AFC1500

FEC AFC1500 User Manual

4.5 (2)

AFC 1500 Multi Unit

Hardware Manual

Version 2.04

(Compatible with AFC User Console Software Version 3.61 and above)

April 2003

51327 Quadrate Drive Macomb, MI. 48042

Ph. 586.781.2100 Fax 586.781.0044

www.fec-usa.com

*** WARNING ***

All applicable National and local codes must be followed when installing and operating the equipment detailed in this manual.

FAILURE TO ABIDE BY THESE CODES AND THE SPECIFICATIONS DESCRIBED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT.

*** WARNING ***

THIS EQUIPMENT IS CAPABLE OF HIGH VOLTAGES HAZARDOUS TO HUMAN LIFE.

Turn off and lock-out all voltage sources prior to performing any work on this equipment.

Do not open or remove any covers, even if the Unit is disconnected from the power source.

Only qualified personnel should attempt to modify or repair this product.

There is a possibility of receiving an electrical shock from this equipment, if used improperly.

This System is designed to operate on 200 VAC. Injury or damage could result from using improper voltage.

OPERATOR AND EQUIPMENT SAFETY

Read this manual carefully before attempting to operate the equipment.

If this System is being operated as a part of a larger system, the larger system should be

clearly marked with the warning information, above. Also, a copy of this notice should be included in all pertinent operations and maintenance manuals. At a minimum, Controller Units must be placed in a NEMA 12 / IP52 enclosure. Some type of Air Handling Unit (air

conditioner, heat exchanger, etc.) may also be required. Be sure to use the recommended circuit breakers with the power supply lines.

Use the power supply voltages recommended in the specifications to prevent possible

personnel injury and equipment damage. Do not modify this equipment, or the warranty will be void. Please contact FEC INC. if any

special modification is required. Inspect the equipment for wear and damage at regular intervals.

Specific precautions regarding equipment installation and location have been incorporated

into this manual. Before operating the equipment, verify that countermeasures have been taken for any adverse conditions that may exist. Failure to address these conditions prior to operation could result in damage to the

equipment.

Any questions regarding the contents of this document or any related matter should be directed to FEC INC. at (586) 781-2100. Requests may be faxed to FEC INC. Product Engineering at (586) 781-0044.

Unauthorized reproduction or distribution of this manual is strictly prohibited. Please contact FEC INC. if you require additional copies.

Table of Contents

.....................................

Table of Contents

Multi Unit Outline

.........................................

..........................................

Functions Outline

Sequence Control ..........................................

Parameter Programming ...................................

Fastening Data Monitoring & Communication ................

General Status Indication ...................................

Specifications

...................................................

.......................................................

Installation Requirements

Installation Environment ...................................

Static Electricity ..........................................

Cleaning .................................................

Handling and Shipping ....................................

Unit Description

Basic Dimensions .........................................

Description of Unit ........................................

....................................................

Setup and Wiring

Multi Unit Installation

Power Input ..............................................

Power wiring reference ....................................

..............................................

.........................................

8 8 8 8 9

10 10 10 10 10

11 12 13

16 16 17

Multi Unit connection

RS485 Communication Port ................................

RS485 port connection ....................................

Serial Communication Ports ...............................

Output Data Available .....................................

Data Output Example

..............................................

18 18 19 20 22 23

....................................

Control Interfaces

........................................

Interface Board Setup

Discrete I/O Interface

Input/Output Signals ......................................

Input Signals (Connector PLC1) ............................

Output Signals (Connector PLC2) ...........................

Bank Select Outputs .......................................

Discrete Signal Connection ................................

Standard I/O Cable - Wire Color Code .......................

..............................................

InterBus S Interface Board

Indication LED ............................................

Termination ..............................................

DeviceNet Interface board

Termination ..............................................

EDS File ..................................................

Indication LED ............................................

Profibus Interface Board

Termination ..............................................

GSD File ..................................................

Indication LED ............................................

Node Address ............................................

Configuration .............................................

.........................................

...........................................

28 29 29 30 30 31 32

33 34 35

36 37 38 38

39 40 40 41 41 41

Mitsubishi CC-Link

Termination ..............................................

Indication LED ............................................

Configuration ............................................

.................................................

Allen Bradley Remote I/O Interface board

Termination ..............................................

Indication LED ............................................

Fieldbus I/O Assignment

ANYBUS-S Reference

AnyBus S Initialization

..............................................

.........................

...........................................

42 43 45 45

46 47 48

50 50

AnyBus - DT Reference

AnyBus DT Initialization ...................................

