool can be removed from the assembly.

- Tool running

Tool maintenance alarm

Reects the different tool maintenance alarm state with or

condition.

Tool maintenance alarm 1 or 2 is active.

No tool maintenance alarm is active.

Invalid spindle settings

Tool characteristics does not match Pset parameters (e.g. negative jog times or contradictions, torque over the maximum tool torque range, speed over the maximum tool speed, maximum tool torque range, etc…)

Pset selection or tool connection.

Tool disconnection or new Pset selected.

Span failure When starting a tightening, before running the tool, the

controller checks the torque span.

"Span failure" indicates that the span drifts by ±3% or more,

causing a tool lockout. This fault can be due to the torque transducer or the tool electronics. The only solution is to replace the tool.

Span failure detection. Disconnecting tool

or new check without fault.

Offset failure Indicates the offset (0 point) drifts by 50 % of full scale or

more. This error exists when, at the beginning of the Pset, the torque

transducer is seen to have 50 % or more of full-scale torque

prior to even starting the motor. With an "Offset failure", the controller cannot adequately compensate for this transducer error and, therefore, will not allow a tightening operation to occur. The only solution is to replace the tool. Offset failures can come from a severely damaged torque

transducer, a bad eld cable or a bad controller.

Offset failure detection Disconnecting tool

or new check without fault.

Motor over temperature

Indicates that the temperature of the tool motor windings has exceeded the temperature threshold. An error message remains.

Temperature threshold:

- 100°C for xed tools

- 60°C for portable tools

The signal turns off as soon as the temperature returns below the threshold (minus hysteresis = 10°C).

Angle measurement fault

Drive detected angle sensor fault. It can be an angle sensor fault, a tool electronic fault or a combination of both. The communication is tested permanently. As soon as the fault disappears, the signal turns off.

Angle fault detection. Disconnecting tool

Angle measurement fault

Angle fault detection. Disconnecting tool

No tool connected

Indicates that the controller is not detecting the tool. Controllers are designed to work with a range of fastening tools. The tools have an Intelligent Tool Interface (ITI) board which is continuously sending status information to the controller. If the controller requests status information from the tool and gets no response, the controller software turns on the "No tool connected" output. This output resets immediately upon successful communication with a tool.

No tool connected or tool not recognized

Tool connected and recognized.

Redundancy error

Redundancy error in case of operational control transducer and faulty monitoring transducer.

Result generation Use of "reset of

redundancy error" input, change of tool free of this error

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Appendix - I/O and events_02/2017 - 21 -

Name Description Raising condition Falling condition

Pset status

Pset selected bits (0..7)

Echoes the binary "Pset select bit 0 to 7" input if the corresponding Pset exists, echoes 0 if the Pset does not exist or there is no Pset selected.

New Pset selected New Pset selected

Tightening running (old cycle declared)

This indicates that the fastening operation has actually started: the tool is running and the torque is over the Pset start torque threshold. The signal switches off as soon as the fastening operation is

nished (all reports sent).

Torque reach the cycle start threshold.

The fastening

operation is nished

(all reports sent)

Tightening

nished

Indicates that a Pset report is available. Result generation. New start (tool trigger

or external start) or reset input

Tightening OK Indicates that the fastening operation (for a specic Tightening

Unit) ends correctly and that all controlled and monitored tightening parameters are within tolerances.

Result generation. New start (tool trigger

or external start) or reset input

Tightening NOK Indicates that the fastening operation (for a specic Tightening

Unit) has failed.

Result generation. New start (tool trigger

or external start) or reset input

Spindle OK Indicates that the fastening operation (for a specic tool) ends

correctly and that all controlled and monitored tightening parameters are within tolerances.

Result generation. New start (tool trigger

or external start) or reset input

Spindle NOK Indicates that the fastening operation (for a specic tool has

failed.

Result generation. New start (tool trigger

or external start) or reset input

Angle low Indicates a low angle reject.

The angle must meet or exceed this value for a correct Pset. When the angle stays below this value, it becomes a "Low angle reject" and this output is turned on. Stays on until a new fastening operation starts.

Result generation. New start (tool trigger

or external start) or reset input

Angle OK Indicates a correct angle.

The angle is inside the limits declared in the step.

Result generation. New start (tool trigger

or external start) or reset input

Angle high Indicates a high angle reject.

The angle must stay below this value to be a correct Pset. When the angle meets or exceeds this value, it becomes a "High angle reject". The tool will stop when this limit is reached and this output is turned on. Stays on until a new fastening operation starts.

Result generation. New start (tool trigger

or external start) or reset input

Torque low Indicates the peak torque low reject.

If the torque stays below the "Peak torque low limit" and results in a “Reject” Pset. This can happen when a Pset is

prematurely nished, a thread strips out or when the Pset is automatically nished due to other error conditions, such as

a High angle fault or when a Pset Time Monitor expires and causes the Pset to be terminated. Stays on until a new fastening operation starts.

Result generation. New start (tool trigger

or external start) or reset input

Torque OK Indicates a correct torque.

Torque is in inside the limits declared in the step.

Result generation. New start (tool trigger

or external start) or reset input

Torque high Indicates the peak torque high reject.

When the torque meets or exceeds this value, this output is turned on and the results is NOK. If a Peak Torque High error persists, it may be advisable to slow down the tool speed or replace the tool with one of lesser capacity. A second variable that can cause Peak Torque High errors is a badly chattering joint. Chatter is the squawking noise you hear on some fasteners at the end of the fastening operation. Chatter is induced by slip-stick and actually causes the fastener to momentarily stop rotating, then crack loose and re-start turning. This condition can cause a Peak Torque High condition. A potential solution for this is to view Psets, General Tab, and set the frequency response slide bar to Better Noise Immunity, Chattering Joint). This causes the software to average many torque readings together to minimize the possibility of using a single high frequency torque value that could trigger a peak torque high fault. Stays on as long as a new fastening operation starts.

Result generation. New start (tool trigger

or external start) or reset input

Page 22

Appendix - I/O and events_02/2017- 22 -

Name Description Raising condition Falling condition

Yellow report on tightening controller

This output reects the state of the controller yellow light. Controller yellow light

is on

New fastening operation starts

Green report on tightening controller

This output reects the state of the controller green light. Controller green light

is on

New fastening operation starts

Red report on tightening controller

This output reects the state of the controller red light. Controller red light is onNew fastening

operation starts

Lock on reject Indicates that a tool is locked out because of an incorrect

tightening operation. The controller will not continue to run the tool depending on “lock on reject option:

- until the "Error Acknowledge" input is activated.

- until a run reverse operation

- until a loosening operation"

Tightening nished

with bad result and option “Lock on reject” activated.

Input “Error acknowledge” activated or runreverse operation or loosening operation

Remove fastener

Indicates that the fastening operation resulted in a torque that exceeded the “Remove Fastener” setpoint. When correctly set, this means that the torque for any reason becomes very high. There is a risk that the fastening operation is not reliable: disassemble the joint and check parts.

Result generation. New start (tool trigger

or external start) or reset input

Tightening

nished without

timeout

Indicates that a Pset report is available and the source stop is not overall timeout.

Result generation. New start (tool trigger

or external start) or reset input

Overall time reached

Max overall time has been reached during tightening Result generation. New start (tool trigger

or external start) or reset input

Synchro out Synchro output: set to 1 when running step starts, reset to 0

when a synchro step is reached.

Start of running step. Synchro step

reached

Invalid parameter set selected

Indicates the Pset is disabled (has not been set). For example, if 3 Psets are used, Psets 1, 2 and 3 are enabled. If, however, any Pset other than 1, 2 or 3 is selected, the Pset is invalid and this output is turned on. It is possible for an Assembly Process to select invalid Psets.

Pset unselection Pset selection

Assembly Process status

Assembly Process selected bits (0..7)

Indicates the Assembly Operation per Tightening Unit currently selected (Bit 0..7)

New AP selected. AP aborted

Assembly Process running

Indicates the assembly operation is being processed. The signal is on as long as the assembly operation is running.

The signal falls down when the assembly operation is nished.

Assembly Process start.

Assembly Process

nished or aborted.

Assembly

Process nished

Indicates when an assembly operation is completed. Assembly Process

nished.

A new Assembly Process start or reset input

Assembly Process OK

Indicates when an assembly operation is completed with no rejects. The signal stays on as long as a new Assembly Process starts.

Assembly Process

nished and OK.

A new Assembly Process start or reset input

Assembly Process NOK

Indicates when an Assembly Process reject occurs. Stays on as long as a new Assembly Process starts.

Assembly Process

nished and NOK or

aborted.

A new Assembly Process start or reset input

Assembly Process aborted

When an Assembly Process has been aborted, "Assembly Process aborted" is activated. Stays on as long as a new Assembly Process starts.

Assembly Process aborted.

A new Assembly Process start or reset input

Current batch count bit (0..6)

Bit indicator of current batch count Batch count increment when batch is

nished, new start

(tool trigger or external start) or reset input or new AP selection

Remaining batch count bit (0-6)

Bit indicator of the number of remaining bolts in the batch Batch count increment When batch is

nished, new start

(tool trigger or external start) or reset input or new AP selection

Page 23

Appendix - I/O and events_02/2017 - 23 -

Name Description Raising condition Falling condition

Batch running A batch process is underway.

The output is set to 1 before the rst tightening operation.

A batch operation is enabled

Batch is nished or

reset input

Batch nished Indicates when the batch count equals the batch size and the

batch is declared completed. It is used together with "Batch OK" to indicate the status of a batch.

Batch is nished. New start (tool trigger

or external start) or reset input

Batch OK Indicates the status of the batch together with the "Batch

nished" output (managed by Assembly Process).

Batch is nished and

OK.

New start (tool trigger or external start) or reset input

Batch NOK Such as when the batch gets aborted…or in the case rejects

are included as part of the batch count (managed by Assembly Process).

Batch is nished and

NOK. A new AP has been selected.

New start (tool trigger or external start) or reset input

Max retries reached

Indicates when max number of retries is reached. Max number of retries

is reached.

Max number of retries is reset.

External outputs AP

External Out AP bit

Outputs that can be set or reset within an Assembly Process Depending of AP

behavior

Depending of AP behavior

External outputs PLC

External Out PLC bit (0..9)

Indicates this output is controlled by a PLC via Fieldbus (like a remote I/O). On PLC side, it is an output.

Depending on PLC behavior

External outputs OP

External Out OP bit (0..9)

Outputs dedicated to Open Protocol. Depending on OP

behavior

Depending on OP behavior

Socket tray

Socket selectable (0..4)

24 V socket trays (BSD). Informs which socket can be taken by the operator.

A new socket has to be taken by the user.

No socket to be taken by the user.

Customized protocol Status

Customer protocol activated

A customer protocol has been activated in conguration Protocol is enabled Protocol is disabled

Customer protocol connected

The activated customer protocol is connected Protocol is connected Protocol is

disconnected

Customer protocol reporting alarm

The activated customer protocol has declared an alarm about result reporting of this Tightening Unit.

Alarm is raised Alarm is cleared

Q_SAS ACK start tightening job - RDY Controller ready - Q_LSN Reverse disabled - WGZ Tool disabled - Q_EDZ Result and reports reset - Q_XMS XML data transfer completed - EIO Result OK - ENO Result NOK - FSCIO Group status OK - FSCNIO Group status NOK - -

CVILOGIX

External Out CVILogix bit (0..100)

Indicates that this output can be used by an internal CVILOGIX application.

- -

Miscellaneous

ON On state, used to set level "1" to physical outputs. At controller startup. Never falls OFF Off state, used to set level "0" to physical outputs. At controller startup. Never falls

Page 24

Appendix - I/O and events_02/2017- 24 -

2 - LOGICAL INPUTS

Name Description Status

General commands

Start stop Tightening on state

Initiates a fastening cycle if:

- the "Spindle validation forward" is active and required by the Tightening Unit,

- a Pset is selected. A rising edge must be detected to initiate a tightening, that is the change in the state of the tool from off to on as the trigger is released, then pressed again must be detected. For the tightening to proceed, this input must remain active. If this input becomes inactive at any time during the tightening, the tightening will be aborted and the tool will stop running. At the end of tightening, a tightening can began only if signal falls and then rise. After power-up, even if this signal is active, an edge is necessary to start tightening."

State

Toggle start stop tightening on edge

This input is enabled for xed tools only (tools without trigger).

Initiates or ends a fastening cycle. A cycle can be initiated only if:

- the "Spindle validation forward" is active and required by the Tightening Unit

- the Pset is selected If no tightening is currently executed, a rising edge will initiate a tightening. A falling edge has no effect on the tightening to proceed. If a tightening is in execution, a rising edge will stop it.