............................................

Input / Output Signals & Fastening Data Outline

...

51 51

Multi Unit Input Signals

Sequence Select Table ....................................

Multi Unit Output Signals

Bank Select Procedure ....................................

Multi Unit Output signals ...................................

Signal Timing

Sequence Select Timing ...................................

......................................................

............................................

..........................................

Output signals from the SAN Servo Controllers

Typical I/O Layout

Abnormal Code

..................................................

.....................................................

..................

54 55

56 56 57

58 59

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Multi Unit Outline

In this chapter

The Multi Unit is a complementary device to

enhance the AFC1500 capabilities by providing

the communication and the sequence control

features required by larger or more

sophisticated multi spindle applications.

§Functions Outline

§Specifications

§Installation requirements

§Unit Description

Functions Outline

The Multi Unit is a complimentary controller device to enhance the AFC1500 capabilities by providing the communication and the sequence control features required by larger or more sophisticated multi spindle applications. When a group of AFC1500 Servo Controllers (SAN Units) are linked to a Multi Unit, the Multi Unit assumes control (over these spindles) of the following functions:

§ Sequence Control

§ Parameter Programming

§ Fastening Data Monitoring & Communication

§ General Status Indication

Sequence Control

The Multi Unit assumes control of the control signals (e.g.: STOP, START, REVERSE, BYPASS, etc.) to all of the AFC1500 Servo Controllers linked to it via the RS485 communication port, thus eliminating direct connection & control to the individual spindles. The control signals for the multi-spindle array can be of different sources: Signals manually generated by pressing the Control Buttons on the front of the Multi Unit or I/O (Input/Output) signals from a PLC or from a PC Based Controller. Also the Multi Unit controls the fastening sequencing eliminating the need for external control devices (PLC) to perform complicated control sequencing. All fastening sequencing is handled by the Multi Unit. This built in feature allows the Multi Unit to control a variety of complex sequencing strategies including; spindle grouping within the same application, several fastening steps, reject (reversing) strategies, wait timing, multiple starts, etc.

Parameter Programming

A Windows® compatible computer running the AFC User Console software package can be connected to the Multi Unit in order to upload or download the preset data to all the SAN (Servo) Controllers connected in the multi spindle array. This eliminates the need to program individual spindles manually.

Fastening Data Monitoring & Communication

The Multi Unit can monitor and process the fastening results collected from the AFC1500 Servo (SAN) Controllers connected to it. It has three (3) configurable RS232C ports to input and output fastening data results. Data monitoring / saving is also a function of the AFC User Console software package. As an added feature, the Multi Unit stores previous fastening data in RAM (volatile) for uploading at another time. The number of cycles stored is based on the number of spindles connected and is as follows; 1 Spdl. = 1817 cycles, 7 Spdls. = 641 Cycles, 10 Spdls. = 479 cycles, 20 Spdls. = 263 cycles, 31 Spdls. = 173 cycles. The number of cycles stored will be reduced if RS232 COM2 data is stored with the fastening data. The data can be uploaded using the AFC User Console software package.

Chapter 1: Multi Unit Outline

General Status Indication

A set of indicator LED’s provide the status for Total Accept, Total Reject, Abnormal, Busy and Power on conditions.

Specifications

The Multi Unit has the following specifications:

Multi Unit Operation Specifications

100 to 220 VAC±15%, 1-phase, 50/60 Hz.Power Supply Voltage 30 Watt MaximumPower Consumption Less than 70 maOperating Current Less than 160 maIn rush current NEC V53ACPU RS232C COM1 (Data output)Data Communication RS232C COM2 (Input port) RS232C (Reserved for future use) RS485 Channel 1 Servo Units Programming RS485 Channel 2 Servo Units Control Discrete I/O (24Vdc Sink)Control Interfaces DeviceNet Interbus-S Profibus Mitsubishi CC Link* Allen Bradley Remote I/O * (Lic. #199906006)

Also Available:

Modbus Plus CANopen ControlNet Ethernet 10/100 (Modbus) LonWorks 100Fastening Sequence

Programming Steps

Torque Control / Angle Control Fastening Control Methods 31 per MultiMaximum number of spindles 16Fastening Parameters

16Fastening Sequences Torque Rate monitoring areas

* Mitsubishi CC Link & Allen Bradley Remote I/O are proprietary and licensed for use.