Rising edge

Reverse direction When activated, the tool green & red lights are ashing to indicate that the Tightening Unit

reverse direction is selected. This signal status is not controlled during a tightening but only when tool is not running.

State

Error acknowledge Enables the "Reject lockout" function. When locked out, the tool cannot run until this input

is reset.

Rising edge

Reset When input reset raises (and there is no cycle running):

- defaults are acknowledged

- batch counter of current Assembly Process is reset

- reports lights on controller and tool are set off

- result on display is erased but the last 5 result values on Vision display stay readable

- in Pset mode, Pset selected remains unchanged. In AP mode, AP is aborted.

- ready output stay on

- echo identier is reset

When input reset raises (and there is cycle running):

- tightening is immediately stopped

- defaults are acknowledged

- batch counter of current Assembly Process is reset

- at tightening end, there is no report generated.

- at tightening end, it is impossible to start a new tight, reset input must be released rst.

- in Pset mode, Pset selected remains unchanged. In AP mode, AP is aborted.

- ready output stay on

- echo identier is reset

State

Reset only status When the input "Reset" raises during the Pset running:

- tightening is immediately stopped Resets only:

- Tightening OK/NOK/nished

- Tool OK/NOK

- Batch OK/NOK/Finished The Assembly Process is not aborted. Result values (angle, torque) are still present in Fieldbus. LEDs on tool and controller are not affected.

State

Ack error message Acknowledge error message displayed on HMI. Rising edge Force Pset mode Forces the Tightening Unit to switch in Pset mode in order to temporary run Psets (nothing

saved). When AP mode + input state high, then switch to Pset mode. When Temporary Pset mode + input state low, then switch to AP mode. Switching on the controller power with the input set will switch to Pset mode. Other cases do nothing.

State

Ack result Acknowledges the current result.

The tool is then unlocked and can tight again. Formerly dedicated to Fieldbus only, this behaviour is now also available for IOs and Open Protocol.

Rising edge

Keep alive Input used to check that the controller is still alive.

State of this input is copied to "Keep alive ack" output. This input is also used by a PLC to inform the controller that Fieldbus communication is working.

State

Time Synchro Trigger Execute date & time synchronisation from Fieldbus (SYN in VWXML protocol) Rising edge

Page 25

Appendix - I/O and events_02/2017 - 25 -

Name Description Status

Enable access manager

Enable/disable access manager State

Lock display Lock/unlock the controller display. State Restart Controller Reboots the controller.

Everything must be done by the software before using this input

Rising edge

Reset identiers Erases all ongoing accepted identiers elds from CVI3/tool memory in order to guarantee

a correct traceability

Rising edge

Tools commands

Tool validation forward

Enables the tool to run the selected Pset. Note: the forward and reverse validation can be done by setting both validations on the same input. When the validation signal falls down, the tool stops.

State

Tool validation reverse

Enables the tool run reverse. Note: the forward and reverse validation can be done by setting both validations on the same input. When the validation signal falls down, the tool stops.

State

Reset tool locks Reset tool locks, only the none safety tool locks will be affected Rising edge Tool stop Stops the tool. Rising edge Tool blue light ctrl

by IO

1 = Tool blue light is controlled by IO 0 = Tool blue light is managed by the controller

State

Tool blue light If "Tool blue light ctrl by IO" is set to 1 (see upward) then:

1 = tool blue light is set to on 0 = tool blue light is set to off

State

Tool green light ctrl by IO

1 = Tool green light is controlled by IO 0 = Tool green light is managed by the controller

State

Tool green light If "Tool green light ctrl by IO" is set to 1 (see upward) then:

1 = tool green light is set to on 0 = tool green light is set to off

State

Tool red light ctrl by IO1 = Tool red light is controlled by IO

0 = Tool red light is managed by the controller

State

Tool red light If "Tool red light ctrl by IO" is set to 1 (see upward) then:

1 = tool red light is set to on 0 = tool red light is set to off

State

Tool yellow light ctrl by IO

1 = Tool yellow light is controlled by IO 0 = Tool yellow light is managed by the controller

State

Tool yellow light If "Tool yellow light ctrl by IO" is set to 1 (see upward) then:

1 = tool yellow light is set to on 0 = tool yellow light is set to off

State

Tool white light ctrl by IO

1 = Tool white light is controlled by IO 0 = Tool white light is managed by the controller

State

Tool white light If "Tool white light ctrl by IO" is set to 1 (see upward) then:

1 = tool white light is set to on 0 = tool white light is set to off

State

Reset of redundancy error

Resets redundancy error only. State

Pset commands

Pset select bit (0..7) Used to select Psets.

These inputs must be in the desired state BEFORE the activation of the cycle start input. If the selected Pset is zero, there is no Pset selected.

State

Select previous Pset Select lower number Pset. Rising edge Select next Pset Select higher number Pset. Rising edge External stop abort

Pset

This input is used with proximity detectors to end immediately Pset running. The user can choose which state or transition will stop the Pset: No, Rising, Falling, Change, High, Low. When a Pset is aborted with this input, the Pset result is NOK.

Rising edge or state

External stop to next step

This input is used with proximity detectors to end the running step. The user can choose which state or transition will stop the Pset : No, Rising, Falling, Change, High, Low. The user can also choose the step result when the stop request occurs: OK, NOK, Monitoring (Monitoring means that the result is computed depending on monitoring requested).

Rising edge or state

Synchro in Step synchronisation input.

The step starts when a transition to 0 is detected.

State

External Tool inputs bit (0..9)

Indicates that these inputs can be used by an external tool (to generate OK/NOK report for example)

State

Page 26

Appendix - I/O and events_02/2017- 26 -

Name Description Status

Assembly Process commands

Assembly Process selection bit (0-7)

Used to select an Assembly Process. These inputs must be in the desired state BEFORE the activation of the assembly process start input.

Rising edge

Abort assembly process (tightening unit)

The "Abort assembly process" input stops the Assembly Process being processed.

The Assembly Process is nished.

The Assembly Process result is memorized as "aborted" and “AP aborted” and "AP NOK" events are set.

Rising edge

Batch-1 The "Batch-1" input allows the operator to select the previous operation of a batch

whatever the result of the next operation. The batch counter is decremented. The action is recorded OK or NOK according to the result and "Batch-1 event" is set.

Rising edge

Batch+1 In case you cannot complete the current operation of a batch, jump to the next one by

using the external input "Batch+1". The action is declared as NOK and "Batch+1" event is set.

Rising edge

Restart batch Restarts the current batch of the current Assembly Process step.

The "Restart batch" event is set.

Rising edge

Reset number of retries

Reset the number of retries counter. If the max counter has been reached, the tool is unlocked.

Rising edge

External inputs AP

External in AP bit (0..9)

Inputs used in Assembly Process in start conditions or in assembly actions sense input Rising edge

External inputs PLC

External In PLC bit (0..9)

Indicates this input can be used by an PLC via Fieldbus (like a remote I/O). For PLC side, it is an input.

State

External inputs OP

External In Open Protocol 1-8

Inputs used in Open Protocol. They can be monitored from the Open Protocol client by subscription. Theses DigIn are named "External monitored 1..8" in Open Protocol

specication.

State

Socket tray

Socket lifted bit (0..4) Used with CVI II controllers only: 24V socket trays (BSD).

Informs which socket has been lifted.

State

Customized protocol commands

PFCS END OF CYCLE

Input used in PFCS Chrysler to ush the result FIFO when the operator has completed the

work

Rising edge

SAS Starts tightening job State RST Resets any running tightening job State LSN Disables reverse State TOL Tool validation State STR Tool start State EDZ Resets results State XMS Synchronous XML State XMA XML activated State

CVILOGIX

External In CVILogix bit (0..100)

Indicates that this input can be used by an internal CVILOGIX application State

Page 27

Appendix - I/O and events_02/2017 - 27 -

Page 28

Appendix - User info codes _02/2017- 28 -

Type of code

Code no.

Description Resolution procedure

Info 1 Tubenut open 1-Tubenut tool is detected as open Info 2 Tool connected 1- The tool is connected and correctly recognized by the controller. Info 3 No tool connected 1- Tool has been disconnected.

2- If the tool is not physically disconnected, check the tool cable.

Info 4 Span fail. 1- Span value from torque sensor is outside bounds.

2 -Try once again to start the tool with no mechanical constraints. If the problem occurs again, contact your Desoutter representative for support

Info 5 Offset fail. 1- Offset value from torque sensor is outside bounds.

2- Try once again to start the tool with no mechanical constraints. If the problem occurs again, contact your Desoutter representative for support.

Info 15 Tool lock on reject 1- The tool is locked forward after a NOK.

2- Unlock the tool in function of the "lock on reject option" selection i.e. by reversing, loosening or input.

Info 16 Tool lock by OP 1- Tool has been locked by Open Protocol

2- Unlock the tool by sending an Enable tool message via Open Protocol

Info 17 Loosening prohibited 1- Loosening is prohibited

2- The loosening is disabled in the Assembly action 3- The batch count type OK + NOK is used

Info 21 Max retries reached 1- The number of retries max has been reached.

2- The tool is locked. 3- The running Assembly Process has to be aborted.

Info 22 Lock wait socket 1- The tool is locked. Put all sockets back and lift the correct socket(s)

combination. Info 24 Loos. prohib. XML 1- Loosening is disabled by VWXML protocol Info 25 Tight. prohib. XML 1- Tightening is prohibited by VWXML protocol Info 26 Tool maint. alarm n1 1- Tool maintenance tightening counter has been reached Info 27 Tool maint. alarm n2 1- Tool maintenance tightening counter has been reached Info 38 Tool logs 1- Unexpected tool software exception

2- Log le has been generated by the tool

3-Contact your Desoutter representative for support Info 40 Tool over speed 1- Motor speed exceeds 130% of its maximum value.

2- Check tool parameters.

3- Wrong motortune parameters. Contact your Desoutter representative

for support. Info 42 Tool locked by GeoPos. 1- Tool has been locked by GeoPositioning

2- Unlock the tool by moving the tool in its dened area

Info 43 Tubenut maintenance 1- Tubenut settings need to be recongured. Please, use CVI Monitor

and refer to user's guide.

2- Contact your Desoutter representative for procedure Info 44 GeoTracking/Positioning

learning mode ongoing

GeoTracking/Positioning learning mode

Info 46 Anormal battery current 1- Anormal battery current consumption, check your PSet settings.

2- This error can due to speed settings. Info 50 Tool detection for pairing No procedure Info 51 ePOD connected ePOD connected Info 54 Pairing success No procedure Info 55 eDOCK already present on

controller

No procedure

Info 56 ePOD disconnected ePOD disconnected Info 57 Pairing error No procedure Info 58 Tool locked by GeoTrack. 1- Tool has been locked by GeoTracking

2- Unlock the tool by moving the tool in its dened are

Info 59 New tool detected No procedure Info 60 Tool synchro ongoing No procedure

APPENDIX - USER INFO CODES

Info For information only. No action is required.

Warning The tool is locked. Tap the message to unlock the tool.

Error The tool is locked. The issue has to be solved to unlock the tool and clear the error message.

Page 29

Appendix - User info codes_02/2017 - 29 -

Type of code

Code no.

Description Resolution procedure

Info 61 ExBC connection conict 1- 2 ExBC are congured with the same network settings

2- Verify communication ports and IP addresses Info 100 Cable id invalid param 1- Invalid tool cable parameter, check that the tool cable is Desoutter

certied

2- Contact your Desoutter representative for support Info 101 Cable id not detected 1- Tool cable communication error, check that the tool cable is Desoutter

certied

2- Contact your Desoutter representative for support Info 102 Cable id not certif 1- Tool cable authentication error, check that the tool cable is Desoutter

certied

2- Contact your Desoutter representative for support Info 199 Console activated 1- The serial console is activated.

2- Warning, this console is dedicated only to debug purposes and should

not be used in production Info 202 Fieldbus lost 1- Fieldbus connection with PLC is lost.

- no heartbeat is received from PLC

- the cable is broken or disconnected

- the PLC is off line or not powered

2- Check the Fieldbus conguration.

Info 204 Tool not validated 1- Tool locked by I/O.