(1st, 2nd, and 3rd Rate)

NEMA12 EnclosureInstallation requirement

0º to 50 ºC (32 º to 122 ºF)Operation Temperature

20% to 90%Operation Humidity

Chapter 1: Multi Unit Outline

Installation Requirements

Installation Environment

Do not use at the following locations: (If these conditions cannot be achieved, contact FEC INC.)

§ Areas under direct sunlight.

§ Areas where the environmental temperature is out of the 32°F-122°F (0º to

50 ºC) range.

§ Areas where the relative humidity is out of the 20-90% range.

§ Areas where the temperature changes quickly, which may cause moisture.

§ Areas where conductive powder, oil mist, saline, or organic solvents exist.

§ Areas that have corrosive or combustible gases.

§ Areas that have strong electric or magnetic fields.

§ Areas where a strong vibration or shock could be transmitted directly to

the Unit.

§ Multi Units must be located a minimum of 600 mm from sources of high transient voltage such as transformers, AC inverters, AC contactors and motor starters. If this cannot be avoided, then the unit must be properly shielded.

Static Electricity

The Multi Unit construction incorporates many electronic Surface Mounted Devices (SMD). Use standard grounding & safety practices to avoid possible electrostatic discharge to the unit.

Cleaning

Do not use any organic solvents, such as thinner, to clean a Multi Unit. The solvent could penetrate inside and damage the circuitry. A cloth dampened with alcohol or warm water should be used to lightly wipe the components.

Handling and Shipping

It is critical that the Multi Unit be properly handled and shipped in order to maintain its integrity. If unit is to be shipped in an enclosure, tighten both mounting screws to prevent unit from becoming dislodged. If unit is to be shipped loose, pack it in an anti-static container or wrap it to prevent damage from electrostatic discharge. Pack & ship to avoid damage from dropping / shock. Avoid shipping conditions or storage areas were the room temperature is out the -5 º to 55 ºC (23 º to 131ºF) range and the humidity is above 90%.

Chapter 1: Multi Unit Outline

Unit Description

PRINTER

S Win 98, NT, 2000, XP

NETWORK I/F UNI

S Win 98, NT, 2000, XP

Connection Configuration

The following figure shows how the Multi Unit is connected in a multi spindle configuration.

The figure depicts the connection configuration for the AFC1500 Servo (SAN) Units, the User Console and the various interface devices to the Multi Unit.

INTERBUS-S I/F

PROFIBUS I/F

DEVICENET I/F

REMOTE I/O BLOCK

SINK/SOURCE I/O

MULTI I/F UNIT

USER CONSOLE

RS485

TOUCH SCREEN PC -WINDOW

RS485 TO RS232 I/F

LAPTOP -WINDOW

UP TO 31 UNITS

Chapter 1: Multi Unit Outline

Basic Dimensions

Shown with Discrete I/O board

Chapter 1: Multi Unit Outline

Description of Unit

Serial Port COM1

Serial Port COM2

Serial Port COM3

Interface board

Power on LED

Busy LED

Accept LED

Reject LED

Abnormal LED

RS485 port

Software EPROMs

Reset button

Start button

Reverse button

Calibration button

Power connector

Multi Unit Panel Description

Busy LED

Accept LED

Reject LED

Abnormal LED

Indicates when power is applied to the Multi Unit.Power On LED Lights when the unit is performing a self check, reverse, fastening operation or is downloading/uploading data to the AFC User Console software package. Lights if a fastening cycle or a self check test falls within acceptable parameters. (This LED indicates status for ALL connected spindles) Lights if a fastening cycle or a self check test is outside of acceptable parameters. (This LED indicates status for ALL connected spindles) Lights when a system abnormal condition is detected in the control system of any connected spindles. (Does NOT indicate a fastening reject). All operations are halted and cannot be restarted until the Abnormal condition is corrected. Can be cleared only by the Reset function. (see AFC1500 Fastening System Manual for Abnormal Troubleshooting)

Chapter 1: Multi Unit Outline

Multi Unit Panel Description

RS485 Port

Reset Button

Start Button

Reverse Button

Cal Button

Power Connector

Interface Board (I/O)

Serial Port COM1 (Output)

Serial Port COM2 (Input)

RJ45 style connector used to connect to all AFC1500 Servo (SAN) Units included in the system, and also the User Console. Two (2) proprietary communication channels CH1 & CH2 are accessed using this port. Resets all signal and communication buffers to “clear” conditions. Clears the Abnormal signal and performs the Torque Transducer Zero Level Check. Starts the fastening cycle. Requires a pulse of 0.1 to 0.5 sec. for “Normal” start selection or must be maintained during complete cycle for “Deadman” start selection.

Turns the spindles in the opposite direction of the preset fastening direction while the button is held active. Performs the Torque transducer shunt calibration test. When depressed, the Servo (SAN) Units will display either a green accept LED or red reject LED indicating status of the individual Calibration test. Connects to incoming power : 100 to 220VAC (auto-sensing), Single phase, 50/60 Hz.

Allocation socket for input/output signal Interface boards. Options available are Discrete I/O, Interbus-S, DeviceNet, Profibus, CClink, or Allen Bradley Remote I/O (Rockwell License #199906006) Communication port for fastening result data output to any external device, i.e.: host computer, serial printer, Network Unit, etc. Data output format is configured using the User Console (AFC) Software package. Communication port for ASCII data input from peripheral devices. ( ex. bar code readers, RF tag, etc.) Allows external ASCII data to be merged with Fastening result data.

Reserved for external remote data DisplaySerial Port COM3

Chapter 1: Multi Unit Outline

Setup and Wiring

•

This chapter describes the Multi Unit mounting

requirements and all wiring connection

references including communication port

specifications.

In this chapter

§Installation

§Connection

Chapter 2: Setup and Wiring

Multi Unit Installation

The Multi Unit should mounted into a NEMA12 / IP52 enclosure at a minimum and spaced similar to the 1500 SAN Units (Shown Below).

Power Input

An auto sensing power supply allows for input power in the range of 100 - 220VAC single phase, 50/60 hertz.

Chapter 2: Setup and Wiring

100 - 220 VAC ±15%

NOT CONNECTED

GROUND

POWER

AC100

AC220

Power wiring reference

Even though the Multi Unit power input allows it to connect to 120 VAC- 220 VAC power lines, typically the unit is connected to the same power source that the SAN Units are connected to. (200 to 220 VAC ± 10%) . In the example wiring diagram shown below there are two power branches: one is for the control circuitry connected to 120 VAC and the other is for the SAN power circuitry, connected to 220 VAC. For convenience, the Multi Unit is wired together with the AFC1500 Servo Controllers. Note that the Multi Unit is using one phase while the Servo Controllers use three phases.

440VAC, 3PH

AFC1500

MULTI UNIT

Chapter 2: Setup and Wiring

Multi Unit connection

RS485 Communication Port

The Multi Unit uses an RS485 port to perform the communication operations with both the AFC1500 Servo (SAN) Controllers and the AFC User Console (computer). Two RJ45 connectors are provided. Both connectors are internally jumpered in parallel. Each port has two channels CH1 and CH2. CH1 is dedicated to handle the communication with the User Console, that is to say, all preset data upload and download, fastening results monitoring and collection. Channel CH2 is a high speed connection to all AFC1500 Servo Controllers. It controls all required commands to perform the fastening cycle.

8 GND 7 GND 6 TX- CH1 5 RX+ CH1 4 RX- CH1

3 TX+ CH1 2 TX/RX- CH2

1 TX/RX+ CH2

RS485 CH1 port specifications

RS485 CH2 port specifications

Chapter 2: Setup and Wiring

9600 OR 38,400 baudSpeed Std Cat 5 EthernetCable 31Maximum number of connected devices ProprietaryProtocol RS485 StandardOperating Voltage

Up to 500K baudSpeed Std Cat 5 EthernetCable ProprietaryProtocol RS485 StandardOperating Voltage

RS485 port connection

Converter RS485/RS232

Cable FEB-1274

(Includes Converter )

Note: Many laptop computers have external RS232 serial ports which require converters to change to RS485 to connect to the Multi Unit. When using a self powered RS485/RS232 converter (Telebyte #253-PP2 www.telebyteusa.com), communication errors may occur due to the loss of power during communication to large numbers of spindles. In this case, use a powered converter or direct RS485 communication.

If your laptop does not have a RS232 card, it is recommended that a PCMCIA Serial RS232 or RS485 card be used. (ie. www.socketcom.com)

We do not recommend USB RS232 converters. Many of these converters in the market will not operate correctly using this system.

Multi Unit

AFC1500 Servo Controllers

Cable FEB-1268

UP TO 31 UNITS

Note: In order for the Multi Unit to communicate properly to the SAN (Servo) Units, the spindle(s) address DIP Switch must be set correctly. No two units may share the same address, however, unit addresses may be skipped or started from a number besides #1. If units are skipped, the missing spindle addresses MUST be removed from the programmed fastening sequence or an abnormal will result. (See AFC1500 Operations Manual Section 4.10 for Address setting information)

Chapter 2: Setup and Wiring

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