2- Check the I/O settings: the "Tool validation" must be active to unlock the

tool. Info 205 Torque settings 1-Invalid Torque setting, torque is greater than tool characteristics

2-Check Pset settings with the current tool characteristics Info 206 Speed settings 1-Invalid speed setting, speed is greater than tool characteristics

2-Check Pset settings with the tool max. speed. Info 207 Assembly done 1- Assembly Process is done, the tool is locked

2- Select new Assembly Process to unlock the tool Info 208 Invalid run reverse param 1-Invalid Run reverse setting, torque or speed are greater than tool

characteristics or reverse strategy is not supported

2-Check Pset settings with the current tool characteristics

3-Reduce max number of turns Info 209 Pset invalid parameters 1 - Software internal error.

2 - Pset is corrupted. Try to transfer it again to the controller.

3 - If the error persists contact your Desoutter representative for support. Info 210 Invalid Pset selected 1- The Pset currently selected does not match the selectable one in the

Assembly Process. Info 211 Invalid trigger conf 1- The tool currently connected to the CVI3 is not equipped with the trigger

required by the tool trigger conguration

2- Adjust your tool trigger conguration to the tool connected or change the

tool according to the expected trigger conguration

Info 215 Current calib. err. 1- Current calibration failed.

2- Try once again.

3- If the problem occurs again, contact your Desoutter representative for

support. Info 224 IGBT too hot 1- Power electronics too warm.

2- Let the controller cool down. Info 225 Err. angle 1- Tool communication error.

2- Check tool and cable connections. If the problem occurs again, contact

your Desoutter representative for support. Info 226 Err. torque 1- Tool communication error. Check tool and cable connections.

2- Try once again, if the problem occurs again, contact your Desoutter

representative for support. Info 234 Fieldbus mismatch 1-The Fieldbus module declared in conguration is not the same that the

one present in controller (e.g. Probus declared but a Pronet module in

CVI3). Info 237 Invalid data 1- The Fieldbus mapping has too many items. Info 238 Invalid address 1- The device address affected to Fieldbus is invalid. Info 239 Invalid com settings 1- Fieldbus communication settings are invalid Info 241 CVINet FIFO alarm 1- The CVINet result FIFO has reached alarm threshold, the CVINet

connection has been lost

2- Check the CVI3 Ethernet cable

3- Check CVI3 Ethernet conguration

4- Check if CVINet is running correctly

Page 30

Appendix - User info codes _02/2017- 30 -

Type of code

Code no.

Description Resolution procedure

Info 242 ToolsNet FIFO alarm 1- The ToolsNet result FIFO has reached alarm threshold, the CVINet

connection has been lost

2- Check the CVI3 Ethernet cable

3- Check CVI3 Ethernet conguration

4- Check if ToolsNet is running correctly Info 244 Accessory disconnected 1- The accessory at the given address has been disconnected from the

eBUS of the CVI3.

2- Check the accessory cable. Info 245 Wait report ack Acknowledge report with its corresponding input Info 251 No Pset selected 1- No Pset is selected

2- Select a Pset before start order Info 254 Drive comm. error 1- Error detected in drive communication

2- Restart the controller

3- If the problem occurs again, contact your Desoutter representative for

support Info 259 Reset input active 1- "Reset" input is active

2- The Tightening Unit will unlock when input switchs to inactive state. Info 261 Locked by IPM 1- IPM protocol has locked the controller

2- Check the connection with the IPM gateway

3- Check CVI3 IPM conguration

Info 262 OP connect. lost 1- Open protocol connection has been lost Info 263 Socket tray conict For this Tightening Unit, do not associate more than one socket

combination to a Pset Info 264 Too many steps Check that an ePOD3 is connected to the controller to enable more steps

per pset Info 266 Message: Incoming message received wth dynamic text Info 269 Pset modied No procedure Info 270 Time settings 1-Invalid Time setting

2-Check Pset settings with correct time value settings Info 271 External tool Pset selected 1- Tool is locked because of External tool Pset selection Info 272 Debug UsrInfo 1- This UsrInfo is for debug. Contact dev team. Info 310 Id OK : 1- An identier has been received and accepted.

2- The identier is matching an Assembly process start condition Info 311 Id NOK : 1- An identier has been received

2- The identier does not match any Assembly process start condition

Info 312 Access expired 1- The access rights on the USB key cannot be read

2- Unplug the key and insert it again

3- If the issue is persistent, the access right le is probably corrupt

4- Contact your CVI Key administrator. Info 313 Access invalid 1- The access rights on the USB key could not be read

2- Try unplugg the key and insert it again

3- If the issue is persistent, the access right le is probably corrupt contact

your CVI Key administrator Info 314 CVIKey plugged 1- an access key has been plugged Info 315 CVIKey unplugged 1- an access key has been unplugged Info 316 Barcode lost no procedure Info 400 Default Ntwk Cfg 1- Network conguration has been set to default. Info 401 Ntwk Cfg Error 1- Network conguration failed.

2- Check your settings.

3- If the problem occurs again, contact your Desoutter representative for

support. Info 500 CVILogix user info Message generated by CVILOGIX program Info 888 Controller software updated no procedure Info 889 Device Software Updated Device Software Updated Info 891 Controller started No procedure Info 899 Downgrade not allowed 1- The SW downgrade is not allowed for this version

2- Check the CVI3 image version on your USB key

3- If the update is still failling, contact your Desoutter representative Info 900 SW update failed 1- The SW upgrade failed

2- Do not remove the USB key and try to restart the CVI3

3- If the upgrade is still failing, contact your Desoutter representative

Page 31

Appendix - User info codes_02/2017 - 31 -

Type of code

Code no.

Description Resolution procedure

Info 901 SW not found 1- The SW upgrade failed, no CVI3 image (*.cvi3) was found at the USB

key root directory

2- Check your USB key, it must have only one CVI3 image Info 902 SW invalid 1- The SW upgrade failed, the CVI3 image copied on your USB key is

corrupted

2- Remove and copy again your CVI3 image

3- Try another USB key

4- Contact your Desoutter representative for more information Info 903 SW updater missing 1- The SW updater is not available or broken

2- Contact your Desoutter representative for more information Info 904 Backup disabled 1- The save parameters utility is not available

2- Contact your Dessouter representative for upgrade Info 905 USB key full 1- Your USB key is full, all data were not saved

2- Delete your old backup les and try again

Info 906 Save param. failed 1- An error occurred during backup, data were not saved.

2- Check the available space on your key, delete les and try again.

3- If the problem persists, contact the Desoutter support team. Info 907 Wrong USB port 1- Your USB device is plugged into the wrong port

2- If your device is a USB key, plug it into the USB front port

3- If your device is a USB barcode reader or keyboard, plug it into the

bottom USB ports Info 908 Too HID device 1- Too many USB devices (barcode reader or keyboard) are plugged to

the controller

2- Remove all devices and plug them again to the bottom USB ports only. Info 909 HID device err 1- Your USB device is not supported by the CVI3 controller

2- Only USB barcode reader and USB keyboard are supported, if you use

one of them, contact your Dessouter representative for upgrade Info 910 Save prg error 1- Plug a USB key to the front panel.

2- Check available space on your USB key, delete some old backup and

try again. Info 911 Load prg error 1- Plug a USB key to the front panel.

2- The .zip le was not found, check that it is in the correct directory.

Info 912 Backup failed 1- Check the ePOD connection.

2- Contact your Desoutter representative for support. Info 913 Restore failed 1- Check the ePOD connection.

2- Contact your Desoutter representative for support. Info 914 Maintenance ongoing Maintenance ongoing: Refer to user manual Info 917 Acc conf err 1-The accessory conguration is not correct

2-Check type of elements and events associated Info 920 Cvi3 reset ePod automatic backup must be congure again if needed Info 921 Pset execution not authorized 1-Check used features allowance

2-Contact your Desoutter representative for support Info 922 Additional transducer span

fail.

1- Span value from additional torque sensor is outside bounds.

2 -Try once again to start the tool with no mechanical constraints. If the

problem occurs again, contact your Desoutter representative for support Info 923 Additional transducer offset

fail.

1- Offset value from additional torque sensor is outside bounds.

2- Try once again to start the tool with no mechanical constraints. If the

problem occurs again, contact your Desoutter representative for support. Info 924 Tool calibration required 1-Perform a calibration of the tool on CVI3 Warning 10 Tool calibration expired 1- The tool calibration date has expired.

2- A tool calibration procedure needs to be done to ensure the

measurement accuracy. Warning 28 Battery tool version error 1 - Battery tool version and controller version are not compatible. Warning 30 The battery is low 1- The battery is low.

2- Recharge the battery. Warning 33 Tool time error 1- The tool time is not set correctly. The tightening results will not be time

stamped.

2- Connect the tool to the controller to set date and time. Warning 36 Tool memory full 1- The tool memory is full.

2- Connect the tool to the controller to empty the memory. Warning 39 Tightening Unit cong err 1- Tightening Unit settings are invalid

Page 32

Appendix - User info codes _02/2017- 32 -

Type of code

Code no.

Description Resolution procedure

Warning 41 Unauthorized tool 1- The tool connected to the controller is not authorized.

2 Maximum number of battery tool reached or tightening unit associated

doesn't exist anymore

3- Check the ePOD connection and capacity. Warning 62 Overload of torque 1- Overload of the torque, could be a rehit

2- Check tool cable is not damaged Warning 201 Replace RTC battery 1- The real time clock backup battery needs to be replaced. Warning 212 Result not stored 1- It was not possible to persist the tightening result in the controller

2- Contact your Desoutter representative for support Warning 214 Short circuit 1- Serial peripheral default.

2- Disconnect and reconnect.

3- Check the serial peripheral. Warning 246 Synchro I/O problem 1- Error detected on synchronisation input

2- Check the conguration of I/O

3- Check the synchronisation cable Warning 250 Pset corrupted 1- Pset is not dened correctly

2- Check the Pset Warning 253 Incorrect tool Id 1- Pset is not dened correctly.

2- One tool declared in the Pset is not part of the tightening unit

3- Check the Pset. Warning 257 Remote start error 1- Verify the tool trigger is correctly pushed Warning 258 Calibration need Pset mode 1- For tool calibration, the Tightening Unit has to be in Pset mode

2- Change the Tightening Unit mode into Pset mode. Warning 267 Result transfer error Result transfer error Warning 273 Debug UsrInfo 1- This UsrInfo is for debug. Contact dev team. Warning 501 CVILogix user info Message generated by CVILOGIX program Warning 600 Controller disconnected DCT_MOT_CONTROLLER_DISCONNECTED_PROCEDURE Warning 601 RESULT NOT OK Result not OK Error 6 Rotor locked 1-Unable to start tool motor (rotor is locked), change your tool

2-Contact your Desoutter representative for support Error 7 Motor too hot 1- Tool is locked because its maximum motor temperature has been

reached.

2- Tool will remain locked until the motor temperature comes back to its

normal value. Error 8 Tool angle fault 1- Problem detected with the tool angle sensor

2- The tool needs maintenance.

3- Contact your Desoutter representative for support Error 9 Tool invalid param 1- Please check the tool compatiblity.

2- The tool memory cannot be read or is invalid.

3- The tool needs maintenance. If the problem occurs again, contact your

Desoutter representative for support. Error 12 Tool EEPROM error 1- The tool memory cannot be read or is invalid.

2- The tool needs maintenance. If the problem occurs again, contact your

Desoutter representative for support. Error 13 Bad tool ground 1- Phase-phase or phase to ground shortcircuit.

2- Disconnect the tool. Contact your Desoutter representative for support. Error 14 Tq. power default 1- The torque sensor is not corrrectly supplied

2- The tool needs maintenance. If the problem occurs again, contact your

Desoutter representative for support. Error 18 Torque out of range ! 1- The target torque value is above the tool max. torque.

2- Check Pset settings against tool characteristics. Error 19 Tool comm. error 1- Tool communication error.

2- Check tool and cable connections. If the problem occurs again, contact

your Desoutter representative for support. Error 20 Tool LED err. 1-Tool LED are not corrrectly supplied

2- Disconnect and reconnect the tool. If the problem occurs again, contact

your Desoutter representative for support. Error 23 Unsupported tool 1- The tool connected to the controller is not supported.

2- Contact your Desoutter representative for more information. Error 29 The battery is empty 1- The battery is discharged. The tool cannot tighten.

2- Recharge the battery. Error 31 Battery error 1- Abnormal battery voltage, the tool cannot tighten.

2- Recharge the battery. If the problem occurs again, replace the battery.

Page 33

Appendix - User info codes_02/2017 - 33 -

Type of code

Code no.

Description Resolution procedure

Error 32 Tool display error 1- Board display malfunction.

2- Contact your Desoutter representative for support. Error 34 Tool mem. err 1- The tool memory does not work properly.

2- Contact your Desoutter representative for support. Error 35 Tool memory locked 1- The tool memory is locked to protect old data from rewriting.

2- Connect the tool to E-dock to retrieve old data. Error 37 Tool trig err. 1- The tool trigger does not work properly.

2- Check and clean the trigger. If the problem occurs again, contact your

Desoutter representative for support. Error 45 Anormal battery voltage 1- Anormal battery high voltage, check your battery.

2- This error can due to charger malfunction or end of life battery. Error 47 Battery is too low 1- Battery is too low, check your battery.

2- If the problem occured again, change the battery with a new one. Error 48 Battery type not allowed 1- Battery type not allowed.

2- Change your battery type or your conguration.

Error 200 Quick stop ! 1- The quick stop has been activated

2- Check the Phoenix connector Error 213 Drive Connect. Lost 1- Connection with the drive has been lost.

2- Reboot the controller.

3- If the issue remains, contact your Desoutter representative. Error 216 Current high 1-Max current exceeded.

2-Contact your Desoutter representative for support Error 217 Drive disabled 1-Drive disabled by external source.

2-Contact your Desoutter representative for support Error 218 Drive power failure 1- Drive hardware failure.

2- Safety issue: contact your Desoutter representative for support Error 219 Trig. safety fail. 1- Drive hardware failure.

2- Safety issue. Contact your Desoutter representative for support. Error 220 Hardware trip 1- Drive hardware failure.

2- Safety issue. Contact your Desoutter representative for support. Error 221 Drive check err. 1- Drive hardware failure.

2- Safety issue. Contact your Desoutter representative for support. Error 222 Controller Too Hot 1- Heatsink too warm.

2- Let the controller cool down. Error 223 Drive init error 1- Software failure.

2- Restart the controller.

3- If the problem occurs again, contact your Desoutter representative for

support. Error 227 Motor stalled 1- Motor stalled (could be missing phase, wrong motortune or power

electronics failure)

2- Try once again, if the problem occurs again, contact your Desoutter

representative for support. Error 228 Drive err. 1- Software failure

2- Restart the controller.

3- If the problem occurs again, contact your Desoutter representative for

support Error 229 Err. ctrl. loop 1- Software failure.

2- Restart the controller.

3- If the problem occurs again, contact your Desoutter representative for

support. Error 230 DC bus high 1- Max current exceeded. DC-bus voltage high

2- Contact your Desoutter representative for support Error 231 DC bus too low 1- Power failure. DC-bus voltage low

2- Contact your Desoutter representative for support. Error 232 Err. ID eldbus 1- The Fieldbus module plugged in the controller cannot be run. It is not an

authorized Desoutter module.

2- Contact your Desoutter representative for more information. Error 233 CVINET FIFO full 1- The CVINet result FIFO is full, the CVINet connection has been lost

2- Check the CVI3 Ethernet cable

3- Check CVI3 Ethernet conguration

4- Check if CVINet is running correctly

Page 34

Appendix - User info codes _02/2017- 34 -

Type of code

Code no.

Description Resolution procedure

Error 236 ToolsNet FIFO full 1- The ToolsNet result FIFO is full, the CVINet connection has been lost

2- Check the CVI3 Ethernet cable

3- Check CVI3 Ethernet conguration

4- Check if ToolsNet is running correctly Error 240 XML not authorized 1- The selected XML protocol is not authorized (check the ePOD

characteristics) Error 243 PFCS not authorized 1- The selected PFCS protocol is not authorized (check the ePOD

characteristics) Error 247 XML version conict 1- Conict detected in Audi / VW XML protocol version.

2- Check the coherence of the version between the controller and master

PC/PLC Error 248 SAS order failed 1- Fieldbus SAS order has failed.

2- Check the value of RRGI, SIO, etc. Error 249 XML PRG 0 1- The PRG value 0 has been set by Fieldbus. Error 255 Drive choke too hot 1- Power electronics too warm.

2- Let the controller cool down. Error 256 Motor too hot 1- Tool is locked because its maximum motor temperature has been

reached.

2- Tool will remain locked until the motor temperature comes back to its

normal value. Error 260 IPM not authorized 1- The selected IPM protocol is not authorized (check the ePOD

connection) Error 265 Socket(s) usable with more

than one TU

Recongure sockets combination to resolve conicts

Error 268 CVI NET incompatible CVI Net and CVI3 are incompatible. Please update CVI Net software Error 502 CVILogix user info Message generated by CVILOGIX program Error 890 Device Software Error Device Software Error Error 915 Inconsistent version 1- The SW version of all CVI3 controllers must be identical

2- Update rmware

Error 916 Workgroup not authorized 1- You need to connect an epod3 on the Workgroup Primary controller Error 918 Emergency stop ! 1- The emergency stop has been activated

2- Check the M8 connector Error 919 Additional transducer error 1- The additional transducer's maximum torque is lesser than the

embedded transducer's maximum torque

2- The Pset uses an additional transducer though non is installed on tool

Page 35

Appendix - User info codes_02/2017 - 35 -

Page 36

Appendix - Connections_02/2017- 36 -

APPENDIX - CONNECTIONS

1 - TOOL CONNECTOR

STA

STB

+15V

Ground

Phase 1

Phase 2

Phase 3

(a)

(b) (b)

1mm² 1mm²

0.25mm²/120Ω

0.35mm²

1mm² or 2.5mm²

(a)

2 - RS232 - SubD 9pt

RX1

TX1

TX2

GND

RX2

RTS1

CTS1

+5V

RS1

RS2

Serial ports

Barcode reader

Legend A Connector 12 pts Male B Connector 12 pts Female a Ground shielded cable b WARNING : Shielded insulate

STA

Twisted pairs: 2x0.25 mm²

at 10 MHz 65 Ω

STB

Cable Color

STA Red

STB Red / Blue

+15V Black / Blue

0V Black

Ground Yellow / Green

Phase 1 Black

Phase 2 Brown

Phase 3 Blue

Page 37

Appendix - Connections_02/2017 - 37 -

3 - DIGITAL INPUTS (0 – 24V)

131426

+24V controller

AGND

0VE controller

Quick Stop Channel 1

Input 1

Quick Stop Channel 2

Input 2

Input 3

Input 5

Input 4

Input 6

Input 7

Input 8

Example of connections:

Possibility to connect a 24V external supply in parallel of the 24V delivered by the controller:

+24V Ext

+24V Controller

0VE controller

152

4 - DIGITAL OUTPUTS (0 – 24V)

+24V controller

AGND

0VE controller

Common 1

Output 2

Output 1

Output 3

Output 4

Output 6

Output 5

Output 7

Output 8

Common 2

Example of connections:

Possibility to connect a 24V external supply in parallel of the 24V delivered by the controller:

+24V Ext

+24V Controller

Common 1

Output 1

Output 2

Output 3

Output 4

Output 5

Output 6

Output 7

Output 8

0VE Controller

Common 2

152

163

Page 38

Appendix - Connections_02/2017- 38 -

5 - Tightening ow chart and timing chart

Input/Output dened by default can be used to control

tightening operation from a PLC or other electronic device.

Here is an example of standard exchange between a CVI3 controller and a PLC.

5.1 - Tightening operation through IO ow-chart

Start

End

Ready = 1 ?

Reset = 0

Reset = 1

Tightening OK &

Tightening NOK

= 0 ?

Pset selected =

expected Pset ?

Tightening

running = 1 ?

Tightening

running = 0 ?

Select Pset number

Spindle validation = 1

(if necessary)

Start stop tightening

on state = 1

Start stop tightening

on state = 0

Read results

OK/NOK

Read (if necessary)

digital result

Page 39

Appendix - Connections_02/2017 - 39 -

5.2 - Tightening operation through IO timing chart

1 2 3 4 5

Phases

READY (O)

PSET SELECT BIT 0 (I)

PSET SELECT BIT 1 (I)

PSET SELECT BIT 2 (I)

PSET SELECTED BIT 0 (O)

PSET SELECTED BIT 1 (O)

PSET SELECTED BIT 2 (O)

SPINDLE VALIDATION (I)

START/STOP TIGHTENINGON STATE (I)

TIGHTENING RUNNING (O)

TIGHTENING OK/NOK (O)

RESET (I)

Phase Designation

The “Reset” signal is sent by the PLC. This leads to reset the report (“Tightening OK/NOK”).

The controller receives the Pset no.1 selection. The command is acknowledged by the “Pset Selected” signals.

The controller detects the “Start Stop Tightening On State” signal transition. The tightening operation starts and “Tightening Running” signal is set to 1.

At the end of the tightening operation, the controller sets "Tightening OK" or "Tightening NOK" signals.

The "Tightening Running" signals returns to zero when all operations are over.

Page 40

Appendix - Connections_02/2017- 40 -

6 - SYNCHRONIZING SINGLE-CHANNEL CONTROLLERS

It is necessary to wire a diode 1N4148 in serial with each synchro out signal.

GND

+24V

0VE

Stop 2

Stop 1

Stop 2

Stop 1

Stop 2

Stop 1

GND

+24V

0VE

5 5

COM2

COM1

GND

+24V

0VE

GND

+24V

0VE

COM2

COM1

GND

+24V

0VE

GND

+24V

0VE

COM2

COM1

COM2

COM1

COM2

COM1

OutputInput

Controller 1

OutputInput

Controller 2

OutputInput

Controller 3

Synchro

OUT

1N4148

Synchro

OUT

1N4148

Synchro

OUT

1N4148

7 - SYNCHRONIZING TWINCVI3 CONTROLLERS

It is necessary to wire a diode 1N4148 in serial with each synchro out signal.

GND

+24V

0VE

Stop 2

Stop 1

Stop 2

Stop 1

Stop 2

Stop 1

GND

+24V

0VE

5 5

COM2

COM1

GND

+24V

0VE

GND

+24V

0VE

COM2

COM1

GND

+24V

0VE

GND

+24V

0VE

COM2

COM1

COM2

COM1

COM2

COM1

OutputInput

Controller 1

OutputInput

Controller 2

OutputInput

Controller 3

Synchro

OUT

1N4148

Synchro

OUT

1N4148

Synchro

OUT

1N4148

Page 41

Appendix - Connections_02/2017 - 41 -

8 - eBUS (for accessories)

B -

GND-EXT

AGND

B +

+24V-EXT

+24V

9 - WORKGROUP

min. 5 mm

tool no. 2 tool no. 3 tool no. 4 tool no. 5

tool no. 1

Customer network

Workgroup network

For each secondary controller, check that the quick stop is on but inactive

Use «Eject» command before disconnecting the ePOD.

ePOD3

SECONDARY CONTROLLERSPRIMARY CONTROLLER

Page 42

Appendix - ePOD_02/2017- 42 -

APPENDIX - ePOD

The ePOD unlocks a specied level of functionality and acts as a back-up unit for the conguration of the CVI3 controllers.

It also increases the number of results, curves and logs in the controller.

There are different models of ePOD and specic ePOD designed for some specic protocols.

Model ePOD1 ePOD2 ePOD3 ePOD2C ePOD3C ePOD4C

Part number 6159360750 6159360760 6159360770 6159363110 6159363180 6159363120

Backup

Complete backup of the controller system

included included included included included included

Results storage

Number of Pset results 10,000 20,000 20,000 20,000 20,000 20,000

Number of curves per tool 20 50 50 50 50 50

Number of Pset versions per Pset 10 20 20 20 20 20

Number of events in the event log 500 1,000 1,000 1,000 1,000 1,000

Basic functions

Number of steps per Pset:

- Tools with cable connection 15 15 40 15 15 40

- Wireless battery tools 10 10 10 10 10 10

CVILOGIX - included included included included included

Workgroup - - included - - included

Programming / Supervision / Controller backup

Results storage - included included included included included

Tightening units management (with CVI3 Vision controller only)

Maximum number of tightening units 2 2 2 3 3 4

Maximum number of wireless battery tools

1 1 1 2 3 4

ePOD1

ePOD1 is a backup module for the controller result and conguration database.

- It can be used as real time backup module. In this case the ePOD1 must always be plugged to the controller.

- It also can be used as a manual backup that stores the conguration database, the results database and the rmware version of

the controller. ePOD1 gets a snapshot of the controller.

ePOD2

ePOD2 has all functionalities of ePOD1.

- ePOD2 activates CVILOGIX (Embedded PLC of CVI3 controllers).

ePOD3

ePOD3 has all functionalities of ePOD2.

- ePOD3 activates the workgroup conguration.

ePODxC

ePODxC has all functionalities of ePOD2 or ePOD3.

- It can be connected to CVI3 Vision controllers only.

Page 43

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